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Summary Manual

Mark V Model 520

Safety

WARNING

Before performing disc sanding operations:

•

READ, UNDERSTAND, and FOLLOW the

SAFETY section, especially for the disc sander

mode.

•

Complete ALL the Assembly and Alignment

procedures.

•

Secure locks.

Disc Sanding Speeds

NOTE

The above mentioned speeds are reccommended

speeds.

Before you begin any disc sanding operation,

know the correct speed at which to set the speed

dial.  The correct speed is determined by the

operation and the type of material you’re sand-

ing. To determine the right speed for the job, refer

to the Disc Sanding Speed Chart.

General Sanding

Position the carriage so that the table is no farther

than 1/16" away from the disc (if you’re not using

the quill feed), or 1/2" (if you are using the quill

feed). Maintain these clearances during sanding.

Position the table surface near the center of the

disc. Maintain these clearances during sanding.

Always sand on the downward motion side of the

disc with the disc either through the insert or next

to the table.

End-Grain Sanding

1. Mount the miter gauge in the left slot and

position it so that it will guide the stock against

the downward side of the disc. Then lock the

gauge in the slot. Turn on and set the Mark V

speed.

NOTE

When end-grain sanding, set the speed a little slower

than you would  for other types of sanding. End

grains "burn" easily.

2. If you’re feeding the stock into the disc, place

the stock against the miter gauge and feed it

toward the disc until it contacts the abrasive.

Hold it there for a few seconds, back it off, then

feed it forward again.  See Figure C-18.

Figure C-18

Disc Sanding Operations

DISC SANDING SPEED CHART

Grit

Hardwood

Softwood

Coarse (60#)

D (1050 rpm)

E (1150 rpm)

Medium (80#)

F (1300 rpm)

G (1450 rpm)

Fine (100#)

G (1450 rpm)

H (1600 rpm)

Grinding or Sharpening Metal Tools — Slow (700 rpm)

`3. If you’re using the quill feed, advance the disc

until it contacts the stock. Hold it there for  a

few seconds, back it off, and feed it forward

again.  See Figure C-19.

Figure C-19

Summary of Contents for MARK V Model 520

Page 1: ...IGNMENTproceduresbefore operating the Shopsmith Mark V Use only Shopsmith parts and accessoriesonyourMarkV Us ing non Shopsmith parts may create a hazardous condition and will void your warranty Shopsmith Mark V Home Workshop System MARK V Model 520 Summary Manual Designed and Built in Dayton Ohio ...

Page 2: ...ion equipment We recommend the Shopsmith DC3300 Dust Collection System Sawdust and chips can be fire hazards and breathing sawdust can be a health hazard Saw dust may cause you physical discomfort espe cially if you have emphysema asthma or an allergicreaction Thesawdustfromsomewoods can also be toxic When sawing or sanding Saw Guards Most shop accidents happen on the table saw For this reason alw...

Page 3: ...sureitisathree conductorcordwith a grounding plug and receptacle Thewiregaugemustbethickenoughtoprevent loss of power and overheating the longer the cord the thicker the wire should be Use the chart to determine the American Wire Gauge wire size required Cord Minimum Length Wire Size 25 ft 14 AWG 50 ft 12 AWG 100 ft 10 AWG Before using an extension cord inspect it for loosewiresordamageinsulation ...

Page 4: ...e fore you begin Turn off the Mark V and wait until all cutters blades or discs come to a complete stop before removing stock and scraps Turn off and unplug the Mark V before making adjustments changing modes or performing maintenance Make sure the switch is in the off position before plugging or unplugging the Mark V Secure the headstock lock carriage lock table height lock table tilt lock and qu...

Page 5: ...ot let go of the quill lever unless you first secure the quill feed lock Do not work with long boards or sheet materi als by yourself unless you use a large rear support table or roller stands Never try to work with boards the are too large for you to handle safely It is best to have a helper Never stand or lean on the machine You could fall on it or it could tip over Keep work areas well lit clea...

Page 6: ... Mark V 20 Auxiliary Spindles The upper spindle powers the Bandsaw Belt Sander Strip Sander and Thickness Planer The lower spindle powers the Jointer and Scroll Saw 21 Logo Cover hidden from view Allows access to the wiring and speed changer mechanism 22 Belt Cover Allows access to the belts and sheaves Terms to Know Right Side Left Side The Shopsmith Mark V will perform all the func tions of a ta...

Page 7: ...ides a working surface 24 Table Insert Used for sawing sanding drilling and boring It can be replaced with inserts for dadoing molding drum sanding and shaping 25 Miter Gauge Slots Guide and secure the miter gauge 26 MiterGaugewithSafetyGrip Holdsstockfirmly at various angles It slides freely or locks in the miter gauge slots 27 Rip Fence Mounts to the table and is used as a guide support or stop ...

Page 8: ...the table is 22 If you remove the table the maximum distance from the bit to the floor is 54 Horizontal Boring Machine The Mark V uses the same drill chuck used in the drill press mode The table can be lowered 2 3 8 belowthechuck enablingyoutoborethecenter of boards up to 4 3 4 thick The width and length of boards that you can bore is limited only by what you can safely handle Lathe As a lathe the...

Page 9: ...on During the following align ment procedures the saw blade provided in the accessories box will represent the main spindle s plane of rotation NOTE If you have installed casters optional on your Mark V make sure they are retracted and the legs on the Mark V sit firmly on a level floor Do this now Tools Needed 3 16 Allen wrench 5 32 Allen wrench long handle provided 5 32 Allen wrench short handle ...

Page 10: ...d and all casters are raised off the floor before lifting the Mark V into the vertical drill press position 5 Unlock the carriage and headstock Move the headstock to the middle of the way tubes Then move the carriage between the head stock and base mount right side 6 Tightentheheadstockandcarriagelocks Place the Mark V in the vertical position by loosen ing the headrest handle firmly grasping the ...

Page 11: ... to 1 2 straight drill bit in the drill chuck and use the chuck key to lock it place See Figure B 53 NOTE Checkthestraightnessofthedrillbitbyrollingiton a flat surface You can also hand rotate the drill chuckwhileholdingthecombinationsquareagainst the drill bit and the table If the bit is not straight DO NOT use it for these alignment instructions 12 With the drill bit above the table opening use ...

Page 12: ...he spindle 17 Loosen the base lock Firmly grasp the way tubes and lower the headstock into the hori zontal position then engage the head rest 18 Loosen the table tilt lock and place the table in thehorizontal 0 position Retightenthetable tilt lock only enough to allow movement with firm pressure 19 Mount the saw blade on the arbor a Remove the arbor nut by turning it clock wise as seen in Figure B...

Page 13: ...t The stop bolt should just contact the side of the stop pin Once the stop bolt is adjusted the stop pin will lock back when the tilt lock is tightened See Figure B 65 Figure B 61 Figure B 62 Figure B 63 Figure B 66 Figure B 65 Figure B 67 Figure B 64 29 Loosen the tilt lock move the worktable then depress the 0 stop pin until the stop bolt contacts it Tighten the tilt lock and recheck the setting...

Page 14: ...d the backsideoftheworktable showninFigureB 72 The stops should just contact the under side of the table 40 Loosen the tilt lock and move the table To recheck the 45 stops repeat Steps 35 through 39 It is very important to recheck the set ting ALIGN THE MITER GAUGE SLOTS 41 Return the worktable to the horizontal 0 stopandtightenthetiltlock Thecarriagelock and headstock lock should also be tightene...

Page 15: ...oosen the bolts consider using a T handle Allen wrench or use a boxed wrench for extra torque Another alternative is to use the hanging hole in an adjustable wrench as demonstrated in Figure B 78a Figure B 74 Figure B 76 Figure B 78 Figure B 75 Figure B 77 c Position the worktable back to the hori zontal 0 and tighten the tilt lock c Position the worktable back to the hori zontal 0 and tighten the...

Page 16: ...0 Figure B 81 53 If the miter gauge face is not perpendicular to the saw blade do the following a Use a long Allen wrench to loosen the lock knob 268 and adjust the miter gauge so it is perpendicular to the saw blade then tighten the lock knob See Figure B 83 Figure B 83 Figure B 84 Figure B 82 b Use a medium screwdriver loosen the screw 273 whichholdstheindicatorplate 275 and set its 0 to the mit...

Page 17: ...workingheight Tighten the lock ALIGN THE PRO FENCE PARALLEL WITH THE WORKTABLE 55 Place the miter gauge in the left slot of the worktable on the infeed side Place the Pro Fence on the right side of the saw table 56 Insert the long 5 32 Allen wrench through the miter gauge and secure it using the short 5 32 Allen wrench and a set screw borrowed from the tool rest 57 MovethefencetowardtheAllenwrench...

Page 18: ...de it cannot be transferred to the left side and still maintain precise alignment Ifyouwishprecisealignmentontheleftside repeat the following instructions but place the extension table on the left side in the headstock 61 Mount the extension table in the Mark V s accessory base mount on the right side at a comfortable height as shown in Figure B 99 Use a 1 2 wrench to loosen the bottom nuts holdin...

Page 19: ...y close the chuck jaws as in Figure B 114 Figure B 117 Figure B 116 Figure B 115 Figure B 113 Figure B 114 61 Mount the cup center into the tailstock s adjustable center as seen in Figure B 115 thenmountthetailstockintothebasemount right side Tighten the mount lock 62 Loosen the quill lock Extend the quill seen in Figure B 116 so the drill chuck almost touches the cup center point and the center p...

Page 20: ...essories secured a To properly mount an accessory push it onto the main spindle all the way Thenusea5 32 Allenwrenchtotightenthe setscrew against the flat of the spindle See FigureB 119 Tomakesuretheaccessoryis securely mounted rock the accessory back and forth slightly as you tighten the set Figure B 119 Mode Setups screw and then again after it is tight while keeping the spindle from turning If ...

Page 21: ...tthebladeprotrudes1 4 higherthanthethicknessofthestock The blade should be centered in the table insert Secure the table height and carriage locks 8 Install the upper saw guard Grasp the top of the riving knife with the guard up and slide the guard through the table insert into the lower saw guard See Figure B 129 Tighten the guard lock knob 4 Mount the saw blade on the arbor Remove the arbor nut ...

Page 22: ...n the vertical position the headstock could fall on you Setting Up the Vertical Drill Press Mode 1 Turn the speed dial to Slow then turn off and unplug the Mark V 2 Position the headstock 10 away from the headrest right side and the carriage 20 away from the base mount Tighten the headstock and carriage locks DO NOT OVER TIGHTEN 3 Position the worktable surface just above the top of the headstock ...

Page 23: ...table height lock and pull the table straight up 3 Position the headstock so that you can reach the main spindle 4 Mount the tool rest in the carriage so the rack engages the pinion 5 Mount the drive center all the way onto the main spindle Tighten the setscrew against the flat of the spindle 6 Mount the tailstock in the base mount right side and tighten the accessory mount left side lock NOTE Whe...

Page 24: ... to the instructions found in your Mark V Model s sec tion Secure locks Table Sawing Speeds NOTE The speeds designated on the speed charts are suggested speeds Before you begin any table saw operation know the correct speed at which to set the speed dial The correct speed is determined by the operation and the type of stock you re sawing To deter mine the right speed for the job refer to the Table...

Page 25: ...the quill feed to make fine adjustments See Figure C 6 NOTE Whenproperlyaligned theripfenceautomatically sets itself parallel to the blade However on critical setups it s wise to check this Measure the distance fromtheripfencetothetipofasawtooth thatisset toward the fence at both the front and back of the machine 2 Mount a feather board in front of the blade to help hold the stock against the fenc...

Page 26: ...clearances during sanding Alwayssandonthedownwardmotionsideofthe disc with the disc either through the insert or next to the table End Grain Sanding 1 Mount the miter gauge in the left slot and positionitsothatitwillguidethestockagainst the downward side of the disc Then lock the gauge in the slot Turn on and set the Mark V speed NOTE Whenend grainsanding setthespeedalittleslower than you would fo...

Page 27: ...ested speeds Before you begin any vertical drilling operation know the correct speed at which to set the speed dial The correct speed is determined by the op eration and the type of material you re drilling To determine the right speed for the job refer to the Vertical Drilling Speed Chart This chart is intended as a general guide when using brad point bits and twist bits If you use other bits fol...

Page 28: ...p then remove the stock Drilling Part Way 1 Sameas DrillingThrough exceptextendthe quill until the cutting flutes of the drill bit just touch the stock Then set and lock the depth control See Figure C 26 2 Then drill the holes you need The depth control will stop the quill when the drill bit reaches the proper depth in the stock All the holes you drill at any one depth control set ting will be exa...

Page 29: ...RING SPEED CHART HORIZONTAL BORING SPEED CHART Size of Hole Hardwood Softwood 1 4 and less H 1600 rpm I 1750 rpm 1 4 to 1 2 F 1300 rpm G 1450 rpm 1 2 to 3 4 D 1050 rpm E 1150 rpm 3 4 to 1 B 850 rpm C 950 rpm Over 1 Slow 700 rpm A 750 rpm Horizontal Boring Operations Figure C 34 4 Extendthequillsothatthecuttingflutesofthe bittouchthescrapwood Setthedepthcontrol to 1 8 beyond and tighten the depth c...

Page 30: ... edge of the tool to pareawaythestock SeeFigureC 40 Positionthe tool rest 1 4 1 2 below the top of the stock and feed the chisel at an angle Lathe Tools Gouges round the stock and make coves roundnosechiselsmakecoves skewchiselsmake beads and cut cylinders parting tools size and part Balance 1 This is extremely important when turning glued up stock long stock and stock more than 3 in diameter Chec...

Page 31: ...V model Lubricate the sheaves Refer to Lubricating Repeat the preceding steps Lubricate the headstock lock Refer to Lubricating MAINTENANCE SCHEDULE Maintenance and Troubleshooting This section of the Mark V Owner s Manual con tains maintenance information and a trouble shooting guide It should cover topics and an swer most questions you may have for normal maintenance and problem solving Follow t...

Page 32: ...k lock Finally move the worktable and carriage as far to the right as it will go Cleaning As you work sawdust will accumulate on and in your Mark V This residue can affect its perfor mance To prevent problems clean your Mark V thoroughly inside and out once every 5 hours of running time or monthly Blowing Out the Headstock 1 With a medium Phillips screwdriver re movethetwoscrewsthatholdthebeltcove...

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