Shop fox W1689 User Manual
INSTRUCTION MANUAL
MODEL W1689
15" Wide Belt Sander
Phone: 1-360-734-3482 • On-Line Technical Support: tech-support@woodstockint.com
COPYRIGHT © August, 2002 BY WOODSTOCK INTERNATIONAL, INC.
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
ONLINE MANUAL DISCLAIMER
THE INFORMATION IN THIS MANUAL REPRESENTS THE CONFIGURATION OF THE MACHINE AS IT IS CURRENTLY BEING SHIPPED. THE MACHINE CONFIGURA-
TION CAN CHANGE AS PRODUCT IMPROVEMENTS ARE INCORPORATED. IF YOU OWN AN EARLIER VERSION OF THE MACHINE, THIS MANUAL MAY NOT
EXACTLY DEPICT YOUR MACHINE . CONTACT CUSTOMER SERVICE IF YOU HAVE ANY QUESTIONS ABOUT DIFFERENCES. PREVIOUS VERSIONS ARE NOT
AVAILABLE ONLINE.
WARNING
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
1. INTRODUCTION..............................................................................................2
About Your New Sander..............................................................................2
Woodstock Service and Support....................................................................2
Warranty and Returns ................................................................................3
Machine Specifications ..............................................................................3
2. SAFETY ......................................................................................................4
Standard Safety Instructions ....................................................................4-5
Additional Safety Instructions For Sanders ......................................................6
Avoiding Potential Injuries ..........................................................................7
Electrical Requirements ............................................................................8
220V Operation ........................................................................................8
Extension Cords........................................................................................8
Grounding ..............................................................................................8
3. ASSEMBLY INSTRUCTIONS ................................................................................9
Unpacking ..............................................................................................9
Box Contents ..........................................................................................9
Shop Preparation ....................................................................................10
Cleaning Machine ....................................................................................10
Beginning Assembly ................................................................................11
Handwheel Handle ..................................................................................11
Installing Platen ......................................................................................12
Attaching Air Hose ..................................................................................13
Installing Sanding Belts ............................................................................13
Tensioning Belt ......................................................................................14
Pressure Rollers ......................................................................................14
Dust Collection ......................................................................................15
4. ADJUSTMENTS ............................................................................................16
General Information ................................................................................16
Oscillation Timing ..............................................................................16-17
Oscillation Speed ....................................................................................17
Oscillation Return ..............................................................................17-18
Limit Switches ........................................................................................18
Platen Depth ..........................................................................................19
Pressure Rollers..................................................................................19-20
Pressure Roller Tension ............................................................................21
V-Belt Tension ........................................................................................21
Feed Belt Tension ..................................................................................22
Feed Belt Tracking ..................................................................................22
5. OPERATIONS ..............................................................................................23
Starting Sander ......................................................................................23
Selecting Sandpaper ................................................................................23
Table Height ..........................................................................................24
Feed Speed............................................................................................24
Using Load Meter ....................................................................................25
Emergency Brake ....................................................................................25
Operating..........................................................................................25-26
Adjusting Platen......................................................................................26
6. MAINTENANCE ............................................................................................27
General ................................................................................................27
Lubrication ............................................................................................27
Cleaning Belts ........................................................................................28
Servicing Filters ......................................................................................28
Platen Graphite ......................................................................................28
Changing V-Belts ....................................................................................29
Servicing Brake ......................................................................................30
Troubleshooting..................................................................................31-32
Wiring Diagrams..................................................................................33-35
6. CLOSURE ..........................................................................................36
Parts Breakdown and Parts Lists ....................................................37-46
ASSEMBLY OPERATIONS
MAINTENANCE
PARTS
ADJUSTMENTSSAFETYINTRODUCTION
USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!
INTRODUCTION
-2-
INTRODUCTION
About Your New Sander
Your new SHOP FOX®Sander has been specially designed to provide many years of trouble-free service.
Close attention to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation.
The Model W1689 is a very versatile and easy to use sander. The wide belt sanding action combined with
the pneumatic oscillation produces near finish quality results every time.
Woodstock International, Inc. is committed to customer satisfaction in providing this manual. It is our
intent to make sure all the information necessary for safety, ease of assembly, practical use and durability of this product be included.
If you should have any comments regarding this manual, please feel free to contact us at:
Woodstock Service and Support
We stand behind our machines! In the event that a defect is found, parts are missing or questions arise
about your machine, please contact Woodstock International Service and Support at 1-360-734-3482 or
send e-mail to: tech-support@woodstockint.com
. Our knowledgeable staff will help you troubleshoot
problems, send out parts or arrange warranty returns.
Woodstock International, Inc.
Attn: Technical Department
P.O. Box 2309
Bellingham, WA 98227
INTRODUCTION
-3-
INTRODUCTION
Warranty And Returns
Woodstock International, Inc. warrants all SHOP FOX®machinery to be free of defects from workmanship and materials for a period of 2 years from the date of original purchase by the original owner. This
warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents,
lack of maintenance, or to repairs or alterations made or specifically authorized by anyone other than
Woodstock International, Inc.
Woodstock International, Inc. will repair or replace, at its expense and at its option, the SHOP FOX
®
machine or machine part which in normal use has proven to be defective, provided that the original
owner returns the product prepaid to the SHOP FOX
®
factory service center or authorized repair facility
designated by our Bellingham, WA office, with proof of their purchase of the product within 2 years, and
provides Woodstock International, Inc. reasonable opportunity to verify the alleged defect through
inspection. If it is determined there is no defect, or that the defect resulted from causes not within the
scope of Woodstock International Inc.'s warranty, then the original owner must bear the cost of storing
and returning the product.
This is Woodstock International, Inc.'s sole written warranty and any and all warranties that may be
implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited
to the duration of this written warranty. We do not warrant that SHOP FOX
®
machinery complies with
the provisions of any law or acts. In no event shall Woodstock International, Inc.'s liability under this warranty exceed the purchase price paid for the product, and any legal actions brought against Woodstock
International, Inc. shall be tried in the State of Washington, County of Whatcom. We shall in no event
be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages arising from the use of our products.
Every effort has been made to ensure that all SHOP FOX
®
machinery meets high quality and durability
standards. We reserve the right to change specifications at any time because of our commitment to continuously improve the quality of our products.
Machine Specifications
Sanding Motor Size ..........................................................5 HP, 220V, Single-Phase
Sanding Motor Speed ............................................................................3450 RPM
Conveyor Motor Size........................................................
1
⁄4 HP, 220V, Single-Phase
Total Amps (Both Motors) ..........................................................................27.8A
Maximum Board Width..................................................................................15"
Maximum Board Thickness............................................................................5
1
⁄2"
Minimum Board Length ................................................................................12"
Surface Speed Of Drums ........................................................................2050 FPM
Conveyor Feed Rate ......................................................................13 & 16.4 FPM
Machine Weight ....................................................................................815 lbs
Dust Port ..................................................................................................5"
SAFETY
-4-
READ MANUAL BEFORE OPERATING MACHINE.
FAILURE TO FOLLOW INSTRUCTIONS BELOW WILL
RESULT IN PERSONAL INJURY.
SAFETY FIRST!
Standard Safety Instructions
1. Thoroughly read the instruction manual before operating your machine. Learn the applications,
limitations and potential hazards of this machine. Keep manual in a safe, convenient place for future
reference. Make sure any other operators have read and understand the manual as well.
2. Keep work area clean and well lighted. Clutter and inadequate lighting invite potential hazards.
3. Ground all tools. If a machine is equipped with a three-prong plug, it must be plugged into a three-
hole grounded electrical outlet or grounded extension cord. If using an adapter to aid in accommodating a two-hole receptacle, ground using a screw to a known ground.
4. Wear eye protection at all times. Use safety glasses with side shields or safety goggles that meet
the national safety standards, while operating this machine.
5. Avoid dangerous environments. Do not operate this machine in wet or open flame environments.
Airborne dust particles could cause an explosion and severe fire hazard.
6. Ensure all guards are securely in place and in working condition.
7. Make sure switch is in the “OFF” position before connecting power to machine.
8. Keep work area clean, free of clutter, grease, etc.
9. Keep children and visitors away. Visitors should be kept at a safe distance away while operating
unit.
10. Childproof workshop with padlocks, master switches or by removing starter keys.
11. Disconnect machine when cleaning, adjusting or servicing.
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, MAY result in property damage.
This symbol is used to alert the user to useful information about proper
operation of the equipment.
NOTICE
SAFETY
-5-
12. Do not force the machine. The machine will do a safer and better job if IT does the work.
13. Use the correct tool. Do not force the tool or attachment to do a job for which it was not designed.
14. Wear proper apparel. Do not wear loose clothing, gloves, jewelry, keep long hair tied up, etc.
15. Remove adjusting keys and wrenches. Before turning the machine on, make a habit of checking
that all adjusting keys and wrenches have been removed before turning the machine ON.
16. Use proper extension cord. Examine the extension cord to ensure it is in good condition. Use the
chart below to determine the correct length and gauge of extension cord needed for your particular
needs. The amp rating of the motor can be found on its nameplate. If the motor is dual voltage, be
sure to use the amp rating for the voltage you will be using. If you use an extension cord with an
undersized gauge or one that is too long, excessive heat will be generated within the circuit increasing the chance of a fire or damage to the circuit. Never use an extension cord that does not have a
ground pin and connected ground wire. Immediately replace an extension cord if it shows any signs
of damage.
17. Keep stable footing and balance at all times.
18. Do not leave machine unattended. Wait until it comes to a complete stop before leaving the area.
19. Perform machine maintenance and care. Follow lubrication and accessory attachment instructions
in the manual.
20. Keep machine away from open flame. Operating machines near pilot lights and/or open flames creates a high risk if dust is dispersed in the area. Dust particles and an ignition source may cause an
explosion. Do not operate the machine in high-risk areas, including but not limited to, those mentioned above.
21. If at any time you are experiencing difficulties performing the intended operation, stop using the
machine! Then contact our Service Department or ask a qualified expert how the operation should
be performed.
22. Habits—good and bad—are hard to break. Develop good habits in your shop and safety will become
second-nature to you.
Operating this equipment creates the
potential for flying debris to cause eye
injury. Always wear safety glasses or goggles when operating equipment. Everyday
glasses or reading glasses only have impact
resistant lenses, they are not safety glasses.
Be certain the safety glasses you wear meet
the appropriate standards of the American
National Standards Institute (ANSI).
Length And Gauge
Amp Rating 25ft 50ft 100ft
0-6 #18 #16 #16
7-10 #18 #16 #14
11-12 #16 #16 #14
13-16 #14 #12 #12
17-20 #12 #12 #10
21-30 #10 #10 No
Extension Cord Requirements
SAFETY
-6-
Additional Safety Instructions For Sanders
No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Use this and
other machinery with caution and respect.
Failure to follow guidelines could result in
serious personal injury, damage to equipment or poor work results.
1. Always wear a dust mask. Sanding operations create large amounts of fine dust. Some types of dust
may cause allergic reactions or respiratory problems. In addition to wearing a dust mask, always use
a dust collector and overhead air filter for maximum protection.
2. Do not allow your fingers to get pinched between the board and the conveyor belt during feed-
ing. The grip of the conveyor belt may pull the operator’s hand into the machine and cause serious
injury or death. Similarly, do not place hands near the sanding belts during operation.
3. Know the limits of the sander. Do not sand stock thinner than
1
⁄8
" or shorter than 9".
4. Never perform sanding operations with the access doors open.
5. Always inspect stock for staples, nails, dirt or other foreign objects before sanding. These items
may cause damage to your sander or may even be thrown at a high rate of speed from the sander
at the operator.
6. Never allow anyone to stand directly in front or behind the path of the stock as it is being fed
through the sander. The stock may be ejected at a high rate of speed and could cause serious injury
to the operator or bystanders.
7. Treat your sander with respect. Do not force stock into the sander during operation or overload
the sanding drums beyond reasonable limits. Also, only sand natural wood fiber through your sander.
Other materials may damage your machine and open the possibility for operator injury. Keep the
internal components clean and lubricated to ensure that the sander can perform the way it was
intended.
8. Never operate the sander without a working dust collection system. The sander is designed to
properly do its job only when wood dust is being evacuated. The buildup of too much wood dust in
the internal components will cause performance problems and may increase the likelihood of operator injury.
9. Wear the proper clothing during all operation and adjustments. Loose clothing or long hair creates the potential for operator injury because they can easily be caught in the moving parts of the
machine. Roll up loose sleeves, tie back long hair and take any other necessary steps to reduce this
hazard.
Read and understand this
entire instruction manual
before performing any
operations with your
machine. Serious personal
injury may occur if safety
and operational information is not understood and
followed.
SAFETY
-7-
Avoiding Potential Injuries
Figure 1. Correct operation.
Figure 2. DO NOT operate without safety glasses/dust mask!
Figure 3. DO NOT stand behind workpiece!
Figure 4. DO NOT operate with door open!
Figure 5. DO NOT allow hand to get pinched in belt!
SAFETY
-8-
Electrical Requirements
220V Operation
We do not recommend using an extension cord
for 220V equipment. Instead, arrange the placement of your machinery and installed wiring to
eliminate the need for extension cords. If you
must use an extension cord, make sure it is
rated Hard Service (grade S) or better. The
extension cord must always contain a ground
wire and plug pin. Always repair or replace
extension cords when they become worn or
damaged.
Extension Cords
Grounding
This machine must be grounded! The electrical
cord supplied with the Model W1679 does not
come with a 220 volt plug. Use a NEMA-style 630 plug and outlet similar to Figure 6. Make sure
your ground source is verified!
The SHOP FOX
®
W1689 has a 5 HP, 220V single-
phase sanding motor and a
1
⁄4
HP, 220V feed
motor. Both of these motors combined draw
approximately 27.8 amps under load.
Use a 30 amp circuit breaker in a circuit that has
wiring rated to handle this amperage draw.
Keep in mind that a circuit being used by other
machines or tools at the same time will add to
the total load being applied. Add up the load
ratings of all machines on the circuit. If this
number exceeds the rating of the circuit breaker or wiring, use a different circuit.
Figure 6. This is a typical NEMA-style 6-30 plug
and outlet.
DO NOT replace the circuit breaker with
one rated at a higher amperage or damage
to the circuit may occur.
Any electrical outlet and circuit that you plug your
machine into must be
grounded. Never remove
the grounding pin from any
plug and always make sure
all wiring to the machine is
grounded before operating.
Serious injury may occur if
this warning is ignored!
6-30R6-30P
ASSEMBLY
-9-
The following is a description of the components
shipped with the SHOP FOX
®
W1689. Lay the
components out in a similar fashion to those in
Figure 7. This will help in identification before
beginning assembly. Should any part be missing,
examine the packaging carefully. If any parts
are missing, find the part number in the back of
this manual and call Woodstock International,
Inc. at 360-734-3482 or e-mail:
tech-support@woodstockint.com
.
Sander ..............................................(1)
Tool Box ............................................(1)
Combination Wrench 8 x 10MM ................(1)
Combination Wrench 11 x 13MM ................(1)
Combination Wrench 12 x 14MM ................(1)
Combination Wrench 17 x 19MM ................(1)
Box Wrench 30 x 37MM ..........................(1)
Phillips Screwdriver ..............................(1)
10-Piece Hex Wrench Set ........................(1)
Door Handles ......................................(2)
Platen ..............................................(1)
Platen Puller ......................................(1)
Handwheel Handle ................................(1)
Sanding Belt #180 ................................(1)
Sanding Belt #240 ................................(1)
Item Qty.
Figure 7. These are the loose parts shipped
with the sander.
Unpacking
Box Contents
The Model W1689 has been carefully packaged
for safe transporting. If you notice the machine
has been damaged, please contact Woodstock
International Service and Support at 1-360-7343482 or send e-mail to:
tech-support@woodstockint.com
.
ASSEMBLY INSTRUCTIONS
Read and understand this
entire instruction manual
before performing any
operations with your
machine. Serious personal
injury may occur if safety
and operational information is not understood and
followed.
The Model W1683 is a
heavy machine at 815
lbs. Use power or
hydraulic equipment to
avoid serious personal
injury or death.
ASSEMBLY
-10-
Shop Preparation
• Floor Load: Your sander represents a large
weight load in a small footprint. Most commercial floors are suitable for the sander.
Some residential floors may require additional bracing to support both machine and
operator.
• Working Clearances: Consider existing and
anticipated needs, size of material to be
processed through each machine, and
space for auxiliary stands, work tables or
other machinery when establishing a location for your sander.
• Lighting and Outlets: Lighting should be
bright enough to eliminate shadows and
prevent eye strain. Electrical circuits
should be dedicated or large enough to
handle amperage requirements. Outlets
should be located near each machine so
power or extension cords are clear of hightraffic areas. Observe local electrical codes
for proper installation of new lighting, outlets, or circuits.
Cleaning Machine
The table and other unpainted parts of the
Model W1689 are coated with a waxy grease that
protects them from corrosion during shipment.
For optimum performance from your machine,
make sure you clean all moving parts or sliding
contact surfaces that are coated. Clean this
grease off with a solvent cleaner or citrus-based
degreaser. Do not use chlorine-based solvents—
if you happen to splash some onto a painted surface, you will ruin the finish.
Always make sure that all
entrances to your shop are
locked or that machines
are equipped with safety
lock-out devices to protect
curious children or visitors
from serious injury. Never
allow unsupervised people
in your shop who have not
been fully trained!
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!
Never smoke while using
any 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 any
waste rags in a sealed
container to make sure
they do not cause fire or
environmental hazards.
ASSEMBLY
-11-
Beginning
Although the main components of the SHOP
FOX
®
W1689 are assembled at the factory, some
assembly is required. The following series of
instructions are the recommended sequence
best suited for final assembly.
Tools required that are not included: A high
quality straightedge, a 45˚ angle gauge and an
adjustable wrench.
Handwheel Handle
Install the handle on the handwheel as follows:
1. Make sure that the jam nut is threaded com-
pletely onto the handle.
2. Use a flat-head screwdriver to thread the
handle all the way into the handwheel as
shown in Figure 8.
3. Unthread the handle
1
⁄2 a turn to make the
plastic sleeve loose enough rotate around
the handle freely.
4. Tighten the jam nut down to the handwheel.
Figure 8. Handle installed on handwheel.
Make sure that your
machine is unplugged
during all assembly procedures! If this warning
is ignored, serious personal injury may occur.
ASSEMBLY
-12-
Figure 9.
Installing platen.
Figure 10. Platen adjustment knob.
Installing Platen
Install the platen into the sander as follows:
1. Facing the front of the sander, open the left
hand access door with the included door
handle.
2. Directly below the adjustment knob is a
slide housing for the platen. Locate the
slide housing and install the platen so that
the graphite pad is on the left-hand side.
Figure 9 shows the correct insertion of the
platen.
When the platen is inserted correctly, it must
be set even with the sanding belt rollers as follows:
1. Lower the conveyor table down as far as it
will go, so that you have enough room to
work under the sanding belt rollers.
2. Place a straightedge across the bottom of
both sanding belt rollers.
3. Using the platen adjustment knob shown in
Figure 10, position the platen so that it
barely touches the straightedge, and thus,
is even with both sanding belt rollers.
The platen at level position is an important reference point for future operations.
ASSEMBLY
-13-
Attaching Air Hose
The regulator on the front of the sander has a
nozzle for attaching the air hose. Connect your
air hose and clamp it in place with a hose clamp
as shown in Figure 11. If you prefer, you can
replace the included air nozzle with a
3
⁄8" male
quick connect air coupling.
When the air hose is installed, regulate the air
pressure to 75 PSI. This is the required operating
pressure for this sander.
Installing
Sanding Belt
The sanding belt must be installed from the left
side of the sander. Before installing, make sure
the protective grease has been cleaned (as
described in “Cleaning Machine” instructions)
from the metal sanding belt rollers.
Pay special attention to the direction of the
arrows on the inside of the sanding belt. These
arrows show the direction that the sanding belt
is designed to rotate during operation. Facing
the inside of the left-hand access door, the
sanding belt will rotate counterclockwise.
Install the sanding belt as shown in Figure 12
and center it on the rollers.
Figure 11. Air hose attached to regulator.
Figure 12. Installing sanding belt over rollers.
The arrows on the inside must point in the
same direction as belt rotation.
DO NOT exceed 75 PSI or damage to the air
system may result!
NOTICE
Keep the air pressure shut off when not in
use to reduce wear and tear on the air system.
NOTICE
ASSEMBLY
-14-
Figure 13. Belt tension switch.
Tensioning Belt
The switch shown in Figure 13 controls the
sanding belt tension. When the air pressure is
connected and the switch is flipped up, the belt
will automatically tighten to the correct tension. Flipping the switch down will immediately
release the belt tension. The belt tension will
only engage while the sander has air pressure.
Likewise, the belt tensioner may not work correctly if the air pressure is not set to the
required 75 PSI.
Pressure Rollers
The pressure rollers are factory set, but we
recommend checking them as follows to minimize the potential for personal injury:
1. Make sure that the sander is unplugged
from the power!
2. Make sure that the platen is even with the
sanding belt rollers before continuing.
3. Obtain a board of uniform thickness that is
at least 24" long. Place the board in the center of the conveyor belt and position it
directly under both the front and rear pressure rollers.
4. The air pressure should be connected and
the sanding belt should be installed and tensioned for this next step. Look underneath
the sanding head at the pressure rollers and
sanding belt. Slowly raise the table and confirm that the board makes contact with
both pressure rollers before it touches the
sanding belt.
If the board DOES NOT make contact with both
pressure rollers before touching the sanding
belt, then the pressure rollers must be adjusted.
Refer to the Adjustments section for step-bystep instructions on how this can be done.
The belt must be tightened before starting
the sander!
NOTICE
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