OWNER'S MANUAL
(FOR MODELS MANUFACTURED SINCE 3/16)
MODEL W1839/W1840
6"/8" VARIABLE-SPEED GRINDER
Phone: (360) 734-3482 • Online Technical Support: [email protected]
COPYRIGHT © MAY, 2016 BY WOODSTOCK INTERNATIONAL, INC. REVISED MAY, 2018 (HE)
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT
THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
#18150JH Printed in China
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 compre-
hension, 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 equip-
ment, such as those dust masks that are specially designed to filter
out microscopic particles.
SET UPELECTRICAL MAINTENANCE
SERVICE PARTS
OPERATIONS
SAFETYINTRODUCTION
USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!
INTRODUCTION .....................................2
Contact Info ....................................... 2
Manual Accuracy .................................. 2
W1839 Machine Specifications ................. 3
W1840 Machine Specifications ................. 5
Components & Controls ......................... 7
SAFETY ...............................................8
Standard Machinery Safety Instructions ...... 8
Additional Safety for Benchtop Grinders ... 10
ELECTRICAL ....................................... 11
Circuit Requirements .......................... 11
Grounding Requirements ...................... 12
Extension Cords ................................ 12
SETUP .............................................. 13
Unpacking ....................................... 13
Items Needed for Setup ....................... 13
Inventory ........................................ 14
Machine Placement ............................ 15
Bench Mounting................................. 15
Assembly ......................................... 16
Test Run .......................................... 18
OPERATIONS....................................... 19
Operation Overview ........................... 19
Workpiece Inspection .......................... 20
Wheel Selection ................................ 20
Wheel Inspection ............................... 21
Wheel Care ...................................... 22
Wheel Dressing ................................. 23
Wheel Removal & Installation ................ 24
ACCESSORIES ...................................... 25
Grinder Accessories ............................ 25
MAINTENANCE .................................... 26
Schedule ......................................... 26
Grinding Wheels ................................ 26
Cleaning & Protecting ......................... 26
Wheel Storage .................................. 26
Wheel Dressing ................................. 26
SERVICE ............................................ 27
Troubleshooting ................................. 27
Electrical Safety Instructions ................. 29
Wiring Diagram ................................. 30
PARTS .............................................. 31
System Breakdown ............................. 31
System Parts List ............................... 32
Labels & Cosmetics ............................ 33
WARRANTY ........................................ 36
Contents
-2-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
INTRODUCTION
We are proud to provide a high-quality owner’s
manual with your new machine!
We
made every effort to be exact with
the
instructions, specifications, drawings, and pho-
tographs contained inside. Sometimes we make
mistakes, but our policy of continuous improve-
ment
also means that sometimes the
machine
you receive will be slightly different than what
is shown in the manual
.
If you find this to be the case, and the difference
between the manual and machine leaves you
confused about a procedure
,
check our website
for an updated version. W
e post current
manuals
and
manual updates for free
on our website at
www.
woodstockint.com.
Alternatively, you can call our Technical Support
for help. Before calling, make sure you write
down the
Manufacture Date and Serial Number
from the machine ID label (see below). Also, if
available, have a copy of your original purchase
receipt on hand. This information is required for
all Tech Support calls.
MODEL XXXX
MACHINE NAME
Motor:
Specification:
Specification:
Specification:
Specification:
Weight:
Specifications
To reduce risk of serious personal injury when using this
machine:
1. Read & understand owner’s manual before operating.
2. Always wear approved eye protection and respirator.
3. Only plug power cord into a grounded outlet.
4. Only use this machine to collect wood dust/chips—never
use to collect glass, metal, liquids, asbestos, silica,
animal parts, biohazards, burning material/ashes, etc.
5. Always disconnect power before servicing or cleaning.
6. Do not expose to rain or wet areas.
7. Keep hands, long hair, and loose clothing away from
inlet.
8. Never leave machine unattended while it is running.
9. Do not use if cord/plug becomes damaged—promptly
repair and protect cord from future damage.
10. Do not use without dust bag or filters in place.
11. Always wear a respirator when emptying bags.
12. Prevent unauthorized use by children or untrained users.
Date
Serial Number
Manufactured for Woodstock in Taiwan
WARNING!
Manufacture
Date
Serial Number
Manual Accuracy
We are committed to customer satisfaction. If
you have any questions or need help, use the
information below to contact us.
IMPORTANT: Before contacting, please get the
original purchase receipt, serial number, and
manufacture date of your machine. This infor-
mation is required for all Technical Support
calls and it will help us help you faster.
Woodstock International Technical Support
Phone: (360) 734-3482
Email: [email protected]
We want your feedback on this manual. What did
you like about it? Where could it be improved?
Please take a few minutes to give us feedback.
Technical Documentation Manager
P.O. Box 2309
Bellingham, WA 98227
Email: [email protected]
Contact Info
-3-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Model W1839 Machine Specifications, Page 1 of 2
MODEL W1839
6" VARIABLESPEED GRINDER WITH WORK LIGHT
Product Dimensions
Weight........................................................................................................... 28 lbs.
Width (side‐to‐side) x Depth (front‐to‐back) x Height................................... 15 x 12 x 17‐1/2 in.
Footprint (Length x Width)..................................................................... 11‐1/4 x 6‐3/4 in.
Shipping Dimensions
Type......................................................................................................... Cardboard
Content........................................................................................................ Machine
Weight........................................................................................................... 29 lbs.
Length x Width x Height........................................................................... 21 x 13 x 11 in.
Must Ship Upright.................................................................................................. Yes
Electrical
Power Requirement.................................................................... 120V, Single‐Phase, 60 Hz
Full‐Load Current Rating........................................................................................ 2.5A
Minimum Circuit Size............................................................................................. 15A
Power Cord Included.............................................................................................. Yes
Power Cord Length............................................................................................... 6 ft.
Power Cord Gauge............................................................................................ 18 AWG
Plug Included....................................................................................................... Yes
Included Plug Type........................................................................................ NEMA 5‐15
Switch Type............................................................. Toggle Safety Switch w/Removable Key
Motors
Main
Horsepower.............................................................................................. 1/3 HP
Phase.............................................................................................. Single‐Phase
Amps.......................................................................................................... 2.5
Speed......................................................................................... 2000 – 3400 RPM
Type........................................................................ Capacitor‐Start Induction Motor
Power Transfer ................................................................................... Direct Drive
Main Specifications
Operation Info
Grinder Type.................................................................................. Variable‐Speed
Wheel Type.................................................................................. Aluminum Oxide
Right Wheel Diameter.................................................................................... 6 in.
Left Wheel Diameter...................................................................................... 6 in.
Right Wheel Grinding Face Width.................................................................... 3/4 in.
Left Wheel Grinding Face Width..................................................................... 3/4 in.
Wheel Bore.............................................................................................. 1/2 in.
Wheel Speed at Maximum Wheel Diameter..................................................... 4450 RPM
-4-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Model W1839 Machine Specifications, Page 2 of 2
Construction
Base.................................................................................................... Cast Iron
Work Rest............................................................................................ Aluminum
Eye Shields........................................................................................ Clear Plastic
Lamp.......................................................................................................... LED
Other
Country of Origin ............................................................................................... China
Warranty ....................................................................................................... 2 Years
Approximate Assembly & Setup Time ................................................................. 15 Minutes
Serial Number Location .................................................................................... ID Label
ISO 9001 Factory .................................................................................................. Yes
Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................... No
Features
1/3 HP Variable‐Speed Induction Motor
Dual 6" Aluminum‐Oxide Grinding Wheels
1/2" Grinding Wheel Bore
4450 RPM Grinding Wheel Speed
Dual Eye Safety Shields
Dual Adjustable Aluminum Work Rests
Base Mounting Holes 3/8" (2) x 9‐7/8" OC
-5-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Model W1840 Machine Specifications, Page 1 of 2
MODEL W1840
8" VARIABLESPEED GRINDER WITH WORK LIGHT
Product Dimensions
Weight........................................................................................................... 40 lbs.
Width (side‐to‐side) x Depth (front‐to‐back) x Height................................... 15‐1/2 x 12 x 19 in.
Footprint (Length x Width)..................................................................... 11‐1/4 x 6‐3/4 in.
Shipping Dimensions
Type.................................................................................................... Cardboard Box
Content........................................................................................................ Machine
Weight........................................................................................................... 43 lbs.
Length x Width x Height........................................................................... 22 x 15 x 13 in.
Must Ship Upright.................................................................................................. Yes
Electrical
Power Requirement.................................................................... 120V, Single‐Phase, 60 Hz
Full‐Load Current Rating........................................................................................... 5A
Minimum Circuit Size............................................................................................. 15A
Power Cord Included.............................................................................................. Yes
Power Cord Length............................................................................................... 6 ft.
Power Cord Gauge............................................................................................ 18 AWG
Plug Included....................................................................................................... Yes
Included Plug Type........................................................................................ NEMA 5‐15
Switch Type............................................................. Toggle Safety Switch w/Removable Key
Motors
Main
Horsepower.............................................................................................. 3/4 HP
Phase.............................................................................................. Single‐Phase
Amps........................................................................................................... 5A
Speed......................................................................................... 2000 – 3400 RPM
Type........................................................................ Capacitor‐Start Induction Motor
Power Transfer ................................................................................... Direct Drive
Main Specifications
Operation Info
Grinder Type.................................................................................. Variable‐Speed
Wheel Type.............................................................................................. Type 1
Right Wheel Diameter.................................................................................... 8 in.
Left Wheel Diameter...................................................................................... 8 in.
Right Wheel Grinding Face Width....................................................................... 1 in.
Left Wheel Grinding Face Width........................................................................ 1 in.
Wheel Bore.............................................................................................. 5/8 in.
Wheel Speed at Maximum Wheel Diameter..................................................... 3600 RPM
-6-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Model W1840 Machine Specifications, Page 2 of 2
Construction
Base.................................................................................................... Cast Iron
Work Rest............................................................................................ Aluminum
Eye Shields........................................................................................ Clear Plastic
Lamp.......................................................................................................... LED
Other
Country of Origin ............................................................................................... China
Warranty ....................................................................................................... 2 Years
Approximate Assembly & Setup Time ................................................................. 15 Minutes
Serial Number Location .................................................................................... ID Label
ISO 9001 Factory .................................................................................................. Yes
Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................... No
Features
3/4 HP Variable‐Speed Induction Motor
Dual 8" Aluminum‐Oxide Grinding Wheels
5/8" Grinding Wheel Bore
3600 RPM Grinding Wheel Speed
Dual Eye Safety Shields
Dual Adjustable Aluminum Work Rests
Base Mounting Holes 3/8" (2) x 9‐7/8" OC
-7-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Controls & Components
Become familiar with the names and locations of the controls and features shown below to better
understand the instructions in this manual.
C. LED Work Lamp: Work lamp turns ON/OFF
when machine is turned ON/OFF.
D. Wheel Guard: Prevents accidental contact
with grinding wheel, and contains sparks
during grinding.
E. Tool Rest (Right): Provides flat surface to
rest workpiece during operation. Tilt angle
is adjustable.
F. ON/OFF Switch w/Disabling Key: Turns
motor ON when flipped up; turns motor
OFF when pressed down. Key prevents
motor from starting when removed.
G. Variable-Speed Dial: Controls grinding
wheel speed. Turn clockwise to increase
speed; turn counterclockwise to decrease
speed.
H. Tool Rest (Left): Provides a 60° "V" shaped
groove for sharpening drill bits. Also
includes a flat surface for general grinding.
Tilt angle is adjustable.
Figure 1. W1839 & W1840 controls and components.
A. Safety Shield: Helps protect operator
from sparks during grinding. Shield is not
a substitute for proper personal protective
equipment.
B. Spark Deflector: Helps contain sparks
inside wheel guard to reduce operator
exposure.
For Your Own Safety Read Instruction
Manual Before Operating Grinder
a) Replace cracked wheel immediately.
b) Always use guards and eye shields.
c) Do not overtighten wheel nut.
d) Only use flanges furnished with grinder.
e) Adjust work rest to maintain
1
⁄16" –
1
⁄8"
distance from wheel as diameter of
wheels will decrease with use. DO NOT
allow more than
1
⁄8" gap between work
rest and wheel.
f) Frequently clean grinding dust from
beneath grinder.
A
C
D
E
F
H
G
B
-8-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SAFETY
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate 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.
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.
NOTICE
SAFETY
OWNER’S MANUAL.
Read and understand this
owner’s manual BEFORE using machine.
TRAINED OPERATORS ONLY.
Untrained operators
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!
DANGEROUS ENVIRONMENTS.
Do not use
machinery in areas that are wet, cluttered,
or have poor lighting. Operating machinery
in these areas greatly increases the risk of
accidents and injury.
MENTAL ALERTNESS REQUIRED.
Full mental
alertness is required for safe operation of
machinery. Never operate under the influence
of drugs or alcohol, when tired, or when
distracted.
ELECTRICAL EQUIPMENT INJURY RISKS. You can
be shocked, burned, or killed by touching live
electrical components or improperly grounded
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.
Standard Machinery Safety Instructions
For Your Own Safety,
Read Manual Before Operating Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
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
themselves do not eliminate danger and are not a substitute for proper accident prevention mea-
sures—this responsibility is ultimately up to the operator!
SAFETY
Standard Machinery Safety Instructions
-9-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SAFETY
WEARING PROPER APPAREL. Do not wear
clothing, apparel, or jewelry that can become
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.
HAZARDOUS
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.
HEARING PROTECTION.
Always wear hearing
protection when operating or observing
loud machinery. Extended exposure to this
noise without hearing protection can cause
permanent hearing loss.
REMOVE ADJUSTING TOOLS.
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!
INTENDED USAGE.
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!
AWKWARD POSITIONS.
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.
CHILDREN & BYSTANDERS.
Keep children and
bystanders at a safe distance from the work
area. Stop using machine if they become a
distraction.
GUARDS & COVERS.
Guards and covers reduce
accidental contact with moving parts or flying
debris—make sure they are properly installed,
undamaged, and working correctly.
FORCING MACHINERY. Do not force machine. It
will do the job safer and better at the rate for
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
loss of control. Before starting, verify machine
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
malfunction, leading to serious personal injury
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
from heated surfaces, high traffic areas, harsh
chemicals, and wet/damp locations.
EXPERIENCING DIFFICULTIES. If at any time
you experience difficulties performing the
intended operation, stop using the machine!
Contact Technical Support at (360) 734-3482.
-10-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SAFETY
Additional Safety for Benchtop Grinders
Serious injury or death can occur from impact injuries if a grinding wheel breaks apart during
operation. Rotating grinding wheels can easily remove skin or cause entanglement injuries if
clothing or apparel is caught in moving parts. Fingers can be pinched/cut by in-running pinch points.
Flying sparks can ignite explosive or flammable materials. To minimize risk of injury or death,
anyone operating machine MUST completely heed hazards and warnings below.
SAFE MOUNTING & WORK AREA. An unsecured
grinder may become dangerously out of control
during operation. Before use, verify grinder is
FIRMLY secured in a location free of explosive
or flammable materials.
STARTING GRINDER. If a wheel is damaged, it
will usually fly apart shortly after start-up. To
protect yourself, always stand to side of grinder
when turning it ON and allow it to run for at
least one minute before standing in front of it.
VISUAL INSPECTION. Verify that grinding wheels
are free of cracks, chips, or dents in wheel
surface before installing. Do not use wheel if
it has any of these problems or it could break
apart during operation.
WHEEL SPEED RATING. Before mounting a new
wheel, be sure wheel RPM rating is equal to
or higher than speed of grinder. Never use
unmarked wheels or wheels rated for lower
RPM than grinder.
VIBRATING WHEEL. Never use a wheel that
vibrates excessively. Replace wheel or shaft
bearings immediately.
SPARK DEFLECTOR GAP. Never allow gap
between end of spark deflector and
grinding wheel to exceed
1
⁄4”. If the
gap is larger, additional sparks and
abrasives will be expelled toward the
operator, which will increase the risk of injury.
TOOL REST POSITION. A large distance (gap)
between tool rest and wheel increases risk
of workpiece being pinched between wheel
and tool rest causing wheel breakage, loss
of control, and possible injury. Never allow
gap between tool rest and wheel to exceed
1
⁄8”. Replace grinding wheel when tool rest
gap becomes wider than
1
⁄8″ and no additional
adjustment can be made to tool rest.
SIDE & TOP GRINDING. Grinding on side of
wheels can cause them to crack and burst—
unless wheel is rated for side grinding.
Grinding on top of wheels greatly increases
risk of workpiece kickback. Always grind on
downward part of wheel.
SPINDLE NUT. Only tighten wheel spindle nut
enough to drive wheel and prevent slippage.
EYE SHIELDS. Place eye shields close to grinding
wheel and re-adjust as wheel wears down.
HAND & WHEEL CONTACT. Keep a firm grip
on workpiece and position your hands a safe
distance away when grinding. Anticipate when
workpiece will heat up, and cool it before it
becomes too hot to hold, or use an appropriate
clamp. Avoid wearing gloves as they may get
caught in grinding wheel and cause even more
serious entanglement injuries.
WHEEL FLANGES. Only use flanges included with
or designed for this grinder when mounting
wheels. Other flanges may not properly
secure wheel and cause an accident. Do not
use warped or damaged flanges, and always
use paper discs (blotters) between wheels
and flanges to reduce risk of flanges cracking
wheel when tightening.
EYE, FACE, & LUNG PROTECTION. Grinding
ejects small particles at a high rate of speed.
These particles can cause blindness, skin
injuries or respiratory damage. ALWAYS wear
approved clothing, safety goggles, face shield,
and a respirator for type of grinding to be
done.
RING TEST. Perform a “ring test” on grinding
wheels before installation to ensure they are
safe to use. A wheel that does NOT pass ring
test may break or fly apart during operation.
-11-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
ELECTRICAL
ELECTRICAL
Circuit Requirements
This machine must be connected to the correct size and
type of power supply circuit, or fire or electrical damage
may occur. Read through this section to determine if an
adequate power supply circuit is available. If a correct
circuit is not available, a qualified electrician MUST install
one before you can connect the machine to power.
A power supply circuit includes all electrical equipment
between the breaker box or fuse panel in the building
and the machine. The power supply circuit used for
this machine must be sized to safely handle the full-
load current drawn from the machine for an extended
period of time. (If this machine is connected to a circuit
protected by fuses, use a time delay fuse marked D.)
Circuit Requirements for 120V
This machine is prewired to operate on a power supply
circuit that has a verified ground and meets the following
requirements:
Circuit Type ............... 110V/120V, 60 Hz, Single-Phase
Circuit Size ............................................. 15 Amps
Plug/Receptacle .................................... NEMA 5-15
Full-Load Current Rating
The full-load current rating is the amperage a machine
draws at 100% of the rated output power. On machines
with multiple motors, this is the amperage drawn by the
largest motor or sum of all motors and electrical devices
that might operate at one time during normal operations.
W1839 Full-Load Current Rating at 120V ........ 2.5 Amps
W1840 Full-Load Current Rating at 120V ...........5 Amps
The machine must be properly set up
before it is safe to operate. DO NOT
connect this machine to the power
source until instructed to do so later in
this manual.
Incorrectly wiring or grounding this
machine can cause electrocution, fire,
or machine damage. To reduce this risk,
only an electrician or qualified service
personnel should do any required
electrical work on this machine.
NOTICE
The circuit requirements listed in this
manual apply to
a dedicated circuit—
where only one machine will be running
at a time. If this machine will be
connected to a shared circuit where
multiple machines will be running at the
same time, consult with an electrician
to ensure that the circuit is properly
sized for safe operation.
-12-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
ELECTRICAL
Grounding Requirements
This machine MUST be grounded. In the event of certain
types of
malfunctions or breakdowns, grounding provides
a path of least resistance for electric current
to travel—in
order
to reduce the risk of electric shock.
Improper connection of the equipment-grounding
wire
will
increase
the risk of electric shock. The wire with green
insulation
(with/without yellow stripes) is the equipment-
grounding
wire. If repair or replacement of the power
cord or plug is necessary, do not connect the equipment-
grounding
wire to a live (current carrying) terminal.
Check with a qualified electrician or service personnel
if
you do not understand these grounding requirements,
or if
you are in doubt about whether the tool is
properly grounded.
If you ever notice that a cord or
plug is damaged or worn, disconnect it from power, and
immediately replace it with a new one.
Grounding Prong
Neutral Hot
5-15 PLUG
GROUNDED
5-15 RECEPTACLE
120V
Figure 2. NEMA 5-15 plug & receptacle.
DO NOT modify the provided plug or
use an adapter if the plug will not
fit the receptacle. Instead, have an
electrician install the proper receptacle
on a power supply circuit that meets
the requirements for this machine.
Extension Cords
We do not recommend using an extension cord with
this machine. Extension cords cause voltage drop, which
may damage electrical components and shorten motor
life. Voltage drop increases with longer extension cords
and smaller gauge sizes (higher gauge numbers indicate
smaller sizes).
Any extension cord used with this machine must contain a
ground wire, match the required
plug and receptacle, and
meet the following requirements:
Minimum Gauge Size at 120V ...................... 16 AWG
Maximum Length (Shorter is Better) ................50 ft.
For 120V Connection
This machine is equipped with a power cord that has an
equipment-grounding
wire and NE M A 5-15 grounding plug.
The plug
must only be inserted into a matching
receptacle
(
see Figure) that is properly installed and grounded in
accordance with local codes and ordinances.
-13-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
SETUP
Description Qty
• Safety Glasses for Each Person ..........................1
• Degreaser or Solvent for Cleaning .......... As Needed
• Disposable Rags for Cleaning ................ As Needed
• Mounting Hardware (Page 15) ............... As Needed
• Phillips Screwdriver #2 ...................................1
• Open-End Wrench 13mm .................................1
Items Needed for Setup
Unpacking
This machine has been carefully packaged for safe
transportation. If you notice the machine has been
damaged during shipping, please contact your authorized
Shop Fox dealer immediately.
The following items are needed, but not included, to set
up your machine.
SUFFOCATION HAZARD!
Immediately discard all
plastic bags and packing
materials to eliminate
choking/suffocation
hazards for children and
animals.
Wear safety glasses during
entire setup process!
This machine presents
serious injury hazards
to untrained users. Read
through this entire manual
to become familiar with
the controls and opera-
tions before starting the
machine!
-14-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
Box Contents (Figure 3): Qty
A. Grinder (not shown) .......................................1
B. Tool Rest Bracket (Right) .................................1
C. Tool Rest Bracket (Left) ..................................1
D. Tool Rest (Left) ............................................1
E. Tool Rest (Right) ...........................................1
F. Spark Deflector (Right) ...................................1
G. Spark Deflector (Left) ....................................1
H. Safety Shield Mounting Brackets ........................2
I. Safety Shield Mounting Plates ...........................2
J. Spark Deflectors ...........................................2
Inventory
The following is a list of items shipped with your machine.
Before beginning setup, lay these items out and inventory
them.
Note:
If you cannot find an item on this list, carefully
check around/inside the machine and packaging materials.
Often, these items get lost in packaging materials while
unpacking or they are pre-installed at the factory.
Hardware (Figure 4): Qty
K. Flat Washers 8mm .........................................2
L. Flat Washers 6mm .........................................4
M. Flat Washers 5mm .........................................4
N. Lock Washers 6mm ........................................4
O. Lock Washers 5mm ........................................4
P. Hex Bolts M8-1.25 x 12 ...................................4
Q. Phillips Head Screws M4-.7 x 12 ........................4
R. Carriage Bolts M6-1 x 12 .................................2
S. Phillips Head Screws M5-.8 x 10 ........................4
T. Flange Nuts M4-.7 .........................................4
U. Knobs M6-1 .................................................2
V. Knob Bolts M6-1 x 18 ......................................2
SUFFOCATION HAZARD!
Immediately discard all
plastic bags and packing
materials to eliminate
choking/suffocation
hazards for children and
animals.
Figure 3. Tool rest and safety shield parts.
H
I
J
C
D
E
F
G
B
Figure 4. Fastener inventory.
O
P
Q
K
L
M N
R
S
T
U
V
-15-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
Machine Placement
Workbench Load
Refer to the Machine Specifications for the
weight and footprint specifications of your
machine. Some workbenches may require
additional reinforcement to support the weight
of the machine and workpiece materials.
Bench Mounting
The base of this machine has mounting holes
that allow it to be fastened to a workbench
or other mounting surface to prevent it from
moving during operation and causing accidental
injury or damage.
The strongest mounting option is a “Through
Mount” (see example) where holes are drilled all
the way through the workbench—and hex bolts,
washers, and hex nuts are used to secure the
machine in place.
Another option is a “Direct Mount” (see
example) where the machine is secured directly
to the workbench with lag screws and washers.
Number of Mounting Slots ........................2
Diameter of Mounting Hardware Needed ..
3
⁄8"
Machine Base
Workbench
Hex
Bolt
Flat Washer
Flat Washer
Lock Washer
Hex Nut
Figure 7. Typical "Through Mount" setup.
Machine Base
Workbench
Lag Screw
Flat Washer
Figure 8. Typical "Direct Mount" setup.
Consider anticipated workpiece sizes and
additional space needed for auxiliary stands,
work tables, or other machinery when
establishing a location for this machine in the
shop. Below is the minimum amount of space
needed for the machine.
Mount the grinder to a workbench to avoid
accidental tipping. For portable bench grinding,
mount it to a heavy plywood base (at least 1"
thick) that is wide enough to prevent tipping or
rocking during use.
Placement Location
Figure 5. W1839 minimum working clearances.
15"
11”
12"
15
1
/
2
"
11”
12"
Figure 6. W1840 minimum working clearances.
-16-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
Assembly
Safety Shield
Mounting Plate
Safety
Shield
Safety Shield
Mounting Bracket
Flange
Nuts
Phillips
Head
Screws
Figure 9. Safety shield components.
Safety
Shield
Assembly
Spark
Deflector
Carriage
Bolt
Flat
Washer
Knob
Figure 10. Safety shield attached to spark
deflectors (1 or 2).
Before beginning the assembly process, refer to Items
Needed for Setup
and gather everything you need.
Ensure all parts have been properly cleaned of any
heavy-duty rust-preventative applied at the factory (if
applicable). Be sure to complete all steps in the assembly
procedure prior to performing the Test Run.
To assemble machine, do these steps:
1. Assemble safety shields (see Figure 9) using (4)
M4-.7 x 12 Phillips head screws, (4) M4-.7 flange
nuts, (2) safety shield mounting plates, (2) safety
shields, and (2) safety shield mounting brackets.
2. Attach safety shield assemblies to spark deflectors
(see Figure 10) using (2) M6-1 x 12 carriage bolts,
(2) 6mm flat washers, and (2) M6-1 knobs.
Figure 11. Spark deflector attached.
Tool Rest
Tool Rest
Bracket
Knob
Bolt
Flat
Washer
Lock
Washer
Figure 12. Tool rest assembly.
x 2
4. Assemble left tool rest using (1) left tool rest
bracket, (1) left tool rest, (1) 6mm flat washer, (1)
6mm lock washer, and (1) M6-1 x 18 knob bolt (see
Figure 12).
5. Assemble right tool rest using (1) right tool rest
bracket, (1) right tool rest, (1) 6mm flat washer, (1)
6mm lock washer, and (1) M6-1 x 18 knob bolt.
3. Attach each spark deflector/safety shield assembly
to grinder with (4) M5-.8 x 10 Phillips head screws,
(4) 5mm flat washers, and (4) 5mm lock washers
(see Figure 11).
-17-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
6. Attach each tool rest assembly to grinder using (4)
M8-1.25 x 12 hex bolts and (4) 8mm flat washers
(see Figure 13).
Figure 13. Tool rest assembly attached to
grinder.
Figure 14. Tool rest gap.
1
⁄16" –
1
⁄8"
The toll rest can be adjusted closer/farther from grinding
wheel or tilted and secured every 15° from 0°—75°.
The tool rest stabilizes the workpiece when grinding.
It must always be positioned correctly when using the
grinder to help prevent the operator's hands from being
pulled into grinding wheel.
Each tool rest features detents that allow it to lock at a
specific angle. To adjust a tool rest, loosen the knob bolt
(see Figure 13) several turns, pivot the tool rest to the
appropriate angle, position it
1
⁄16" away from the grinding
wheel, and then tighten knob bolt to secure setting.
As grinding wheel wears, shift tool rest closer to grinding
wheel to maintain a gap of
1
⁄16" –
1
⁄8" (see Figure 14).
IMPORTANT: If the gap reaches
1
⁄8" and the tool rest
cannot be adjusted any closer to the wheel, the grinding
wheel MUST be replaced before you can resume safely
operating grinder.
Tool Rest Adjustment
x 4
Figure 15. Spark deflector gap.
1
⁄8" –
1
⁄4"
The spark deflector prevents sparks from showering the top
of the workpiece and the operator's hands. As the wheel
wears, adjust the spark deflector closer to the grinding
wheel to maintain a gap of
1
⁄8"–
1
⁄4" (see Figure 15). If
the gap reaches
1
⁄4" and no additional adjustments can be
made, replace the grinding wheel.
Spark Deflector Adjustment
Some grinding wheels must be replaced before spark
deflector or tool rest reach their final adjustment. As
diameter of a grinding wheel is reduced, so is surface
speed. Grinding under these conditions can lead to
faster abrasive loss and poor grinding results. Always
follow wheel manufacturer's directions.
x 4
Knob
Bolt
Never grind WITHOUT tool rest in place and properly
positioned. "Free hand" grinding or too large of a gap
between wheel and tool rest increases risk of pinching,
which may result in wheel breakage or operator injury.
-18-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
Figure 16. Removing switch key from
toggle switch.
Test Run
Serious injury or death can result
from using this machine BEFORE
understanding its controls and related
safety information. DO NOT operate, or
allow others to operate, machine until
the information is understood.
DO NOT start machine until all
preceding setup instructions have been
performed. Operating an improperly set
up machine may result in malfunction
or unexpected results that can lead
to serious injury, death, or machine/
property damage.
Once assembly is complete, test run the machine to
ensure it is properly connected to power and safety
components are functioning properly.
If you find an unusual problem during the test run,
immediately stop the machine, disconnect it from power,
and fix the problem BEFORE operating the machine again.
The
Troubleshooting table in the SERVICE
section of this
manual can help.
To test run machine, do these steps:
1. Clear all setup tools away from machine.
2. Connect machine to power supply.
3. Rotate variable-speed dial all the way left and turn
machine ON, verify motor operation, and slowly
rotate variable-speed dial to the right, then turn
machine OFF.
The motor should run smoothly and without unusual
noises.
4. Remove key from toggle switch (see Figure 16).
5. Try to start machine with switch.
Machine should NOT start. If it does start, the switch
disabling feature is not functioning properly and the
switch must be replaced.
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