Shop fox W1678 User Manual

MODEL W1678

26" DOUBLE DRUM SANDER

INSTRUCTION MANUAL

Phone: 1-360-734-3482 • On-Line Technical Support: tech-support@woodstockint.com

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT

THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.

Printed in Taiwan

This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

TABLE OF CONTENTS

PAGE

INTRODUCTION .................................................................................... 2

Woodstock Tech Support ........................................................................... 2

Specifications ................................................................................. 3

SAFETY ............................................................................................. 4

Standard Safety Instructions .....................................................................4-5

Additional Safety Instructions for Drum Sanders .............................................. 6

Avoiding Potential Injuries ......................................................................... 7

ELECTRICAL REQUIREMENTS ................................................................... 8

Extension Cords ....................................................................................... 8

Grounding .............................................................................................. 8

ASSEMBLY ........................................................................................ 10

Unpacking .............................................................................................10

Box Contents ......................................................................................... 10

Shop Preparation ....................................................................................11

Initial Cleaning .......................................................................................11

Beginning ..............................................................................................12

Dust Port and Handles .............................................................................. 13

Control Box ...........................................................................................13

Crank and Handle ....................................................................................13

220V Operation ....................................................................................... 8

SAFETYINTRODUCTION

ELECTRICAL

ASSEMBLY

Drums and Pressure Rollers ...................................................................... 14

Dust Scoop Gap....................................................................................... 20

V-Belt Tension ........................................................................................21

Conveyor Belt ........................................................................................ 22

ADJUSTMENTS ................................................................................... 14

OPERATIONS ..................................................................................... 23

Overview ..............................................................................................23

Control Panel ......................................................................................... 23

Basic Sanding .........................................................................................24

Troubleshooting ......................................................................................27

Sanding Belts .........................................................................................29

Lubrication ............................................................................................30

Brush Replacement ..................................................................................31

Sandpaper Replacement ........................................................................... 21

Bearing Replacement ...............................................................................32

General Cleaning .................................................................................... 34

Wiring Diagram ....................................................................................... 35

MAINTENANCE ................................................................................... 29

General ................................................................................................29

CLOSURE ......................................................................................... 37

Parts Breakdown and Parts List ..............................................................38-45

ADJUSTMENTS

OPERATIONS

MAINTENANCE

WARRANTY ....................................................................................... 49

USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!

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INTRODUCTION

Woodstock International, Inc. is committed to customer satisfaction. Our intent with this manual is to include the basic information for safety, setup, operation, maintenance, and service of this product.

In the event that questions arise about your machine, please contact Woodstock International Technical Support at (360) 734-3482 or send e-mail to: tech-support@shopfox.biz. Our knowledgeable staff will help you troubleshoot problems or process warranty claims.

If you need the latest edition of this manual, you can download it from http://www.shopfox.biz. If you have comments about this manual, please contact us at:

Woodstock Technical Support

Woodstock International, Inc.

Attn: Technical Documentation Manager

P.O. Box 2309

Bellingham, WA 98227

Email: manuals@woodstockint.com

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Specifications

Drum Sander Motor.............. 5 HP, 220 VAC, 25 Amp., 3450 RPM, 60 Hertz, Single-Phase

Drum Drive .............................................................................. Dual V-Belt

Drum Size ................................................................................. 6" x 27

Drum Surface Speed ............................................................................. 2300 FPM

Drum Rotation .......................................................Opposite of Feed Conveyor

Conveyor Motor .............................

⁄3 HP, 60 VDC, 2 amp., 60 RPM, Varable Speed

Conveyor Drive ................................................................ Sprocket and Chain

Conveyor Surface Speed ................................................................. 0-20 FPM

Maximum Lumber Dimensions ................................................... 4

Minimum Lumber Dimensions ..............................................

⁄2" Thick x 26" Wide

⁄8" Thick x 9" Long

Dust Port O.D. ..............................................................................................4"

Conveyor Table Size .................................................................26

⁄8" x 301⁄4"

Stand .......................................................Cabinet Style, Powder Coated Paint

Bearings ....................... Both Serviceable and Permanently-Lubricated Ball Bearings

Power Control ................................. Magnetic Switch, with Emergency Shut-Down

Footprint ................................................................................. 36" x 23

Shipping Weight .............................................................................435 lbs.

⁄4"

INTRODUCTION

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SAFETY

OWNER’S MANUAL.

TRAINED OPERATORS ONLY.

DANGEROUS ENVIRONMENTS.

MENTAL ALERTNESS REQUIRED.

electrical components or improperly grounded

manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by

SAFETY

For Your Own Safety,

Read Manual Before Operating Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This

SAFETY

themselves do not eliminate danger and are not a substitute for proper accident prevention measures—this responsibility is ultimately up to the operator!

NOTICE

Standard Machinery Safety Instructions

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

This symbol is used to alert the user to useful information about proper operation of the equipment or a situation that may cause damage to the machinery.

Read and understand this

owner’s manual BEFORE using machine.

have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof!

machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury.

alertness is required for safe operation of machinery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

Untrained operators

Do not use

Full mental

ELECTRICAL EQUIPMENT INJURY RISKS. You can

be shocked, burned, or killed by touching live

machinery. To reduce this risk, only allow an electrician or qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

DISCONNECT POWER FIRST. Always disconnect

machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This eliminates the risk of injury from unintended startup or contact with live electrical components.

EYE PROTECTION. Always wear ANSI-approved

safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are not approved safety glasses.

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WEARING PROPER APPAREL. Do not wear

clothing, apparel, or jewelry that can become

HAZARDOUS

HEARING PROTECTION.

REMOVE ADJUSTING TOOLS.

INTENDED USAGE.

AWKWARD POSITIONS.

CHILDREN & BYSTANDERS.

GUARDS & COVERS.

FORCING MACHINERY. Do not force machine. It

will do the job safer and better at the rate for

loss of control. Before starting, verify machine

malfunction, leading to serious personal injury

from heated surfaces, high traffic areas, harsh

entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips, which could cause loss of workpiece control.

DUST. Dust created while using

machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material, and always wear a NIOSH-approved respirator to reduce your risk.

Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

Tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verify removal before starting!

Only use machine for its intended purpose—never make modifications without prior approval from Woodstock International. Modifying machine or using it differently than intended will void the warranty and may result in malfunction or mechanical failure that leads to serious personal injury or death!

Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.

Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a distraction.

which it was designed.

NEVER STAND ON MACHINE. Serious injury may

occur if machine is tipped or if the cutting tool is unintentionally contacted.

STABLE MACHINE. Unexpected movement during

operation greatly increases risk of injury or

is stable and mobile base (if used) is locked.

USE RECOMMENDED ACCESSORIES. Consult

this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase risk of serious injury.

UNATTENDED OPERATION. To reduce the risk

of accidental injury, turn machine OFF and ensure all moving parts completely stop before walking away. Never leave machine running while unattended.

MAINTAIN WITH CARE. Follow all maintenance

instructions and lubrication schedules to keep machine in good working condition. A machine that is improperly maintained could

or death.

CHECK DAMAGED PARTS. Regularly inspect

machine for any condition that may affect safe operation. Immediately repair or replace damaged or mis-adjusted parts before operating machine.

MAINTAIN POWER CORDS. When disconnecting

cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside, resulting in a short. Do not handle cord/plug with wet hands. Avoid cord damage by keeping it away

chemicals, and wet/damp locations.

SAFETY

accidental contact with moving parts or flying debris—make sure they are properly installed, undamaged, and working correctly.

Guards and covers reduce

EXPERIENCING DIFFICULTIES. If at any time

you experience difficulties performing the

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intended operation, stop using the machine! Contact Technical Support at (360) 734-3482.

Additional Safety Instructions for Drum Sanders

26" DOUBLE DRUM SANDER

SAFETY

MODEL W1678

INSTRUCTION MANUAL

Phone: 1-360-734-3482 • On-Line Technical Support: tech-support@shopfox.biz

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT

THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.

Printed in Taiwan

Read and understand this entire instruction manual before using this machine. Serious personal injury may occur if safety and operational information is not understood and followed. Do not risk your safety by not reading!

Use this and other machinery with caution and respect, and always consider safety first, as it applies to your individual working conditions. Remember, no list of safety guidelines can be complete, and every shop environment is different. Failure to follow guidelines can result in serious personal injury, damage to equipment or poor work results.

• ALWAYS keep bystanders and yourself away from the infeed and outfeed ends when a workpiece is

fed into the sander.

• ALWAYS secure aprons, clothing, and long hair away from all sander moving parts.

• ALWAYS use a respirator along with a dust collection system when sanding. Dust from some woods is toxic,

so make sure you research the dangers of the specific species of wood you will sand.

• ALWAYS keep your hands away from the sanding drums during operation, and wear eye and hearing

protection.

• ALWAYS keep fingers away from the conveyor and the underside of the workpiece during sander and

conveyor operation. Otherwise, fingers can get pinched between the workpiece and the conveyor belt, and pull your hand into the machine causing serious injury or death!

• ALWAYS adjust the conveyor feed rate and sanding drum height, so when you feed the workpiece

into the sander using light pressure, you do not overload the sander. Never force the workpiece into the sander.

• ALWAYS shut the sander down, let the drums come to a complete stop, and disconnect power or

engage applicable safety-lock devices before you service, adjust, troubleshoot, or leave the machine unattended.

• ALWAYS keep this machine in correct adjustment and properly serviced. Never attempt to clear a

jammed workpiece while the sander is running.

• ALWAYS replace the sandpaper when it is worn, and only use undamaged sandpaper.

• ALWAYS inspect the workpiece for nails, staples, knots, imbedded stones, and other material that

could be dislodged and thrown from the machine during sanding operations.

• NEVER sand if there is any doubt about the stability or integrity of the workpiece.

• NEVER sand more than one workpiece at a time.

• NEVER sand stock smaller than

⁄8" thick x 9" long.

• NEVER sand thin stock by using a “sled” (another board) under the workpiece.

• NEVER adjust the conveyor belt tracking when the sanding drums are engaged.

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Avoiding Potential Injuries

SAFETY

Figure 1. NEVER hold the stock where the conveyor and stock can pinch your fingers.

Figure 3. NEVER stand in the path of potential

workpiece kickback.

Figure 2. ALWAYS keep fingers away from

conveyor and the underside of the stock.

Figure 4. ALWAYS keep yourself and bystanders

away from the path of potential workpiece kickback.

Figure 5. NEVER sand more than one piece of

stock at a time.

Figure 6. ALWAYS feed the sander with only one

piece of stock at a time.

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SAFETY

Figure 7. NEVER sand stock using a “sled”

(another board) under the workpiece.

Figure 8. ALWAYS sand the workpiece with it

sitting flat against the conveyor belt.

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ELECTRICAL REQUIREMENTS

220V Operation

The SHOP FOX® Model W1678 Drum Sander uses one 220 VAC single-phase motor. This sanding drum motor is rated at 5 HP and draws approximately 25 amps under a normal sanding load.The uses 60 VDC and draws approximately 2 amps.

Refer to the wiring diagram on Pages 35 and 36, and hard wire the power supply to the sander, or use a NEMA-style L6-30 plug and receptacle as shown in Figure 9. In either case, the supply circuit, circuit breaker, or fuse must be able to carry a load of at least 27 Amps. Remember other machines using this circuit add to the total electrical load applied to the circuit. If this total amperage load exceeds the amperage rating of the circuit breaker or fuse, use a different circuit with a higher amperage rating.

DO NOT modify an existing low-amperage circuit by only replacing the circuit breaker with a breaker rated for a higher amperage. The breaker and the complete circuit must be replaced by a qualified electrician.

⁄3 HP varyable speed conveyor motor

Grounding

Any electrical outlet and circuit that you plug your machine into must be grounded. Serious injury or fire may occur if this warning is ignored!

Ground this machine! The electrical cord

supplied with the Model W1678 does not come with a 220 volt plug. Use a plug with a ground pin as shown in Figure 9. If your receptacle does not accommodate a NEMA-style L6-30 plug with a ground pin, have the receptacle replaced by a qualified electrician or have an appropriate adapter installed and grounded properly.

NOTICE

When using an adapter, always make sure it is grounded.

ELECTRICAL

Extension Cords

We do not recommend using an extension cord with 220V equipment because the cord can generate heat that may cause fire or circuit damage. If you must use an extension cord, use the guidelines listed below and determine the correct cord length and gauge. The amp rating of both motors combined is 27 amps at normal operation; however, the amperage will increase or decrease depending on the load you apply on the Double Drum Sander.

•Use a Standard Service (Grade S) cord or better

•Use a cord that is 50 feet or less only

•Use a cord with a NEMA-style L6-30 plug

•Use an undamaged cord only

Extension Cord Requirements

TABLE 2

Length and Gauge Amp Rating 25ft 50ft 100ft

17-20 #12 #12 #10 21-30 #10 #10 N/A

TABLE 2 to

Remember, an adapter with a grounding wire does not guarantee the machine will be grounded. A ground source must always be verified in the electrical circuit within the wall or conduit.

L6-30R

L6-30P

Figure 9. NEMA-style L6-30 plug and

receptacle.

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ASSEMBLY

Unpacking

Get moving assistance before starting assembly. The Model W1678 Double Drum Sander is a heavy load at 435 pounds.

The Model W1678 26" Double Drum Sander is carefully packed. However, if it is damaged or is missing any parts, please contact Woodstock International Service and Support at 1-360-734-3482 or send e-mail to: tech-support@shopfox.biz.

Figure 10. W1678 26" Double Drum Sander.

Box Contents

Lay out and inventory the shipped parts to familiarize yourself with your Model W1678 26" Double Drum Sander. See Figures 10 and 11. This will help with the machine assembly.

ASSEMBLY

Item Qty.

1. W1678 26" Double Drum Sander 1

2. Control Box 1 3 Crank Wheel 1

4. Dust Port (Concave Base) 1

5. Crank Handle 1

6. Dust Port (Flat Base) 1

7. Hand Knobs 2

8. Hardware and Tool Bag: 1

• Self Tapping Screw (#8 X

• Flat Washer (#10) 8

• Hex Bolt (3/8"-16 X 2") 2

• Flat Washer (3/8") 2

• Hex Wrench (3 mm) 1

• Hex Wrench (5 mm) 1

⁄2") 8

Figure 11. Components.

NOTICE

Depending on manufacture date, some of the box contents may already be installed on your sander.

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Shop Preparation

Make sure shop entrances are locked and machines are equipped with safety lock-out devices when not in use. DO NOT allow untrained people in your shop! Otherwise, injury or death can occur.

• Machine Mobility: If you need to move your

drum sander or other machinery to achieve any of the following requirements, Woodstock International Inc. offers a line of SHOP FOX sander, use the SHOP FOX Duty Mobile Base (Model Number D2058) and the SHOP FOX (Model Number D2246).

• Double Drum Sander Location: Choose a

location where, if a workpiece should be ejected, you or bystanders will not be struck. Take all necessary safety precautions.

Mobile Bases. For your drum

Super Heavy-

36" Extension Bars

Initial Cleaning

If the sander has any dust or slight stains from shipping, DO NOT use a mineral-spirit solvent or chlorine-based cleaner to clean any painted or plastic surface, or the rubber conveyor belt. If you do, you will permanently ruin the surface. Instead, use a clean moist towel dampened with mild dish soap and water to clean these surfaces.

If the sander has any grease spots which may have fallen on metal parts from a drum bearing during shipping, read and understand the following Warnings and Cautions, and then use mineral spirits to remove the excess grease. Then coat the cleaned metal surface with a light coat of machine oil to prevent corrosion.

Never use flammables such as gas or other petroleum-based solvents to clean your machine. These products have low flash points and present the risk of explosion and severe personal injury!

ASSEMBLY

• Working Clearances: Consider your current

and future needs with respect to the size of lumber to be processed at each machine, space for auxiliary stands, work tables, and other machinery.

• Lighting: Make sure your lighting eliminates

shadows and prevents eye strain.

• Outlets: Make sure electrical circuits are

dedicated or large enough to handle the amperage requirements of the new machinery. Electrical outlets should be located near each machine so power or extension cords are clear of high-traffic areas.

Never smoke while using cleaning solvents. Smoking may cause explosion or risk of fire when exposed to these products!

Most solvents used to clean machinery are toxic when inhaled or ingested. When using these products, work in a well ventilated area and keep away from any potential ignition sources (pilot lights). Always dispose of waste rags in a sealed container to make sure they do not cause fire or environmental hazards.

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Beginning

Dust Ports

The main components of the Model W1678 are assembled at the factory. However, some assembly is required. We recommend the following sequence in this section for assembly.

ASSEMBLY

Keep your drum sander unplugged during all assembly, maintenance, and adjustment tasks. Ignoring this warning can cause serious personal injury to you or others!

Wear safety glasses during assembly. Serious injury may occur if this warning is ignored!

Get moving assistance before starting assembly. The Model W1678 Double Drum Sander is a heavy load at 435 pounds.

When connected to a dust collection system, the dust ports direct suction to remove harmful wood and abrasive dust from the workpiece and your work area. Make sure the dust collection system draws at least 600 CFM at the drum sander; however,

DO NOT operate this machine without the correct dust collection system. Failure to use a dust collection system can result in short and longterm respiratory illness.

there will still be a normal layer of dust on the workpiece when it exits the sander unless a larger capacity dust collector is used.

Make sure you connect flexible ducting to the dust ports. This ducting allows you to open the dust hood, change sandpaper, and service your sander without having to disconnect the ducting.

For additional information on the correct dust collection system, additions, or modifications; contact your Woodstock International dealer for your copy of the Dust Collection Basics handbook and available accessories.

Figure 12. Dust ports installed.

To install dust ports, do these steps:

1. Position the dust ports on the dust hood so the screw holes line up. See Figure 12.

2. With the dust ports held in position on the

dust hood, install the #10 flat washers on the

⁄2" self tapping screws and secure the dust

#8ports to the dust hood.

3. Connect your dust collection suction hose to the dust ports, so when you open the dust hood the suction hoses will not bind, leak, or disconnect the dust-collector ducting ground.

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Shipping

Bolts

L-Bracket

Figure 13. The control box, L-brackets, and

bolts for shipping.

Control Box

The control panel allows you to control the sander electronically. For shipping, the control box comes bolted to the sander with L-brackets. Retain these brackets should you ever need to ship the sander. See Figure 13.

To install the control box, do these steps:

1. Remove the L-brackets, bolts, and washers

securing the control box to the back of the sander. See Figure 14.

2. Position the control box on the sander and secure with (2) 3/8" flat washers and (2) 3/8"-16 X 2" hex bolts.

3. Tighten the bolts. See Figure 14.

Crank and Handle

The crank and handle is used to raise and lower the conveyor. For each revolution of the crank, the conveyor moves 0.021".

ASSEMBLY

Hex

Bolts

Figure 14. Installing new hex bolts and

washers.

Handle

Set Screw

To install the crank and handle, do these steps:

1. Thread the handle into the crank and use a

⁄2" wrench to tighten the handle to the crank.

2. Slide the handwheel onto the shaft and

align the threaded set screw bore on the crank with the flat on the shaft.

3. Thread the

crank to secure the handwheel to the shaft. See Figure 15.

4. Use the 4 mm hex wrench and tighten the set

screw.

⁄16"-18 x 1⁄2" set screw into the

Figure 15. The crank and handle installed.

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ADJUSTMENTS

Drums and Pressure

Rollers

To get the best sanding results and longest life

Adjust the sanding drums and pressure rollers correctly. Complete PART 1, PART 2, PART 3, and PART 4 of this section in sequence. Otherwise, the sanding drums can grab and project the workpiece damaging the sander, and injuring you and bystanders!

out of your sandpaper, both the front and rear sanding drums must: (1) be square with the conveyor table, (2) run parallel with each other and parallel to the conveyor feed direction, and (3) must be slightly staggered in height with one another. Pressure-roller spring tension and height must also be set correctly.

Figure 16. Gauge blocks for drum alignment.

As you become more familiar with your sander you can vary your sander settings to fine-tune the machine for your ultimate sanding goals.

PART 1: Drum-to-Conveyor

Squareness

ADJUSTMENTS

For this adjustment, you will align the drums so the drums are square with the feed conveyor belt surface. See Figure 18.

To adjust the drum-to-conveyor squareness, do these steps:

1. Make two gauge blocks from a quality piece

of straight two-by-four hardwood stud. One block should be 30" long, and the other 2 long. See Figure 16.

Keep your drum sander unplugged during these adjustments. Otherwise, serious personal injury may occur!

Figure 17. W1678 dust hood open.

⁄8"

2. Unplug the Double Drum Sander!

3. Unlatch and open the dust hood. See Figure

17.

Figure 18. Drums to conveyor not square.

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+ 36 hidden pages