MARK V ALIGNMENT & MAINTENANCE - Shopsmith · MARK V ALIGNMENT & MAINTENANCE. SHOPSMITH MARK V...

MARK VALIGNMENT & MAINTENANCE

SHOPSMITH MARK V 845180

NOMENCLATURE

The Shopsmith MARK V will perform all thefunctions of a Table Saw, Disc Sander, DrillPress, Horizontal Boring Machine, and WoodLathe.

Basically, the MARK V is a rigid Bench thatholds the Headstock and a Worktable System.The upper part of this Bench can be positionedhorizontally or vertically. The Headstock andthe Worktable slide independently and arepositioned along the Upper or Way Tubes.

You can mount Accessories to the Headstockand operate them at different speeds. TheWorktable can be positioned over, under orbeside these accessories to hold stock at vari-ous angles. In this way, the Bench, Headstock,Worktable, and Accessories combine to makea unique, capable and versatile Woodwork-ing System.

Before you proceed, familiarize yourself withthe MARK V's basic parts:

1. Legs - Support the Way Tubes and BenchTubes.

2. Headrest Lock - Secures the MARK V in

the horizontal position.3. Accessory Mount Locks - Secures the

Extension Table, Major Accessories, andthe Lathe Tailstock.

4. Power Mount - Holds the ExtensionTable and the Major Accessories.

5. Way Tube Tie Bar - Holds the free end ofthe Way Tubes.

6. Way Tubes - Supports the Headstockand Carriage and allows them to slide.

7. Auxiliary Spindles - The Upper Spindleprovides power to the Bandsaw, BeltSander, Strip Sander and ThicknessPlaner. The Lower Spindle providespower to the Jointer and Scroll Saw.

8. Logo Cover - Provides access to the wir-ing and Speed Changer Mechanism.Used for maintenance access. (Hiddenfrom view)

9. Power Switch - Turns the MARK V onand off. Has a removable Safety Key onnewer MARK V’s or is a Toggle Switchon older units.

10. Quill Lock - Secures the Quill in posi-tion.

11. Quill Feed Stop - Stops the Quill atpredetermined distances out from the

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RIGHTSIDE

LEFTSIDE

845180 SHOPSMITH MARK V

Headstock. (Hidden from view)12. Quill - Contains the Main Spindle &

Spindle Bearings.13. Main Spindle - Mounts the Saw Blades,

Sanding Discs, and other Accessories.14. Quill Feed Lever - Extends the Quill out

from the Headstock.15. Base Mount - Holds the Extension Table

and Lathe Tailstock.16. Base - Allows the Way Tubes to pivot to

either a horizontal or vertical position.17. Base Lock - Secures the MARK V in the

vertical position.18. Headstock Lock - Secures the Head-

stock on the Way Tubes.19. Speed Dial - Controls the speed of the

Main and Auxiliary Spindles. ONLY turnthe speed dial when the MARK V isrunning. Otherwise, you will damagethe speed changing mechanism. Turnthe speed dial to "Slow" after every op-eration and then turn MARK V off.

20. Bench Tubes - Holds the MARK V rigid.21. Headrest - Holds the Way Tube Tie Bar.22. Belt Cover - Allows access to the Belts

and Sheaves.

MARK V MODEL 50023. Extension Table - Mounts in either the

3435

2325

24 2726

28 29

30

31

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3336

Power Mount or the Base Mount to pro-vide extra support for the stock.

24. Rip Fence - Mounts to the Table and isused as a guide, support or stop. It auto-matically aligns itself parallel to theBlade. Holes in the Fence are used tomount fixtures and fence extensions.

25. Miter Gauge Slots - Guide and securethe Miter Gauge.

26. Table Insert - Used for sawing, sanding,drilling and boring. It can be replacedwith inserts for dadoing, molding, drumsanding and shaping.

27. 10" Saw Blade - Mounts to the 1-1/4"Arbor which then mounts to the MainSpindle. This Saw Blade is use for bothcrosscutting and ripping.

28. Upper Saw Guard - Provides a physicalbarrier between you and the part of theBlade above the Table. An anti-kickbackmechanism helps control kickbacks.

29. Miter Gauge with Safety Grip - Holdsstock firmly at various angles. It slidesfreely or locks in the Miter Gauge Slots.

30. Worktable - Holds the stock and pro-vides a working surface.

31. Lower Saw Guard - Protects you fromthe part of the Blade or cutter below theTable.

32. Table Support Tubes - Support the Tableabove the Bench. Each tube has racksthat mesh with Pinions in the Carriage toraise and lower the Table.

33. Carriage - Slides along the Way Tubesand holds the Table Support Tubes andthe Lathe Tool Rest.

34. Carriage Lock - Secures the Carriage onthe Way Tubes.

35. Table Height Handle - Turns the Pin-ions in the Carriage which raise andlower the Table.


36. Table Height Lock - Secures the Table atany height.

37. Trunnions - Allows the Table to tilt up to90° Left and 45° Right.

38. Table Tilt Indicator - This Vernier Scaleindicates the Table angle.

39. Table Tilt Lock - Secures the Table atany angle, up to 90° Left and 45° Right.

40. Table Tie Bar - Supports the Table Sup-port Tubes and the Trunnions.

41. Table Stops - When properly adjusted,they stop the Table at 90° Left, 45° Rightand 0°. (Note: one of the two 90° TableStop Bolts is shown.)

MARK V MODELS 510 & 520

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42. Extension Table - Mounts in either thePower Mount or the Base Mount to pro-vide extra support for the stock.

43. Miter Gauge Slots - Guide and securethe Miter Gauge.

44. Rip Fence - Mounts to the Table and isused as a guide, support or stop. It auto-matically aligns itself parallel to theBlade. Holes in the Fence are used tomount fixtures and fence extensions.

45. Table Insert - Used for sawing, sanding,drilling and boring. It can be replacedwith inserts for dadoing, molding, drumsanding and shaping.

46. 10" Saw Blade - Mounts to the 1-1/4"Arbor which then mounts to the MainSpindle. This Saw Blade is use for bothcrosscutting and ripping.

47. Upper Saw Guard - Provides a physicalbarrier between you and the part of theBlade above the Table. An anti-kickbackmechanism helps control kickbacks.

48. Miter Gauge with Safety Grip - Holdsstock firmly at various angles. It slidesfreely or locks in the Miter Gauge Slots.

49. Worktable - Holds the stock and pro-vides a working surface.

50. Lower Saw Guard - Protects you fromthe part of the Blade or cutter below theTable. The Saw Guard has a Dust Chute.The Lower Saw Guard is also used withthe Sanding Disc.

51. Table Support Tubes - Support the Tableabove the Bench. Each tube has racksthat mesh with Pinions in the Carriage toraise and lower the Table.

52. Carriage - Slides along the Way Tubesand holds the Table Support Tubes andthe Lathe Tool Rest.

53. Carriage Lock - Secures the Carriage onthe Way Tubes.

54. Table Height Lock - Secures the Table atany height.


Place the Square against the good edge anddraw a line across the width. Flop the Squareover and hold it against the same edge anddraw another line next to the first one. If thelines are parallel, your Square is accurate.

TOOLS NEEDED:

This list covers all tools required for all mod-els. Some tools listed may not be necessary foryour Model MARK V.

3/16" Allen Wrench5/32" Allen Wrench, Long Handle5/32" Allen Wrench, Short Handle5/16" Allen Wrench9/16" WrenchArbor Wrench1/2" WrenchAdjustable Wrench1/2" SocketSocket Wrench with Short Extension1/2" Drill BitSmall Straight Blade ScrewdriverMedium Straight Blade ScrewdriverMedium #12 Phillips ScrewdriverLarge #3 Phillips ScrewdriverHigh Quality Combination Square

All the parts and accessories which support orguide the stock MUST be aligned parallelwith or perpendicular to the Main Spindle'splane of rotation. During the following align-ment procedures the Saw Blade will representthe Main Spindle's plane of rotation. This isthe only time the Saw Blade is used withoutthe Upper or Lower Saw Guards and thenonly after the MARK V is turned off andunplugged.

NOTE

If there are Casters installed on your MARK V,make sure they are retracted and the Legs on theMARK V sit firmly on a level floor. Check this

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6059

55

56

57

55. Trunnions - Allows the Table to tilt up to90° Left and 45° Right.

56. Table Tilt Indicator - This Vernier Scaleindicates the Table angle.

57. Table Tilt Lock - Secures the Table atany angle, up to 90° Left and 45° Right.

58. Table Height Crank - Turns the Pinionsin the Carriage which raise and lowerthe Table.

59. Table Tie Bar - Supports the Table Sup-port Tubes and the Trunnions.

60. Table Stops - When properly adjusted,these Bolts stop the Table at 90° Left, 45°Right and 0°. (Note: Only the two 90°Table Stop Bolts are shown.)

WARNING

Make sure the Speed Dial is set to"Slow", then turn off and unplug theMARK V before performing any ALIGN-MENT procedure.

Complete ALL of the following procedures -and then recheck them at regular intervals.

You MUST use an accurate CombinationSquare for alignment and adjustment. Tocheck that your Square is accurate, select aboard with at least one straight and true edge.


now.Also, remember that your MARK V could possiblygo out of alignment if it is moved to an area withvarying floor levelness. Remember to recheckalignment and make needed adjustments aftermoving your MARK V, if needed.

ADJUST THE HEADREST LOCK(ALL MARK V MODELS)

1. To check the Headrest Lock, grasp theWay Tubes near the Tie Bar and pull up,as demonstrated by the Right Hand inFigure 1.

2. If there is "give" in the Lock, unlock theHandle and use Medium Straight BladeScrewdriver to turn the Lock Shaft clock-wise, as done by the Left Hand in Figure1. If the Lock is difficult to operate, theLock Shaft is too tight. To loosen, unlockthe Handle and turn the Lock Shaft coun-terclockwise.

Figure 1

ADJUST THE CARRIAGE LOCK(MARK V MODELS 510 & 520)

1. If the Carriage Lock Handle does notlock past the horizontal position to four-o’clock or the Carriage moves when thelock handle is in this position, the Lockneeds adjusting. To adjust the Lock, usea 1/2" Socket with an Extension andRatchet Handle to tighten or loosen the

Nut located at the back of the CarriageAssembly, as shown in Figure 2.

Figure 2

2. When the Carriage Lock Handle lockspast the horizontal position to four-o’clock and the Carriage no longer moveswhen the Handle is in this position,tighten the Nut a final 1/4 turn.

WARNING

The Carriage Lock Handle MUST lockpast the horizontal position to Four-O’clock, otherwise the Carriage Lockwill vibrate loose.

SET WORKTABLE'S 90° LEFT STOP(MARK V MODEL 500)

1. Unlock the Carriage and Headstock.Move the Headstock to the middle of theWay Tubes. Then move the Carriagebetween the Headstock and Base Mount(right side).

2. Tighten the Headstock and CarriageLocks. Place the MARK V in the verticalposition by loosening the HeadrestHandle, firmly grasping the Way Tubesnear the Headrest end, and lifting theTubes into the 90° position, as demon-strated in Figure 3.


Figure 3

WARNING

Always make sure the MARK V Head-stock and Carriage are locked and allCasters are raised off the floor beforelifting the MARK V into the verticalDrill Press position.

3. Use your fingers to tighten the Base Lock.

NOTE

The Base Lock is slightly off center to the counter-sink found in the Base, as shown in Figure 4. Thisoffset allows the Base Lock to more firmly hold theBase Arm in place.

Figure 4

4. Move the Worktable into the 90° posi-tion by loosening the Table Tilt Lock,then putting the Worktable in the hori-zontal 90° position, as shown in Figure 5.Retighten the Table Tilt Lock only enoughto allow movement with firm pressure.

Figure 5

5. Use a 5/32" Allen Wrench to remove theTable Insert, as demonstrated in Figure6.

Figure 6

6. To install the Drill Chuck, mount theChuck on the Spindle and align theChuck's Set Screw with the SpindleKnob's Set Screw, as shown in Figure 7.This allows the Chuck's Set Screw to seton the flat part of the Spindle. Use a5/32" Allen Wrench to securely tightenthe Drill Chuck's Set Screw.

Figure 7

7. Install a 1/2" Straight Drill Bit in theDrill Chuck and use the Chuck Key tolock it place. See Figure 8.


10. Both 90° Stops should contact the top ofthe Table Support Tubes, as in Figure 11.If they don't, use a 1/2" Wrench to adjustthe Stops.

Figure 11

11. Recheck the setting by loosening the TiltLock, moving the Table, and then re-peating Steps 9 and 10. (Rechecking thesetting is very important!)

SET WORKTABLE'S 90° LEFT STOP(MARK V MODELS 510 & 520)

1. Unlock the Carriage and Headstock.Move the Headstock to the middle of theWay Tubes. Then move the Carriagebetween the Headstock and Base Mount(right side).

2. Tighten the Headstock and CarriageLocks. Place the MARK V in the verticalposition by loosening the HeadrestHandle, firmly grasping the Way Tubesnear the Headrest end, and lifting theTubes into the 90° position, as demon-strated in Figure 12.

Figure 12

Figure 8

NOTE

Check the straightens of the Drill Bit by rolling iton a flat surface or you can also hand-rotate theDrill Chuck while holding the Combination Squareagainst the Drill Bit and the Table. If the Bit is notstraight DO NOT use it for these alignment instruc-tions.

8. With the Drill Bit above the Table open-ing, use the Quill Feed to extend the DrillBit 1/2" into the Table opening, as inFigure 9.

Figure 9

9. Set the Combination Square against theDrill Bit and Table, as shown in Figure10. The Square should contact the DrillBit along its entire length. When theTable is exactly perpendicular to the DrillBit, lock the Table.

Figure 10

90° STOP(Front)


WARNING

Always make sure the MARK V Head-stock and Carriage are locked and allCasters are raised off the floor beforelifting the MARK V into the verticalDrill Press position.

3. Use your fingers to tighten the Base Lock.

Figure 13

NOTE

The Base Lock is slightly off center to the counter-sink found in the Base, as shown in Figure 13. Thisoffset allows the Base Lock to more firmly hold theBase Arm in place.

4. Move the Worktable into the 90° posi-tion by loosening the Table Tilt Lock, asshown in Figure 14, then putting theWorktable in the horizontal 90° position,as shown in Figure 15. Retighten theTable Tilt Lock only enough to allowmovement with firm pressure.

Figure 14

Figure 15

5. Use a 5/32" Allen Wrench to remove theTable Insert, as demonstrated in Figure16.

Figure 16

6. To install the Drill Chuck, mount theChuck on the Spindle and align theChuck's Set Screw with the SpindleKnob's Set Screw, as shown in Figure 17.This allows the Chuck's Set Screw to seton the flat part of the Spindle. Use a 5/32" Allen Wrench to securely tighten theDrill Chuck's Set Screw.

Figure 17

7. Install a 1/2" Straight Drill Bit in theDrill Chuck and use the Chuck Key tolock it in place. See Figure 18.


Figure 20

10. When the Table is exactly perpendicularto the Drill Bit, lock the Table, as seen inFigure 21.

Figure 21

11. Both 90° Stops (shown in Figures. 22 and23) should contact the underside of theTable. If they don't, use a 1/2" Wrench toadjust the Stops.

Figure 22

90° Stop(Front)

Figure 18

NOTE

Check the straitness of the Drill Bit by rolling it ona flat surface or you can also hand-rotate the DrillChuck while holding the Combination Squareagainst the Drill Bit and the Table. If the bit is notstraight DO NOT use it for these alignment instruc-tions.

8. With the Drill Bit above the Table Open-ing, use the Quill Feed Handel to extendthe Bit 1/2" into the Table Opening, asshown in Figure 19.

Figure 19

9. Set the Combination Square against theDrill Bit and Table, as shown in Figure20. The Square should contact the DrillBit along its entire length.


Figure 23

12. Recheck the setting by loosening the TiltLock, moving the Table, and then re-peating Steps 9 through 11. (Recheckingthe settings is very important!)

SET THE WORKTABLE'S 0° STOP

1. Remove the Drill Bit and Drill Chuckfrom the Spindle.

2. Loosen the Base Lock. Firmly grasp theWay Tubes and lower the Headstockinto the horizontal position, then engagethe Headrest.

3. Loosen the Table Tilt Lock and place theTable in the horizontal 0° position. Re-tighten the Table Tilt Lock only enoughto allow movement with firm pressure.

4. Mount the Saw Blade on the Arbor:

b. Hold the Blade with the teeth point-ing toward you, as shown in Figure25, then insert the Arbor throughthe hole. Replace the Nut and fin-ger tighten it.

90° Stop(Rear)

a. Remove the Arbor Nut by turningit clockwise, as seen in Figure 24.Hold the Arbor with the threadedpart pointing to the left.

c. Place the Blade and Arbor on yourWorkbench with the Nut pointingup.

d. Hold the Arbor with an AdjustableWrench and tighten the Arbor Nutwith the Arbor Wrench, as demon-strated in Figure 26. Another wayto tighten the Arbor Nut is to clampthe Arbor in a Bench Vise, as illus-trated in Figure 27, and tighten theNut with the Arbor Wrench.

Figure 24

Figure 25

Figure 26

Figure 27


10. Place the Combination Square againstboth the Saw Blade and Worktable, asseen in Figure 32. Make sure the square'sblade does not touch a saw tooth anddoes rest in a gullet between teeth.

Figure 32

11. If the Worktable is not exactly perpen-dicular to the Saw Blade, adjust theWorktable so it is perpendicular to theSaw Blade, then tighten the Tilt Lock.

(MARK V MODEL 500)

12. Use a Small Screwdriver to back out the0° stop 2-3 turns. Depress the Plunger

WARNING

The only time the Saw Blade is usedwithout the Upper or Lower SawGuards is during alignment and ONLYafter the MARK V is turned off andunplugged.

5. Mount the Saw Blade on the Spindle andalign the Arbor Set Screw with theSpindle Knob's Set Screw, then use a 5/32" Allen Wrench to tighten the ArborSet Screw.

6. Reinstall the Table Insert in the Work-table.

7. Raise the Worktable so that it clears thetop of the Saw Blade.

8. Loosen the Carriage Lock and slide theCarriage so the Saw Blade is directlybeneath the slot in the Table Insert. SeeFigure 28 or 29. Tighten the CarriageLock.

MARK V Model 500

Figure 28

MARK V Models 510 & 520

Figure 29

9. Lower the Worktable (nearly all the waydown) so the Saw Blade comes throughthe slot. Lock the Table Height, as seen inFigure 30 or 31.

Figure 31

MARK VModels 510 & 520

Figure 30

MARK VModel 500


ADJUST THE WORKTABLE'S 45° STOP(MARK V Model 500)

1. Loosen the Table Height Lock and raisethe Table until it clears the Saw Blade.Tighten the Height Lock.

2. Loosen the Tilt Lock and tilt the Work-table to the right.

3. Tighten the Tilt Lock only enough toallow movement with firm pressure.

4. Loosen the Quill Feed (shown in Figure37) and extend the Quill so the Saw

under the Table Tilt Indicator up towardthe Front Trunnion, and hole it therewith your finger. Slowly turn the 0° stopin until you feel it just touch the Plunger.See Figure 33.

Figure 33

13. Recheck the setting by repeating Steps10 through 12. (It is very important torecheck this setting!)

(MARK V MODELS 510 & 520)

12. To adjust the 0° Stop, simultaneouslydepress the Table Stop Pin and use a 1/2" Wrench to adjust the Stop Bolt. TheStop Bolt should just contact the side ofthe Stop Pin. Once the Stop Bolt is ad-justed, the Stop Pin will "snap" backwhen the Tilt Lock is tightened. See Fig-ure 34.

Figure 34

13. Loosen the Tilt Lock, tilt the Worktable,then depress the 0° Stop Pin until theStop Bolt contacts it. Tighten the Tilt

Lock, and recheck the setting by repeat-ing Steps 10 through 12. (It is very impor-tant to recheck this setting!)

ADJUST THE TABLE TILT INDICATOR

1. Tighten the Table Tilt Lock and checkthat the 0° mark on the Indicator alignswith the 0° mark on the Trunnion.

2. To adjust the scale, use a Medium PhillipsScrewdriver to loosen the two Screwswhich hold the Indicator to the Tie Bar.See Figure 35 or 36. Then while holdingthe Indicator in position so the 0's arealigned, retighten the Screws.

MARK VModel 500

Figure 35

MARK VModels 510 & 520

Figure 36


7. Loosen the Tilt Lock and tilt the Tablepast the 45° setting. Then depress thePlunger and tilt the Table back towardthat angle until the Stop hits the Plunger.Tighten the Tilt Lock, then check theangle. If the angle is not 45°, the Stopneeds adjusting.

8. To adjust the 45° Right Stop, see Figure40. Set the Table to 45° Right. Then usethe Combination Square to set the tilt ofthe Table to precisely 45° Right. Use aSmall Screwdriver to back out the 0° stop2-3 turns. Depress the Plunger under theTable Tilt Indicator up toward the FrontTrunnion, and hold it there with yourfinger. Slowly turn the 45° Stop in untilyou fell it touch the Plunger.

Figure 40

9. Loosen the Tilt Lock and move the Table.To recheck the 45° Stop, repeat Steps 4through 9. (It is very important to re-check the setting!)

ADJUST THE WORKTABLE'S 45° STOP(MARK V MODELS 510 & 520)

1. Loosen the Table Height Lock and raisethe Table until it clears the Saw Blade.Tighten the Height Lock.

2. Loosen the Tilt Lock and tilt the Work-table to the right until it makes contactwith the two 45° Stop Bolts.

3. Tighten the Tilt Lock only enough toallow movement with firm pressure.

Blade is centered beneath the slot in theTable Insert. When it is centered, lock theQuill Feed.

Figure 37

5. Lower the Worktable so the Saw Bladeextends through the Table Insert slot.See Figure 38. Lock the Table Height.

Figure 38

6. Remove the Blade from the Combina-tion Square and place the Square againstthe Saw Blade and the Worktable, asshown in Figure 39. Make sure the Com-bination Square doesn't rest on the TableInsert.

Figure 39


4. Loosen the Quill Feed (shown in Figure41) and extend the Quill so the SawBlade is centered beneath the slot in theTable Insert. When it is centered, lock theQuill Feed.

Figure 41

5. Lower the Worktable so the Saw Bladeextends through the slot. See Figure 42Lock the Table Height.

Figure 42

6. Remove the bar from the CombinationSquare and place the square against theSaw Blade and the Worktable, as shownin Figure 43. Make sure the CombinationSquare doesn't rest on the Table Insert.

Figure 43

7. If the Worktable is not exactly 45° to theSaw Blade, adjust the Worktable so it is.

8. Tighten the Tilt Lock, then use a 1/2"Wrench to adjust the 45° Stop on thefront side of the Worktable (shown inFigure 44).

Figure 44

9. Also, the back side of the Worktable(shown in Figure 45). The stops shouldjust contact the underside of the Table.

Figure 45

10. Loosen the Tilt Lock and move the Table.To recheck the 45° stops, repeat Steps 4through 8. (It is very important to re-check the setting!)

ALIGN THE MITER GAUGE SLOTS

1. Return the Worktable to the horizontal0° stop and tighten the Tilt Lock. TheCarriage Lock and Headstock Lockshould also be tightened.

2. Place the Miter Gauge in the Right MiterGauge Slot, and use a 5/32" Allen Wrenchto remove the Quick Clamp from theSafety Grip, as shown in Figure 46.


Figure 48

Figure 49

5. If the Miter Slots need to be aligned, dothe following:

(MARK V MODEL 500)

Figure 50

a. Use a 9/16" Wrench to loosen theBolts which hold the Worktable tothe Trunnions, (Front TrunnionBolts shown in Figure 50) and theTable Base. Loosen these four Boltsonly enough to allow movementwith firm pressure.

Figure 46

3. Insert the Long 5/32" Allen Wrenchthrough the Miter Gauge. Borrow a SetScrew from the Lathe Tool Rest and usethe Short 5/32" Allen Wrench to install itin either top Miter Gauge hole, as seen inFigure 47. Place the tip of the LongWrench against the front side of the SawBlade and tighten the Set Screw.

Figure 47

4. Move the Miter Gauge from front to backalong the Saw Blade, as shown in Figs. 48and 49. If it hangs up on the Blade or agap develops, the Miter Gauge Slots needto be aligned. Make sure the AllenWrench does not contact a Saw Bladetooth, because the tooth "set" will causemisalignment.

Trunnion Bolts(Front)


Figure 51

b. Adjust the Worktable, then againmove the Miter Gauge and Wrenchalong the face of the Saw Bladeuntil the Wrench tip consistentlycontacts the entire Saw Blade sur-face.

c. When the Miter Gauge Slot isaligned, tighten the two TrunnionBolts which are closer to the Head-stock. Then tighten the other twoTrunnion Bolts.

d. Loosen the Table Tilt Lock and movethe Table, then return it to the hori-zontal 0° position. Recheck the Slotalignment. If it is off, repeat steps 5athrough 5c. (It is very important torecheck this setting!)

(MARK V MODELS 510 & 520)

a. Tilt the Table to 45° and tighten theTilt Lock.

b. Use a 5/16" Allen Wrench to loosenall four Bolts which hold the Work-table to the Trunnions, as pointedout in Figure 51. Loosen the Boltsonly enough to allow movementwith firm pressure.

c. Position the Worktable back to thehorizontal 0° and tighten the TiltLock.

d. Adjust the Worktable, then againmove the Miter Gauge and Wrenchalong the face of the Saw Bladeuntil the Wrench tip consistentlycontacts the entire Saw Blade sur-face.

e. When the Miter Gauge Slot isaligned, use the 5/16" AllenWrench to retighten the two Trun-nion Bolts which are closer to theHeadstock. Then loosen the TableTilt Lock, tilt the Worktable to 45°,and tighten the Table Tilt Lock. Usethe 5/16" Allen Wrench to tightenthe other two Trunnion Bolts.

NOTE

If you find it difficult to loosen the Bolts, considerusing a T-Handle Allen Wrench, or use a Box EndWrench for extra torque. Another alternative is touse the hanging hole in an Adjustable Wrench, asdemonstrated in Figure 52 and 53.

Figure 52

Figure 53

Trunnion Bolts


slide it back and forth in the Slot to checkif the Miter Gauge scrapes against theTable. If the Miter Gauge rocks or scrapesthe Table, adjust the Glides.

Figure 56

3. If the Glides need to be adjusted, do thefollowing:

Miter Gauge shownbefore adjusting the glides.

a. Remove the Miter Gauge from theSlot and turn it over.

b. Use a Medium Screwdriver to ad-just the Glides in or out, as illus-trated in Figure 71, so that the Glideshold the Miter Gauge 1/64" to 1/32" off the Worktable and the MiterGauge does not rock in the Slots.

Figure 57

4. Return the Miter Gauge to the Slot andrecheck and readjust it, if needed.

ADJUST THE MITER GAUGE FACE

1. Remove the Safety Grip from the MiterGauge.

2. Put the Miter Gauge in the Right Slot andplace the Combination Square againstthe Saw Blade and Miter Gauge Face, asseen in Figure 58.

NOTE

Tighten the Bolts only after the Table Tilt Lock issecured. Otherwise the Worktable will bow or bindthe next time the Table Tilt Lock is tightened.

INSTALL THE TABLE INSERT

1. Place the Table Insert in the Worktablerecess. Use a 5/32" Allen Wrench to startboth screws. See Figure 54.

Figure 54

2. First tighten the rear screw. Then thefront of the insert will be sprung slightlyabove the Table. Level the insert by plac-ing your hand on the front of the insert,and slowly turning the front screw untilit draws the front of the insert flush withthe Worktable surface. Shown in Figure55.

Figure 55

ADJUST THE MITER GAUGE GLIDES

1. Place the Miter Gauge in the Worktable'sMiter Gauge Slot.

2. Check to see if the Miter Gauge wobblesside-to-side, typified by Figure 56. Also,


ADJUST THE 90° POSITIVE STOP

1. Use a Small Screwdriver to back out the90° Stop Screw 2 to 3 turns, as shown inFigure 61.

Figure 61

2. Depress the Plunger, then turn the StopScrew until you feel it touch the Plunger.

ADJUST BOTH 45° STOPS

1. Loosen the Lock Knob and pull out thePlunger. Then, at the same time, rotatethe Miter Gauge and push in the Plungeruntil it hits the 45° Stop (there is one oneach side of the 90° Stop).

2. Use a Combination Square to set theMiter Gauge Face at 45° to the Saw Blade.If the 45° Stop needs adjustment, use aMedium Screwdriver to back out the 45°Screw 2 to 3 turns.

3. Depress the Plunger, then turn the StopScrew until you feel it touch the Plunger.

4. To adjust the other 45° Stop, repeat Steps1 to 3.

REMOVE THE SAW BLADE

1. Loosen the Table Height Lock and raisethe Table so that it clears the Saw Blade,

a. Use a Long Allen Wrench to loosenthe Lock Knob and adjust the MiterGauge so it is perpendicular to theSaw Blade, then tighten the LockKnob. See Figure 59.

Figure 59

b. Use a Medium Screwdriver, loosenthe Screw which holds the Indica-tor Plate, and set its 0° to the MiterGauge's 90°. Tighten the Screw. SeeFigure 60.

Figure 58

3. If the Miter Gauge Face is not perpen-dicular to the Saw Blade, do the follow-ing:

Figure 60

90° Stop

45° Stop

45° Stop


then tighten the lock. Unlock the Car-riage Lock and move the Worktable tothe right.

2. Use the 5/32" Allen Wrench to loosenthe Arbor Set Screw. Remove the SawBlade. See Figure 62.

Figure 62

3. Unlock the Table Height Lock and lowerthe Table to a comfortable workingheight. Tighten the Lock.

ALIGN THE RIP FENCE(MARK V MODEL 500 STYLE 1)

1. Place the Rip Fence on the Worktable byfirst putting the Fence Base on the FrontRail, then lowering the rest of the RipFence.

2. Use a 5/32" Allen Wrench to back out thetwo Adjusting Set Screws from the FenceBase so they don't contact the infeededge of the Table Rail.

NOTE

The Outfeedlock should press against the bottomedge of the Table, not hook under it. As you tightenthe Locking Handle, a clamp just behind the FenceBase pulls the Rip Fence so the Fence Base restsflush against the Table mounting bar, and is nowautomatically aligned to the Blade. The OutfeedLock now secures the Fence at the same time.

3. Place the Miter Gauge in the Left Slot ofthe Worktable on the infeed side, asshown in Figure 63.

Figure 63

4. Insert the Long 5/32" Allen Wrenchthrough the Miter Gauge and secure itusing a Short 5/32" Allen Wrench and aSet Screw borrowed from the Lathe ToolRest, as seen in Figure 64.

Figure 64

CAUTION

Be sure the end of the Allen Wrench is smooth.Watch that you don't scratch the Rip Fence surface.

5. Move the Rip Fence toward the AllenWrench until it just touches it. When isdoes touch the Fence, lock the Base Knob,as in Figure 65.

Figure 65


Figure 66

a. Loosen the Base Knob.

b. Use a 1/2" Wrench to loosen thetwo Hex Bolts attaching the FenceBase, so they are just tight enoughto require firm pressure to align theFence. See Figure 66.

c. Make any needed adjustments.DO NOT tighten the Hex Bolts yet.

d. Tighten the Base Knob.

e. Slide the Miter Gauge back andforth, readjusting the Fence untilthe Allen Wrench makes consistentcontact along the entire length ofthe Rip Fence.

f. When alignment is reached, tightenthe two Hex Bolts in the Base.

g. Carefully unlock the Handle andthe Base Knob on the Base and liftthe Rip Fence from the Table.

h. To recheck the alignment, repeatSteps 5 through 7g. (It is very im-portant to recheck the alignment!)

ALIGN THE RIP FENCE(MARK V MODEL 500 STYLE 2)

1. Place the Rip Fence on the Worktable byfirst putting the Fence Base on the FrontRail, then lowering the rest of the RipFence. Figure 67.

Figure 67

2. Place the Miter Gauge in the Left Slot ofthe Worktable on the infeed side. Insertthe Long 5/32" Allen Wrench throughthe Miter Gauge and secure it using aShort 5/32" Allen Wrench and a Set Screwborrowed from the Lathe Tool Rest, asseen in Figure 68.

Figure 68

3. Move the Rip Fence toward the AllenWrench until it just touches. Tighten theHandle, then lock the Outfeed ClampLever to secure both ends of the RipFence, as shown in Figure 69.

Figure 69

6. Slide the Miter Gauge back and forth inthe Slot. The tip of the Allen Wrenchshould keep in slight contact with theRip Fence.

7. If it pulls away from or binds against theRip Fence, the Fence needs aligning. Ifso, do the following:


Figure 72

ALIGN THE RIP FENCE(MARK V MODEL 510)

1. Place the Rip Fence on the Worktable byfirst putting the Fence Base on the front,as demonstrated in Figure 73, then low-ering the rest of the Rip Fence.

Figure 73

2. Use a 5/32" Allen Wrench to back out theAdjusting Set Screw from the Fence Baseso it doesn't contact the infeed TableTube, as shown in Figure 74.

Figure 74

c. Adjust the Fence by pulling or push-ing it closer to, or farther from, the5/32" Allen Wrench, as shown inFigure 71.

d. Lock the Rear Clamp Lever. Again,slide the Miter Gauge from front toback, as described in Step 11. TheFence should be parallel with theMiter Gauge Slot. If not, repeat Steps10 through 12b.

4. Slide the Miter Gauge back and forth inthe Slot, as seen in Figure 70. The tip ofthe Allen Wrench should keep in slightcontact with the Rip Fence. Watch thatyou don't scratch the Fence.

Figure 70

5. If it pulls away from or binds against theRip Fence, the Fence needs aligning. Toalign the Rip Fence, do the following:

a. Loosen the Rear Clamp Lever.

b. Loosen the four Socket Head CapScrews under the infeed end cast-ing just enough to move it with firmpressure.

Figure 71

e. Once aligned, tighten the SocketScrews with a 5/32" Allen Wrench,as shown in Figure 72. Repeat Step12c to double check alignment. (It isvery important to recheck the align-ment!)


ADJUST THE OUTFEED CLAMP(MARK V MODEL 510)

1. Place the Rip Fence Base on the infeedTable Tube, then lower the Rip Fenceonto the outfeed tube. The outfeed clampshould just miss the Table Tube as it islowered into place.

2. Lock both the Base Lock and the Handle.Figure 77.

Figure 77

3. If the clamp is too tight and hits the TableTube, or too loose and allows slippagewhile it is locked, it needs adjusting. Toadjust the Outfeed Clamp, do the fol-lowing:

b. Place the Rip Fence back on theTable and lock the Handle.

c. Use your fingers to adjust the FenceRest until it fully contacts theoutfeed Table Tube.

d. Unlock the Handle and carefullyraise the Fence. Use the MediumPhillips Screwdriver to tighten theFence Rest Screws.

a. Raise the outfeed end of the RipFence and use a Medium PhillipsScrewdriver to loosen the twoScrews that attach the Fence Rest.Tighten the Fence Rest just enoughto move it with firm pressure. SeeFigure 76.

a. If too tight, raise the Handle, anduse a 1/2" Socket with RatchetWrench to loosen the Lock Nut.When the Clamp touches the TableTube, loosen the Lock Nut 1/8 turnor less.

b. If too loose, lock the Handle, anduse a 1/2" Socket with RatchetWrench to tighten the Lock Nut.When the Clamp touches the TableTube, loosen the Lock nut 1/8 turnor less. See Figure 78.

3. Check to see if the Fence Rest fully con-tacts the outfeed Table Tube, as shown inFigure 75.

Figure 75

4. If it doesn't, adjust the Fence Rest bydoing the following:

Figure 76

e. Recheck the Fence Rest by remount-ing the Rip Fence on the Worktable.If further adjustments are needed,repeat Steps 4a through 4d.

OutfeedClamp

FenceRest

Handle

BaseLock


CAUTION

Be sure the end of the Allen Wrench is smooth.Watch that you don't scratch the Rip Fence surface.

3. Move the Rip Fence toward the AllenWrench until it just touches it. Lock theBase Knob and Handle on the Base tosecure both ends of the Rip Fence. SeeFigure 81.

Figure 81

4. Slide the Miter Gauge back and forth inthe Slot. See Figure 82. The tip of theAllen Wrench should keep in slight con-tact with the Rip Fence.

Figure 82

5. If it pulls away from or binds against theRip Fence, the Fence needs aligning. Ifso, do the following:

a. Loosen the Handle and Base Knob,remove the Rip Fence from the Tableand turn the Fence upside down.

Figure 78

ALIGN THE RIP FENCE PARALLELWITH THE WORKTABLE(MARK V MODEL 510)

1. Place the Miter Gauge in the Left Slot ofthe Worktable on the infeed side, asshown in Figure 79.

Figure 79

2. Insert the Long 5/32" Allen Wrenchthrough the Miter Gauge and secure itusing the Short 5/32" Allen Wrench anda Set Screw borrowed from the ToolRest, as seen in Figure 80.

Figure 80


c. Return the Rip Fence to the Work-table. Slide it toward the AllenWrench until it contacts the AllenWrench at the infeed end.

d. Only tighten the Base Knob.

e. Slide the Miter Gauge back andforth, adjusting the Fence until theAllen Wrench makes consistent con-tact along the entire length of theRip Fence. Again, remember to notscratch the Fence.

f. When alignment is reached, lockthe Handle. Slide the Miter Gaugeback and forth along the Fence todouble check that the Fence did notmove when you locked the Handle.

g. Reach under the Table and use theLarge Phillips Screwdriver totighten the Screw closer to the Base.See Figure 84.

Figure 83

Figure 84

b. Use a Large Phillips Screwdriver toloosen the Screw nearest the FenceBase, so it is just tight enough torequire firm pressure to align theFence. See Figure 83.

h. Carefully unlock the Handle andthe Base Knob on the Base and liftthe Rip Fence from the Table.

i. Tighten the other AdjustmentScrew.

j. To recheck the alignment, repeatSteps 3 through 6g. (It is very im-portant to recheck the alignment!)

ALIGN THE RIP FENCE PARALLELWITH THE WORKTABLE(MARK V MODEL 520 - PRO FENCE)

1. Place the Miter Gauge in the Left Slot ofthe Worktable on the infeed side. Placethe Pro Fence on the right side of the SawTable.

2. Insert the Long 5/32" Allen Wrenchthrough the Miter Gauge and secure itusing the Short 5/32" Allen Wrench anda Set Screw borrowed from the ToolRest.

3. Move the Fence toward the Allen Wrenchuntil it just touches it.

4. Lock the Lower Fence Lock Handle first,then lock the Upper Fence Lock Handleto secure both ends of the Pro Fence.


slide the Carriage to the right until thetwo Tables touch. Tighten the CarriageLock.

2. Using a Straightedge, adjust the heightof the Worktable so that its infeed sur-face is even with the infeed surface of theExtension Table. (Figure 85).

Figure 853. Move the Straightedge to the outfeed of

the Extension Table and check that theExtension Table outfeed surface is evenwith the Worktable outfeed surface. Ifit’s not, shim and adjust the ExtensionTable.

4. To shim and adjust the Extension Table,loosen (1-1/2 - 2 turns) all four Boltsthat hold the Extension Table to the Ex-tension Table Base.

5. Remove the two Bolts on the low side ofthe Extension Table. Place enough Shimsbetween the Extension Table and theExtension Table Base to raise the lowside level with the surface of the Work-table.

NOTE

The Shim Kit contains two size Shims. You’ll usea combination of thicknesses to align the Exten-sion Table surface with the Worktable surface.

6. Replace and tighten all four Bolts. Checkyour work. When the Extension Table isproperly shimmed, you will be able toadjust the height of the Worktable so thatthe infeed and outfeed surface of the

a. Using the Short 5/32" Short AllenWrench, loosen the four ButtonHead Cap Screws, located on thetop of the Fence, slightly. Theyshould be just tight enough to re-quire firm pressure to align theFence.

b. Raise the Upper Fence Lock Handleonly to unlock the rear of the Fence.

c. Adjust the rear end of the Fence sothat it just touches the Allen Wrenchas the Miter Gauge slides along theFence.

d. When alignment is reached, lockthe Upper Fence Lock Handle. Slidethe Miter Gauge back and forth todouble check your alignment. Us-ing the Short 5/32" Allen Wrench,tighten the four Button Head CapScrews completely.

ALIGN THE EXTENSION TABLE(MARK V MODEL 500 STYLE 1)

The Extension Table Fence Mounting Bar mustbe parallel to an in line with the Fence Mount-ing Bar on the Worktable. Also, the surface ofthe Extension Table must be even with thesurface of the Worktable.

1. To check the alignment of the ExtensionTable, mount the Extension Table in theBase Arm. Loosen the Carriage Lock and

5. Slide the Miter Gauge back and forth inthe Slot. The tip of the Allen Wrenchshould keep in slight contact with theFence. Watch that you don't scratch theFence.

6. If the Allen Wrench pulls away from orbinds against the Fence, the Fence needsaligning. If so, do the following:


Extension Table is even with the infeedand outfeed surface Worktable.

7. Check that the Extension Table FenceMounting Rail is in line with the FenceMounting Rail on the Worktable.

8. Lay a Straightedge across the bevel ofboth Rails. (Figure 86). If adjustment isneeded, loosen (1/2 turn) the four Boltsholding the Extension Table to the Ex-tension Table Base. Tap the ExtensionTable forward or backward until thebevel of the Fence Mounting Rails arealigned. Retighten the Bolts by turningeach a small amount until all four aresecure. Check the alignment.

Figure 86

ALIGN THE EXTENSION TABLE(MARK V MODELS 500 SYLE 2, 510 & 520)

NOTE

These instructions are for aligning the ExtensionTable on the right side of the Headstock. You canalso follow these same procedures to align it to theleft side of the Headstock.

For most projects, align the Extension Table on theright side. It is also occasionally used on the leftside. However, once the Extension Table is alignedon the right side, it cannot be transferred to the leftside and still maintain precise alignment.

If you wish precise alignment on the left side,repeat the following instructions - but place theExtension Table on the left side in the Headstock.

1. Mount the Extension Table in the MARKV's Accessory Base Arm (on the rightside) at a comfortable height, as shownin Figure 87.

Figure 87

2. Use a 1/2" Wrench to loosen the BottomNuts holding the Table Base to the Tableapproximately 1/2" from the bottom ofthe Table. This will allow you room forlater adjustment. See in Figure 88.

Figure 88

3. The Worktable should already bemounted in the Carriage Mount. Movethe Worktable next to the Extension Tableand adjust it to about 1/4" above theExtension Table, as seen in Figure 89.

Figure 89

FenceRail

Bevel


8. Hold a Straightedge on the outfeed topsurface of both the Worktable and theExtension Table, as shown in Figure 93.As needed, adjust the Top Nuts locatedon the outfeed side of the Extension Table,in order for the Straightedge to be levelacross both the Worktable and the Ex-tension Table outfeed sides.

Figure 93

9. Double check the levelness at the infeedand outfeed sides of the Table surfaces.All four Top Nuts (those nearest theTable) used in leveling the ExtensionTable should be touching the Base.

10. When the Tables are aligned on threesides - infeed side edge (along the TableBars, as in Figure 90), infeed top surface(as in Figure 91), and outfeed top surface(as in Figure 93) - securely tighten theBottom Nut on each of the four Studs.

WARNING

DO NOT overtighten the nuts. Tightenthe nuts until they bottom out, thenno more than 1/8 additional turn. Over-tightening the nuts will stretch anddamage the threads.

NOTE

If you move the MARK V to another location -especially one with an uneven floor - remember torecheck the Extension Table alignment.

4. Hold a Straightedge against the infeededge of both the Worktable and Exten-sion Table, as in Figure 90.

Figure 90

5. Line up the Extension Tables infeed edgewith the Worktables infeed edge. Theelongated holes in the Extension TableBase permit you to slide the ExtensionTable forward and backward.

6. Hold a Straightedge on the infeed topsurface of both the Worktable and theExtension Table, as shown in Figure 91.

Figure 91

7. As needed, adjust the Top Nuts locatedon the infeed side of the Extension Table,in order for the Straightedge to be levelacross both the Worktable and the Ex-tension Table infeed sides. See Figure 92.

Figure 92


ALIGN THE EXTENSION TABLE TUBES(MARK V MODEL 510)

1. Place the Straightedge along the infeedside tops of both the Worktable and Ex-tension Table Tubes, as shown in Figure94.

Figure 94

2. If the Extension Table's Tube is notaligned with the Worktable's Tube, use a7/16" Wrench to slightly loosen bothKeps Nuts attaching the Tube to theExtension Table. Make the needed ad-justments, then retighten the Nuts. SeeFigure 95.

Figure 95

3. Repeat Steps 1 and 2 for the ExtensionTable's Tube located on the outfeed side.

MOUNT THE LOWER SAW GUARD(MARK V MODEL 500)

1. Loosen the Accessory Mount Lock andremove the Extension Table. Loosen theTable Height Lock and remove the Work-table.

2. Fit the Lower Saw Guard's Clamp on theSpindle Quill, so that the collar on theSaw Guard butts against the Stop Collaron the Quill.

3. Use a 5/32" Allen Wrench to tighten theSocket Head Screws on the Saw GuardRetainer, as seen in Figure 96.

Figure 96

4. Place the Saw Blade in the Saw Guardand mount the Arbor on the MainSpindle. Line up the flat on the Spindlewith the Arbor Set Screw. Use a 5/32"Allen Wrench to securely tightened theArbor Set Screw. Readjust the Saw Guardclose to the Blade.

MOUNT THE LOWER SAW GUARD(MARK V MODELS 510 & 520)

1. Loosen the Accessory Mount Lock andremove the Extension Table. Loosen theTable Height Lock and remove the Work-table. Place the Saw Blade and Arbor inthe Lower Saw Guard Cover.

2. Fit the Lower Saw Guard's Clamp on theSpindle Quill. Line up the Arbor SetScrew with the Spindle Knob's Set Screw(where the Spindle Flat is located). Use a5/32" Allen Wrench to tighten the ArborSet Screw, as in Figure 97.

KepsNuts


Figure 99

INSTALL THE UPPER SAW GUARD(MARK V MODEL 500)

1. Slide (from left to right) the Upper SawGuard into the slots in the MountingBlock, located beneath the Table on theoutfeed side.

2. Make sure that the Splitter is fully seated.Tighten the Guard Knob.

3. Raise the Upper Guard and lay a Straight-edge on the Worktable so that it touchesthe Blade and the Splitter, as demon-strated in Figure 100.

Figure 100

Figure 97

3. Use the 5/32" Allen Wrench to tightenthe Socket Head Screw on the Saw GuardCollar, as in Figure 98.

Figure 98

ATTACH THE TIE BAR SHIELD(MARK V MODEL 500)

1. Remove the Worktable from the Car-riage and turn over.

2. Make sure the two Button Head SocketScrews are engaged in the Tie Bar andslip the Tie Bar Shield over them.

3. Use a 5/32" Allen Wrench to tighten theButton Head Socket Screws. Remountthe Worktable on the MARK V. The Mounting

Block is locatedbeneath theTable on theoutfeed side.

MountingBlock

Button HeadSocket Screws

Tie BarShield

Tie Bar


a. Notice which way the Riving Knifeis not centered with the Saw Blade.

b. Un-clamp and remove the UpperSaw Guard, then remove the SawBlade and Lower Saw Guard.

4. Move the Upper Saw Guard to the rightor left, as needed, so the Straightedgerests flush against both the Blade and theSplitter.

5. Tighten the locking knob. The Splittermust be aligned every time you mountthe upper guard or adjust the Saw Bladeusing the Quill.

INSTALL THE RIVING KNIFE(MARK V MODELS 510 & 520)

1. Loosen the Guard Lock Knob and insertthe Upper Saw Guard's Riving Knifebetween the Guard and the Lock Plate,as demonstrated in Figure 101.

Figure 101

2. Make sure the Riving Knife is fully seatedbetween the Guard and the Lock Plate,as in Figure 102.

Figure 102

3. The curved portion of the Riving Knifeshould be very close to the Saw BladeTeeth (about 1/8"), as illustrated in Fig-ure 103.

Figure 103

4. Tighten the Guard Lock Knob. Look tosee if the Riving Knife is centered withthe Saw Blade, as shown in Figure 104.

Figure 104

5. If the Riving Knife is not centered withthe Saw Blade, follow these steps:


• If the Riving Knife is to the leftof the Saw Blade, back out theStop Screw (counterclock-wise).

• If the Riving Knife is to theright of the Saw Blade, screwin the Stop Screw (clockwise).

ALIGN THE LATHE CENTERS

1. Remove the Saw Guards and the SawBlade, then loosen the Carriage andHeadstock Locks. Move the Headstockand Carriage all the way to the right andlock them in place.

2. Mount the Drill Chuck on the Spindle, asshown in Figure 106.

Figure 105

d. Reinstall the Saw Blade, Lower SawGuard and Riving Knife, accordingto Steps 1 through 4. If the RivingKnife is still not centered on theSaw Blade, repeat this Step 5.

c. Use a 5/32" Allen Wrench to adjustthe Stop Screw located below theLower Saw Guard's Collar. Shownin Figure 105.

Figure 106

3. Completely close the Chuck Jaws, as inFigure 107.

Figure 107

4. Mount the Cup Center into the Tailstock'sAdjustable Center, as seen in Figure 108then mount the Tailstock into the BaseArm (right side). Tighten the Base ArmLock.

Figure 108

5. Loosen the Quill Lock. Extend the Quill(shown in Figure 109), so the Drill Chuckalmost touches the Cup Center Point andthe Center Point could fit into the ChuckJaws.


Figure 111

MAINTENANCE PREPARATION

WARNING

Turn off and unplug the MARK V BE-FORE you begin any maintenance pro-cedure.

Before you begin a maintenance pro-cedure, remove the blades, bits orany other accessories that aremounted on the machine. Set themachine in the horizontal positionand secure the Headstock Lock. Fi-nally, move the Worktable and Car-riage as far to the right as it will go.

CLEANING

As you work, sawdust will accumulate onand in your MARK V. This residue can affectits performance. To prevent problems, cleanyour MARK V thoroughly inside and out onceevery 5 hours of running time or monthlywhich ever is first.

BLOWING OUT THE HEADSTOCK

1. With a Medium Phillips Screwdriver,remove the Screws that hold the BeltCover. Then slide the Belt Cover backalong the Way Tubes toward the left.Open the Logo Cover to reveal the Ac-cess Hole.

a. To adjust the Cup Center Point hori-zontally, loosen the Set Screw thatlocks the Adjustable Center, as seenin Figure 110. Rotate the AdjustableCenter as needed to line up the CupCenter with the Drill Chuck, thentighten the Set Screw.

Figure 109

6. If the center point does not "fit" into theChuck Jaws, determine whether youneed to adjust the Cup Center Point hori-zontally and/or vertically. Then do thefollowing:

Figure 110

Be sureto loosen

both screws

b. To adjust the Cup Center Point ver-tically, loosen the Base Mount Lock,then loosen the Tailstock Stop Col-lars. Raise or lower the Tailstock inthe Base Mount until the Cup Cen-ter Point vertically lines up with theDrill Chuck, then tighten the BaseMount Lock. Press the Stop Collarsdown firmly against the Base Mountand tighten the Collar Set Screws,as shown in Figure 111.


NOTE

Some older MARK V’s do not have an access hole.Blowing out the Headstock, on those machines,must be done by lowering the Motor Pan Assem-bly.

2. Using an air compressor, work throughthe openings and completely blow outall the sawdust from the inside of theHeadstock. Replace the Logo Cover.

CLEANING THE WORKTABLE

1. Clean the Miter Gauge Slots with a cleansoft rag and mineral spirits. With a 5/32"Allen Wrench, remove the two Screwsthat secure the Table Insert. Using a smallstick or small stiff brush, remove anysawdust that has accumulated under theTable Insert.

CLEANING THE RACKS

1. With a small, stiff brush, reach in throughthe Logo Cover opening and brush offthe teeth on the portion of the Quillinside the Headstock, as demonstratedin Figure 112. Then extend the Quill outfrom the Headstock as far as it will goand brush off the outside teeth.

Figure 112

2. To clean the Table Rack, remove theTable from the Carriage. Brush the saw-dust from between the teeth on the TableSupport Tubes and the Pinions in theCarriage.

BRUSHING OFF

1. Give the entire machine a good goingover with a soft brush to remove anyremaining sawdust. If you find anygrease or grime on the Way Tubes, orany other part, clean it off with mineralspirits.

2. When your MARK V is clean, wax andbuff all parts (refer to Waxing), replacethe Table in the Carriage, reinstall theTable Insert, Belt Cover, and Logo Cover.

LUBRICATING

All the bearings are shielded and perma-nently lubricated so they do not need lubrica-tion. However, there are several other partsthat require lubrication.

To lubricate your MARK V, first clean themachine thoroughly, as described in Clean-ing. But don't reinstall the Belt Cover or LogoCover. Then follow these procedures

LUBRICATING THE SHEAVES

Every 25 hours of running time or once amonth if not in use, lubricate the FloatingSheaves (Pulleys) with a good 10w non-deter-gent oil. Be sure to oil both Upper and LowerSheaves. Apply the oil sparingly (2-5 dropsonly) as too much will mix with sawdust andcause parts to stick.

NOTE

DO NOT use penetrating oils or oils in aerosolcans. They tend to gum up at low temperatures.

1. To lubricate the Sheaves, first plug in theMARK V, turn it on and run the SpeedDial up to the highest speed. Then turnthe machine off and unplug it. This is the


4. When you've lubricated both Sheaves,replace the Logo Cover and Belt Cover.Attach the Sanding Disc to the MainSpindle and while rotating the Disc(clockwise) turn the Speed Control Dialto “Slow” speed. Plug in the MARK Vand turn it on. Run the machine com-pletely through the speed range severaltimes to help spread out the oil.

LUBRICATING THE LOCKS

Every 50 hours of running time or at least oncea year, apply a dry lubricant product to thethreads of the Headstock Lock.

1. First inspect the Threaded Rods of theHeadstock Lock (found inside the Head-stock) and the Carriage Lock (under-neath the Carriage). Brush off or wipe offany foreign materials.

2. To lubricate the Headstock Lock, loosenthe Lock as far as possible. Then reachinside the Access Hole opening and ap-ply a small amount of powdered graph-ite to the points where the Threaded Rodscrews into the Wedge Locks, as illus-trated in Figure 115.

Figure 115

3. Replace the Logo Cover and secure theHeadstock Lock.

only time the MARK V should be turnedoff at other than “Slow” speed.

2. Oil the Upper Control Sheave first. Whilelooking through the Access Hole open-ing, turn the Main Spindle by hand (clock-wise) until you locate the hole in theSleeve. With the oil can tube inside theheadstock apply 2-5 drops of oil in thehole, as seen in Figure 113.:

Figure 113

3. To oil the Lower Floating Sheaves, rotatethe Main Spindle by hand (clockwise)until you find the hole in its Sleeve. Thishole may be difficult to find because ofthe Motor Spring that fits over the Sleeve.When you find the hole, spread theSpring Coils that cover the hole with aLarge Straight Blade Screwdriver. Thenapply 2-5 drops of oil in the hole, asshown in Figure 114.

Figure 114


c. Table Support Tubes - After wax-ing, brush Tubes to remove all resi-due from the Racks.

d. Mounting Holes - Wrap a ragaround a dowel to apply wax in-side these holes. Use the same tech-nique to buff it out.

Figure 116

a. Way Tubes - Don't slide the Head-stock and/or Carriage over newwax before you buff it out. Other-wise, wax may accumulate insidethe Headstock or Carriage and im-pede movement.

• Bench and Way Tubes• Worktable surface, Miter Gauge

Slots, Table Support Tubes, andTable Tubes

• Quill• Rip Fence (both sides)• Miter Gauge Bar• Extension Table Surface, Support

Tubes, and Table Tubes• Mounting Holes in the Power

Mount, Base Mount and Carriage.

1. Apply the wax sparingly and buff itthoroughly. If you apply too much waxor don't buff it out, the wax will mix withsawdust, impede moving parts, and leaveresidue on the wood.

2. Some of the parts that need waxing re-quire special care:

CHECKING THE BELT TENSION

Every 50 hours of running time or once a year,check the tension of the Poly V-belt. You mayalso need to check the tension on this belt if thedrive train seems to be "slipping" or the top ofthe Headstock gets very hot when you areworking.

1. To check the Belt tension, remove theBelt Cover. With your fingers, push in onthe Poly V-belt, as demonstrated in Fig-ure 117. If you can push the Belt in morethan 1/8" when applying pressure, theBelt needs to be tightened.

WAXING

NOTE

Use paste floor or furniture wax. Do not use carwax or spray furniture polish. The MARK Vneeds wax for both protection and lubrication.Car wax offers good protection for paint, but it isextremely hard and has little value as a lubricant.Furniture polish isn't hard enough. Paste floor orfurniture wax protects and lubricates.

Every 5 hours of running time, wax and buff thefollowing parts:

b. Quill - Extend the Quill as far as itwill go, lock it in place, then wax.After waxing, brush the Rack witha stiff brush to remove all the resi-due between the teeth, as shown inFigure 116.


Figure 119

4. With your finger, test the tension to seethat you have taken the "slack" out of theBelt. Retighten the Bolt.

WARNING

DO NOT overtighten the Bolt. Onlytighten the Bolt until it bottoms out,then turn the Allen Wrench no morethan 1/4 additionally. Overtighteningthe Bolt will cause you Headstock tobreak.

MAINTAINING ACCESSORIES

In addition to maintaining the basic machineand the parts you use in more than one mode(such as the Miter Gauge or Rip Fence), youmust maintain the individual accessories foreach separate mode - Saw Guards, SandingDiscs, Drill Bits, etc...

SAW GUARD SYSTEM

1. As needed, brush off and blow away thesawdust that accumulates in the SawGuards. The Upper Saw Guard has aplastic insert toward the front, wheremost of the sawdust builds up. This caneasily be removed, cleaned, and rein-stalled. Dissolve the impacted sawdustwith mineral spirits.

NOTE

If the Poly V-belt seems tight but it still slips, DONOT increase the belt tension, this will just stretchthe Belt out of shape. Instead, apply a very smallamount of "belt dressing" to the inside of the Beltto increase its traction.

Figure 117

2. To adjust the tension, loosen the Bolt thatholds the Idler Shaft Eccentric Bushingin the Headstock Casting, as shown inFigure 118.

Figure 118

3. Insert a Straight Blade Screwdriver inthe slot of the Eccentric Bushing and turnthe Bushing clockwise in the Castinguntil it stops, as seen in Figure 119.


NOTE

DO NOT use lacquer thinner to clean the SawGuards. This solvent dissolves the plastic parts,distorting them or making them cloudy.

2. Every 10 hours of running time, wax andbuff the Riving Knife on the Upper SawGuard. Check that the anti-kickback sys-tem and the Lower Saw Guard operatesmoothly. If either of these seems stiff,apply powdered graphite or a dry lubri-cant product to the rods. DO NOT use oilon these parts.

SANDING DISC

1. As you work, sawdust, wood oils, gluesand other materials will "load up" on theSandpaper. As needed, hold an abrasivecleaning stick against the Disc while theMARK V is running at slow speed. Thesoft rubber reaches in between the gritand digs out the impacted materials with-out stripping the abrasive off the sand-paper.

DRILL CHUCK

1. Every 10 hours of running time, apply asmall amount of powdered graphite or adry lubricant product to the inside of the

Drill Chuck to keep it operatingsmoothly.

SAW BLADES, DRILL BITS, LATHE TOOLS,ETC. ...

1. These Cutters will become dull with use.Sharpen as needed. A sharp cutter per-forms better and is safer.

STORING

1. In normal use, regular cleaning, lubrica-tion, and waxing will prevent the fer-rous parts of the MARK V from rusting.However, if the machine is to be storedfor an extended period or under unusu-ally humid or corrosive conditions, spraythe Way Tubes, Saw Blades, Drill Chuckand Bits, and any other ferrous parts andaccessories with a rust-inhibiting lightoil. Remove this oil with mineral spiritsand rewax the MARK V before using itagain.

NOTE

If you have any questions, please call our CustomerService Department Toll Free 800-762-7555 ordrop us an E-mail at [email protected] our Website at www.shopsmith.com


NOTES


6530 Poe AvenueDayton, Ohio 45414

www.shopsmith.com

845180 Rev B 8/01© 2001 Shopsmith, Inc.

All Rights ReservedPrinted In U.S.A.

MAINTENANCE SCHEDULE

• Clean the Saw Guards & Sanding Disc.Refer to Maintaining Accessories.

• Sharpen Saw Blades, Drill Bits & LatheChisels.

• Clean the MARK V.Refer to Cleaning.

• Wax the MARK V.Refer to Waxing.

• Repeat the preceding steps.

PLUSCheck the action on the anti-kickbacksystem and the Lower Saw Guard,wax the Splitter on the Upper SawGuard & lubricate the Drill Chuck.Refer to Maintaining Accessories.

Check the alignment & adjustment ofthe Headrest & Carriage Locks, Work-table Stops, Table Tilt Indicator, MiterGauge Slots, Miter Gauge, Rip Fence,Extension Table & Lathe Centers.Refer to Alignment for your MARK Vmodel.


PLUSLubricate the Floating Sheaves on theIdler & Motor ShaftsRefer to Lubricating.


• Lubricate the Headstock Lock & Car-riage Lock.Refer to Lubricating.

As Needed

Every 5 Hours of Running Time

Every 10 Hours of Running Time

Every 25 Hours of Running TimeOnce A Year (if not used)

Every 50 Hours of Running TimeOnce A Year (if not used)

MARK V ALIGNMENT & MAINTENANCE - Shopsmith · MARK V ALIGNMENT & MAINTENANCE. SHOPSMITH MARK V...

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