MODEL W1678 26" DOUBLE DRUM SANDER INSTRUCTION MANUAL Phone: 1-360-734-3482 • On-Line Technical Support: tech-support@shopfox.biz COPYRIGHT © MAY, 2003 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.
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.
PAGE INTRODUCTION ....................................................................................2 Specifications ................................................................................3 SAFETY ..............................................................................................4 Standard Safety Instructions ....................................................................4-5 Additional Safety Instructions for Drum Sanders ..............................................
INTRODUCTION INTRODUCTION About Your New 26" Double Drum Sander Your new SHOP FOX® W1678 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 W1678 features a 220V single-phase 5 HP motor, dual 4" dust ports, controls for major and micro sanding drum adjustments, amperage measuring load meter, and many other features.
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.
SAFETY SAFETY READ MANUAL BEFORE OPERATING MACHINE. FAILURE TO FOLLOW INSTRUCTIONS BELOW WILL RESULT IN PERSONAL INJURY. 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.
12. Do not force tool. The machine will do a safer and better job at the rate for which it was designed. 13. Use correct tool. Do not force machine or attachment to do a job for which it was not designed. 14. Wear proper apparel. Do not wear loose clothing, neck ties, gloves, jewelry, and secure long hair away from moving parts. 16.Avoid using an extension cord. But if you must use Extension Cord Requirements 16. TABLE 1 one, examine the extension cord to ensure it is in good condition.
SAFETY Additional Safety Instructions for Drum Sanders MODEL W1678 26" DOUBLE DRUM SANDER INSTRUCTION MANUAL Phone: 1-360-734-3482 • On-Line Technical Support: tech-support@shopfox.biz COPYRIGHT © MARCH, 2003 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 Read and understand this entire instruction manual before using this machine.
Avoiding Potential Injuries SAFETY Figure 1. NEVER hold the stock where the conveyor and stock can pinch your fingers. Figure 2. ALWAYS keep fingers away from conveyor and the underside of the stock. Figure 3. NEVER stand in the path of potential workpiece kickback. 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.
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.
ELECTRICAL REQUIREMENTS 220V Operation Grounding 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 1⁄3 HP varyable speed conveyor motor uses 60 VDC and draws approximately 2 amps. Any electrical outlet and circuit that you plug your machine into must be grounded.
ASSEMBLY Unpacking Get moving assistance before starting assembly. The Model W1678 Double Drum Sander is a heavy load at 435 pounds. 1 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. 2 Figure 10.
Shop Preparation 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. Make sure shop entrances are locked and machines are equipped with safety lock-out devices when not in use.
Beginning Dust Port and Handles 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. 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. ASSEMBLY Keep your drum sander unplugged during all assembly, maintenance, and adjustment tasks.
Control Box The control panel allows you to control the sander electrically. For shipping, the control box comes bolted to the sander with L-brackets and long and short bolts. Retain these brackets should you ever need to ship the sander. See Figure 13. Short Bolts Long Bolts To install the control box, do these steps: L-bracket 1. Remove the L-brackets, bolts, and washers, and reinstall the two short bolts (5⁄16"-18 x 1 ⁄2") and washers into the sander. See Figure 14. 2.
ADJUSTMENTS Drums and Pressure Rollers Adjust the sanding drums and pressure rollers correctly. Complete PART 1, PART 2, PART 3, and PART 4 of this section in sequence.
4. Lower the conveyor table and position the 30" gauge block under one end of the front drum and flush with the end of the conveyor. See Figure 19. 5. Turn the micro adjusting knob and raise the rear drum so it will not contact the gauge block. Gauge Block Barely Touching the Underside of Drum. 6. Rotate the front drum by hand, and raise the conveyor table until you hear the gauge block barely rub the underside of the front drum. Gauge Block End Flush with End of Conveyor. 7.
PART 2: Drum-to-Conveyor Parallelism Center-Tracking Conveyor For this adjustment, you will align the front drum so the sanding path runs parallel with the conveyor belt feed path. You will then align the rear drum to the front drum so it is parallel with the front drum. See Figure 22. Right-Tracking Drum NOTICE Left-Tracking Drum If the drum-to-conveyor parallelism is out of adjustment, the sandpaper may become loose and load-up over to one side of the drum(s). Figure 22.
5. At one end of the rear drum, place the 25⁄8" gauge block on the dust collector bar and between both drums. Your goal is to slide the rear drum against the block so the rear drum sanding path runs true with the front drum, which now runs true with the conveyor feed path. See Figure 25. 6. Loosen the left bearing-block mounting nuts at the end of the rear drum just enough to slide the bearing block. See Figure 26. 7.
PART 3: Drum-to-Conveyor Height For this adjustment, you will find a reference height for the front drum and then adjust the rear drum so it is 0.007" to 0.010" lower than the front drum. See Figure 27. REAR DRUM FRONT DRUM 0.007" to 0.010" NOTICE Make sure you use the same part of the 30" gauge block at the opposite side of the conveyer belt when adjusting the drum-to-conveyor height. Otherwise, the adjustment may be inconsistent. Figure 27. Drum-to-conveyor height.
PART 4: Pressure Roller Adjustment Pressure Roller Spring Tension Adjustment Depending on your sanding needs, adjust the pressure roller height and spring tension. See Figure 30. To adjust pressure-roller height, do these steps: 1. Loosen all six height jam nuts. See Figure 31. Pressure Roller Height Adjustment 2. Position the 30" gauge block to one side of the conveyor belt and under the three pressure rollers. See Figure 32. 0.012" to 0.024" 3.
Dust Scoop Gap For this adjustment, you will adjust the dust scoops so they can efficiently focus dust collection system suction where the most dust is created as the workpiece travels through the drum sander. You will set the dust scoops above the bottom of the drums. See Figure 33. Dust Scoop 1 Keep your drum sander unplugged during all assembly, maintenance, and adjustment tasks. Ignoring this warning can cause serious personal injury to you or others! 32" Figure 33. Dust scoop gap.
V-Belt Tension The sanding drums are driven by two heavy-duty V-belts. After drum adjustments and normal operation, the belts may need adjustment. The belt looseness or deflection must be approximately 1". Front Panel Mounting Screw Keep your drum sander unplugged during all assembly, maintenance, and adjustment tasks. Ignoring this warning can cause serious personal injury to you or others! Figure 36. Front panel and mounting screws. Make sure you inspect the V-belts correctly when adjusting the belts.
Conveyor Belt For this adjustment, you will adjust the feed conveyor belt hanging gap and the tracking, so the conveyor runs in the center of the table and the drive roller does not slip at maximum sanding load. See Figure 39. NOTICE ONLY make adjustments to the infeed roller side so the drive-chain tension is not affected. 1 2" Figure 39. Conveyor belt hanging gap. Make sure loose clothing and long hair is secured and kept away from all moving parts.
OPERATIONS Overview Control Panel The Model W1678 26" Double Drum Sander accepts stock up to 41⁄2" thick by 26" wide, and is capable of completing rough and finish sanding in one pass. The control panel enables you to turn the conveyor ON/OFF, control the workpiece feed rate, turn the sanding drums ON/OFF, and monitor the sanding load applied by observing the load meter on the control panel. The panel controls are described in detail below. See Figure 42 for control locations.
Basic Sanding The normal sanding depth for most workpieces is 1 ⁄64". This depth can be achieved by approximately a 3⁄4 turn of the table height handwheel. For each turn of the handwheel, the conveyor table moves approximately 0.021" See Figure 43. Remember, heavy cuts and/or a feed rate that is too fast can jam or burn the workpiece, instantly burn the sandpaper, slip the drive belts and give poor sanding results. See Figures 44 and 45.
NOTICE ALWAYS take a few moments to listen and observe for unusual noise and vibration after starting the Double Drum Sander. To use the double drum sander, do these steps: 1. Twist and pull the emergency stop switch knob, and position your finger over the knob. Be ready to push the knob and shut the sander OFF if there is a problem. See Figure 46. Figure 46. Main power ON/OFF safety switch. 2. Push the sanding drum ON button and listen for any unusual noises.
NOTICE Since various types of stock will react differently with various loads, use a process of trial-and-error to determine the best load settings and feed rate for your sanding needs. A slower feed rate will sand the surface smoother, but risks burning the wood; a faster feed rate will remove material faster, but risks overloading the motor. As a general rule, always start with a small load and work your way up.
Troubleshooting Use this troubleshooting chart to correct potential W1678 Double Drum Sander problems. SYMPTOM The sanding drums will not start. The feed conveyor will not start, or it operates incorrectly. The main power emergency stop button is pushed in, or it is faulty. Twist and pull the main power emergency stop button, or test and replace the switch. NEVER attempt to repair safety switches, ONLY replace them with new ones.
Troubleshooting (Continued) SYMPTOM HOW TO REMEDY POSSIBLE REASON The feed conveyor belt stops or chatters. The conveyor belt tension is incorrect. Adjust the conveyor belt tension. The conveyor belt tracking is incorrect. Adjust the conveyor belt tracking. The sanded surface is glazed and shiny. The sandpaper is worn out. Replace the sandpaper. The drums are only applying light pressure against the sanded surface. Increase the sanding pressure on the workpiece surface.
MAINTENANCE General Sanding Belts Regular maintenance on your Model W1678 helps ensure optimum performance. Inspect your machine each time you use it for the following conditions. Adjust, repair, or replace parts when worn. As sanding drums are used, the sandpaper can quickly become "loaded" with sawdust. If not removed, this sawdust may harden on the abrasive surface and can glaze instead of sand the wood, thus, rendering the sandpaper useless. 1. Inspect for loose bolts and panels.
Lubrication The four drum bearings in the bearing blocks need to be lubricated every 20 hours of operation. However, all other bearings used on this machine are shielded and permanently lubricated. Simply leave them alone until they need to be replaced. DO NOT lubricate them, as this will only attract dust and cause possible premature bearing failure. Light Oil on Sprockets and Chain DO NOT apply grease on any exposed areas on the sander like the feed conveyor chain, sprockets, and the table lead screws.
Brush Replacement After long periods of heavy sander use, it may be necessary to replace the conveyor motor carbon brushes. Brush Cover To replace the carbon brushes, do these steps: Figure 54. Conveyor motor brush cover. 1. Unplug the double drum sander! 2. Raise the table to the highest position. 3. Use a flat-head screwdriver and remove the brush cover. See Figure 54. 4. Carefully slide out the spring and carbon brush. See Figure 55. 5.
Bearing Replacement The Model W1678 26" Double Drum Sander is designed for many years of reliable service. But after long periods of heavy sander use, it may be necessary to replace the drum bearings. Always replace both bearings on the same drum. Mounting Nuts Keep your drum sander unplugged during all assembly, maintenance, and adjustment tasks. Ignoring this warning can cause serious personal injury to you or others! Set Screws Zerk Fitting and Dust Cap Figure 57.
7. Remove any metal or abrasives trapped in the bearing grease groove and grease port, or contaminants will be pumped into the new bearing when you lubricate it, causing bearing failure. Figure 60. 8. Clean and inspect the bearing-block for cracks, burrs, wear, and other damage; replace/repair as required. Grease Port Bearing Block Grease Groove The “bearing race” should rotate inside of the “bearing block” smoothly.
General Cleaning DO NOT use a mineral-spirit solvent or chlorinebased cleaner to clean a painted or plastic surface, or the rubber conveyor belt. If you do, you will permanently ruin the surface. To clean grease from the sander, do these steps: 1. Unplug the double drum sander. 2. Use mineral spirits to remove the excess grease on the metal parts, and follow all manufacturer’s safety warnings. To clean dust from the sander, do these steps: 1. Unplug the double drum sander. 3.
W1678 26" Double Drum Sander Drive System Wiring Diagram Keep your machine unplugged during all service and wiring procedures. Otherwise serious personal injury may occur! Seek assistance from a qualified electrician if you do not understand the wiring diagram in this manual. Always follow the applicable electrical codes and standards. Otherwise serious personal injury or death may occur! NOTE: The motor power-supply wires in the POWER JUNCTION BOX besides the green wire are interchangeable.
W1678 26" Double Drum Sander Control System Wiring Diagram FEED MOTOR OFF N/C FEED MOTOR ON FEED MOTOR SPEED DRUM MOTOR OFF N/C CONV. MOTOR SPEED CIRCUIT BOARD (Frontside View) FUSE 10 A BLACK RED GREEN WIRING BLOCK (GROUND) CONV. MOTOR SWITCH CONV. MOTOR WHITE BLACK GREEN MAINTENANCE DRUM MOTOR SWITCH DRUM MOTOR GREEN RED BLACK -36- .
CLOSURE We recommend you keep this manual for complete information regarding Woodstock International, Inc.’s warranty and return policy. Should a problem arise, we recommend that you keep your proof of purchase with your manual. If you need additional technical information relating to this machine, or if you need general assistance or replacement parts, please contact the Service Department at 1-360-734-3482 or e-mail: tech-support@shopfox.biz.
46 2 41 45 42 1 40 74 37 36 64 61 29 66 51 50 59 49 36 37 32 64 32 61 29 17 51 51 62 67 75 74 64 65 47 61 32 51 29 57 32 74 23 55 56 76 32 64 74 29 63 59 37 56 10 36 61 37 50 54 36 12 11 68 52 77 44 39 43 PARTS 69 -38- 3
REF PART # 1 2 3 10 11 12 17 23 29 32 36 37 39 40 41 42 43 44 45 46 47 49 X1678001 XPHTEK7 XPK34M XPN02 XPSB05 XPW06 X1678017 XPSS08 X1678029 XPN03 XPSB05 XPS06 X1678039 X1678040 XPS07 XPW06 X1678043 X1678044 X1678045 XPFH12 XPLN02 X1678049 DESCRIPTION SCALE SELF TAP SCREW #8 X 3⁄8" KEY 5 X 5 X 20MM HEX NUT 5⁄16"-18 CAP SCREW 1⁄4"-20 X 3⁄4" FLAT WASHER 1⁄4" ADJUSTMENT PLATE SET SCREW 5⁄16"-18 X 1⁄2" SPECIAL BOLT HEX NUT 3⁄4"-16 CAP SCREW 1⁄4"-20 X 3⁄4" PHLP HD SCR #10-24 X 3⁄8" 1 ⁄3 HP FEED BELT MOTOR
143 144 146 142 145 146 145 151 98 154 110 111 88 106 105 81 110 154 146 143 145 144 146 142 145 74 94 148 104 111 107 106 81 109 70 151 88 74 148 93 105 101 71 92 110 111 106 81 154 107 154 110 111 109 106 81 136 137 138 137 133 135 140 141 130 140 112 137 133 139 113 118 119 116 141 115 PARTS 127 129 123 122 118 114 112 128 128 115 116 121 120 117 121 120 125 126 124 141 125 126 -40- 127 129 122 117 119 124 123 139 140 133 130 141 140 137 133 137 136
REF PART # 70 71 74 81 88 92 93 94 98 101 104 105 106 107 109 110 111 112 113 114 115 116 117 118 119 120 121 122 X1678070 X1678071 X1678174 X1678081 X1678088 X1678092 X1678093 X1678094 X1678098 X167892A XPK10 XPSS09 XPSS02M XPSS08 X1678109 XPLN01 XPW02 XPLN02 X1678113 X1678114 X1678115 XPSB01 XPSB12 X1678118 X1678119 X1678120 XPSS29 X1678122 DESCRIPTION PRESSURE ROLLER SANDING DRUM BUSHING BEARING BLOCK COMPRESSION SPRING FINE SNDPPR 3" X 195" COARSE SNDPPR 3" X 195" DRUM PULLEY V-BELT B-67 HOOK-AND-L
271 264 280 15 218 216 217 214 289 282 289 219 221 246 293 230 241 239 238 240 6 265 265 4 8 7 294 208 286 237 236 210 211 18 8 7 8 9 6 265 269 261 287 237 259 16 287 284 20 230 203 231 297 205 204 235 205 206 5 PARTS 271 286 -42- 271 292 283 274 289 259 236 202 201 273 272 261 295 298 291 218 217 279 265 251 250 244 249 248 19 220 14 265 265 6 259 261 216 215 7 6 265 281 227 296 228 282 245 284 296 290 228 13 220 244 227
REF PART # 4 5 6 7 8 9 13 14 15 16 18 19 20 201 202 203 204 205 206 208 210 211 214 215 216 217 218 219 220 221 227 228 230 231 235 236 237 238 X1678004 X1678004A X1678006 X1678007 X1678008 X1678009 X1678013 X1678014 X1678013A X1678016 X1678218 XPK23M X1678020 XPB18 XPN08 X1678203 XPB18 XPW02 XPN08 XPSS07 XPB19M XPW02 X1678214 X1678215 XPS17M XPHTEK7 XPN04M X1678219 XPS38M XPLN01M XPSB07 XPN02 X1678230 XPHTEK7 X1678235 XPB02 XPN05 X1678238 DESCRIPTION REF SIDE PANEL SIDE PANEL SPROCKET 10-TEETH SPROCK
302 309 311 343 310 306 347 303 300 301 304 314 308 305 313 312 307 320 316 319 317 324 325 346 226 315 5 4 6 3 7 223 2 8 1 9 10 318 344 322 0 328 323 321 336 335 224 340 348 334 222 260 334 335 342 335 349 332 334 PARTS 337 -44-
REF PART # 222 223 224 226 260 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 X1678222 X1678223 X1678224 X1678226 X1678260 X1678300 X1678301 X1678302 XPSS11 XPSS08 X1678303 X1678306 XPSB05 X1678308 X1678309 XPB18 XPW02 X1678312 XPS06 XPS06 X1678315 XPS01 XPLWO3 DESCRIPTION MAGNETIC SWITCH ON SWITCH OFF SWITCH LOAD AMP METER VS MOTOR CIRCUIT BOARD CRANK HANDLE COLLAR SET SCREW 1⁄4"-20 X 1⁄4" SET SCREW 5⁄16"-18 X 1⁄2" WORM GEAR 10 TEETH SHAFT MOUNT CAP SCREW 1⁄4"-20 X 3⁄4" BUSHIN
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FOLD ALONG DOTTED LINE Place Stamp Here WOODSTOCK INTERNATIONAL, INC. P.O.
WARRANTY CARD Name __________________________________________________________________________________________ Street __________________________________________________________________________________________ City ____________________________________________________________________State________Zip_________ Phone Number_______________________E-Mail_________________________________FAX___________________ MODEL #____________ Serial #______________Date of Purchase:______________Time in Use: _____________ The foll