MARK V
MOUNTED OVERARM PIN ROUTER
555970
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................2
SAFETY ......................................................................................................................................3
TYPES OF ROUTER BITS .........................................................................................................8
TERMS TO KNOW ...................................................................................................................10
OVERARM ROUTER ASSEMBLY ........................................................................................... 11
ALIGNMENT AND ADJUSTMENT ...........................................................................................16
OVERARM PIN ROUTING OPERATIONS...............................................................................18
GENERAL GUIDELINES FOR BOTH TYPES OF OVERARM ROUTING ..............................18
ROUTER DUPLICATION USING SHOP MADE FIXTURES....................................................20
CONVENTIONAL ROUTING OPERATIONS WITH THE OVERARM ROUTER .....................30
CARING FOR YOUR SHOPSMITH OVERARM PIN ROUTER ...............................................39
MAINTENANCE ........................................................................................................................41
TROUBLESHOOTING GUIDE .................................................................................................42
MARK V – MOUNTED OVERARM PIN ROUTER
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is traced over the table pin, creating a fin-
ished piece that’s exactly the same size and
shape as the groove in your template or
fixture
SAFETY
WARNING
• Remove the workpiece, replace with a new
blank and repeat the process above . . . as
many times as you like
Read this safety section and complete
the Assembly procedures BEFORE op-
erating your Shopsmith Overarm Pin
Once you’ve made a template or fixture, cut
out as many parts as you like, then set the Router
template aside until the next time you want
to make more of the same project. It will be
ready when you are.
Shopsmith’s MARK V-mounted Pin Router
offers many built-in safety features. How-
ever, the effectiveness of these features de-
pends on you. Power tool safety requires
good common sense, and misuse of this
tool can cause serious injury.
We know that you’re eager to get started us-
ing your Overarm Router, but please take the
time to read this manual before you begin.
Then keep it handy for future reference.
To protect yourself from injury:
OVERARM ROUTER
SPECIFICATIONS:
• READ, UNDERSTAND AND FOLLOW
ALL the information in this Owners
Manual.
Maximum router motor HP.......................... 3 hp
• Also, READ, UNDERSTAND AND FOL-
LOW ALL the information in the Own-
ers Manual that came with your router
motor.
Diameters of router motors
accepted (round motors only)................. 2-1/2" to 4"
Throat depth (router bit
centerpoint to Way Tubes)* .........10-1/2" to 18-1/2"†
• READ, UNDERSTAND AND FOLLOW
ALL the information in the MARK V
Owners Manual.
Vertical motor travel (lever-controlled)............ 3-1/2"
Maximum workpiece thickness ............. Approx 11"‡
Worktable size
(laminate-covered MDF) .......18-1/2" d x 28" w x 3/4"
Fence size (2) .......................... 13-1/4" w x 1-1/4" h
Guide pin diameters furnished ...... 1/4", 3/8" and 1/2"
Starter pin diameter furnished .......................... 1/4"
Maximum router bit diameter (with insert) ...... 1-3/8"
Maximum router bit diameter (without insert) ....... 2"
Dust port diameter ....................................... 2-1/4"
* With a 3-1/2" diameter router motor. Distances will
vary, depending on router motor diameter.
† Maximum dimensions, based on which set of four
Arm mounting holes are used
‡ Varies, depending on router motor and bit used
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MARK V – MOUNTED OVERARM PIN ROUTER
HEARING PROTECTION
Throughout this manual, we list WARN-
INGS, CAUTIONS, and NOTES. We advise
that when you come to one of these listings,
please read and understand it fully. Their
meanings are:
Prolonged exposure to high intensity noise
from high speed power tools will damage
your hearing.
• Hearing protectors screen out certain fre-
quencies and noise levels that can dam-
age your hearing. For that reason, we
recommend that you ALWAYS wear hear-
ing protection when using your Overarm
Pin Router.
WARNING
A WARNING is given when failure to
follow the directions is likely to result
in injury, loss of limb, or life.
GUARDING FOR ROUTING
Most shop accidents happen to woodwork-
ers who fail to follow instructions, or fail to
use guards and safety devices. Although
proper use of guards and safety devices of-
ten requires additional setup, the protection
for you and your family is well worth the
effort.
A CAUTION is given when failure to fol-
low the directions is likely to result in
damage to the equipment.
NOTE
DRESS
A NOTE is used to highlight an important
procedure, practice or condition.
Loose hair and clothing which could be en-
tangled in rotating bits are very hazardous.
• Tuck long hair under a hat or tie it up. Do
not wear ties, gloves, loose clothing, rings
or other jewelry. Roll sleeves up above
your elbows.
EYE PROTECTION
Always wear eye protection when you use
power tools. Use goggles, safety glasses or a
face shield to protect your eyes.
ELECTRICAL REQUIREMENTS
• Goggles completely surround and protect
your eyes. Many goggles will also fit over
regular glasses. Be sure your goggles fit
closely, but comfortably.
Follow the electrical requirements that ap-
pear in the Owners Manual that came with
your router. Do not overload your electrical
circuits.
• Safety glasses don’t fog as easily as
goggles and can be worn all the time.
Regular glasses normally have only im-
pact resistant lenses. They are not safety
glasses.
ROUTER MOTOR — OVERARM
Use the following specifications required to
mount a router in the OVERARM:
• A face shield protects your entire face, not
just your eyes.
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MARK V – MOUNTED OVERARM PIN ROUTER
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NOTE
MOUNTING ROUTER BITS
• Turn off and unplug the router motor be-
fore mounting router bits.
Customer Service representatives and Store
personnel will help you select the proper
motor.
• Follow the recommendations of the router
motor manufacturer as to the sizes and
types of router bits to use.
• Use only UL Approved router motors.
• Make sure the router bit is secured prop-
erly in the collet. Loose bits could work
free and cause serious injury. Insert the bit
all the way into the collet and retract it
about 1/8" to avoid the transition between
shank and cutter.
• Motor housing must be round, not square,
for router arm.
• Motor must be 2-1/2" to 4" in diameter.
• Motor power cord must be located so it
comes out the top section of the router.
• Motor power cord should be securely at-
tached to the top of the Arm during op-
eration with tape or rubber bands to keep
it safely out of your way during routing.
• If your using an arbor-style bit with inter-
changeable cutters, be sure the cutting
edge is facing to the left when mounted
on the arbor.
• Switch must be located so that it can be
positioned toward the front of the Over-
arm Router and be easily accessible dur-
ing operations.
• Listen for chatter or signs of looseness at
start-up. If you hear, see or suspect prob-
lems, stop the tool immediately, unplug it,
and check the tool thoroughly. Correct any
problem before proceeding. If you are un-
able to locate the problem, you can con-
tact your Shopsmith Service Representa-
tive or store personnel for advice. Never
operate the Overarm Router if it is not
functioning properly.
• You must be able to remove the handles
and base from the motor without remov-
ing the switch.
• Motor must properly mount on the Over-
arm Router so that base locating pins on
the motor housing do not interfere with
the router motor holding clamps.
• Keep bits clean, maintained and sharp.
• Motor must not exceed 3 hp.
• Don’t try to make your own collet adapter
to hold different sized bits. Balance is im-
portant at high speeds, so always buy
appropriately sized collets.
SAWDUST AND CHIPS
Sawdust and chips can be a fire hazard and
breathing sawdust can be a health hazard.
The sawdust from some woods is toxic. To
help protect yourself from sawdust:
GENERAL SAFETY RULES
FOR POWER TOOLS
• Know your power tool. Read the owners
manual. Learn its application and limi-
tations as well as the specific potential
hazards peculiar to this tool.
• Attach your Overarm Pin Router to a dust
collection system to help capture flying
chips and debris.
• Or wear a close-fitting dust mask. Clean
or replace the filters in the mask regularly.
Also, open a window or use a fan to ven-
tilate your shop.
• Ground all tools (unless double insu-
lated). If tool is equipped with an ap-
proved 3-conductor cord and a 3-prong
grounding type plug to fit the proper
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MARK V – MOUNTED OVERARM PIN ROUTER
grounding type receptacle, the green con- • Secure workpieces. Use clamps, fixtures,
ductor in the cord is the grounding wire.
Never connect the green wire to a live
terminal.
and other devices to hold workpieces
when practical. It’s safer than using your
hands and it frees your hands to operate
the tool.
• Wear proper eye and ear protection. Also,
wear a dust mask.
• Do not overreach. Keep proper footing
and balance at all times.
• Keep guards in place. Always keep
guards in working order and in proper • Turn off the tool and wait until it comes
alignment and adjustment. Most injuries
occur on unguarded power tools.
to a complete stop before removing
workpieces and scraps.
• Remove adjusting keys and wrenches.
• Do not try to stop the tool by grabbing
the workpiece or any part of the tool.
Turn off the tool and let it come to a com-
plete stop by itself.
• Wear proper apparel. Do not wear loose
clothing, ties, gloves, rings or other jew-
elry. Roll sleeves up above your elbows,
wear nonslip footwear, and tuck long • Do not leave the tool running unat-
hair under a hat.
tended. Turn power off. Don’t leave tool
until it comes to a complete stop.
• Do not operate power tools if you are
tired, taking medication, or under the in- • Avoid unintentional starting. Make sure
fluence of alcohol or drugs.
the switch is in the “off” position before
plugging in or unplugging the tool.
• Avoid dangerous environments. Don’t
use power tools in damp, wet or explo- • Disconnect tools. Turn off and unplug
sive atmospheres.
tools before changing accessories and set-
ups, making adjustments, and perform-
ing maintenance and repair.
• Keep work areas well lit, clean, and free
from clutter.
• Do not stand or lean on the tool. You
could fall onto the tool or it could tip
over injuring you and/or damaging the
tool.
• Do not force the tool. It will do the job
better and safer at the rate for which it
was designed.
• Use the right tool. Don’t force a tool or
accessory to do a job for which it is not
designed.
• Maintain tools. Keep parts and tools
sharp, clean and maintained according to
the Owners Manual.
• For direction of feed — ALWAYS feed the
workpiece into the cutter against the ro-
tation of the cutter. NEVER feed the
workpiece into the cutter with the rota-
tion of the cutter.
• Make your workshop childproof. Use
padlocks, master switches or remove
starter keys.
• Keep children away. All visitors should
stay a safe distance from power tools, and
wear eye and ear protection.
• Check damaged parts. A damaged guard
or part should be properly repaired or re-
placed before further use. If a strange • Do not permit anyone who is inexperi-
noise or vibration develops, immediately
turn off the power, unplug the machine
and correct the problem. Never operate
a power tool that is not functioning
properly.
enced to use your power tools without
supervision.
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MARK V – MOUNTED OVERARM PIN ROUTER
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wood. Limit depth-of-cut to 3/8" for each
pass when using bits up to 1/2"
diameter in softwood. When using bits
over 1/2" diameter, limit depth-of-cut to
half the recommended depths for 1/2"
diameter bits.
SAFETY RULES FOR THE
SHOPSMITH OVERARM ROUTER
• Be sure to read and understand this entire
Owners Manual before using the Overarm
Router. Also, do not use the Overarm
Router unless you are sure it is assembled
properly, all safety devices are installed,
and you understand the operations you
are attempting to perform.
• Always use a fixture, fence, and/or starter
and guide pins to help control the
workpiece.
• Always feed the workpiece against the
rotation of the bit, not with it. Otherwise
the bit will grab and throw the
workpiece.
• Keep the guard in place and in working
order. Always set the guard no more than
1/4" above the workpiece.
• Keep your hands, fingers and other parts
of your body at least 3" away from the
rotating bit.
• Keep a firm grip on the workpiece at all
times and never hold the workpiece with
your hands in line with the router bit.
• Use a push stick, push block, feather-
board(s), miter gauge with safety grip,
fixtures, or other safety devices to maneu-
ver a workpiece into a rotating bit. If a
kickback occurs, these devices help to
protect your hands and fingers.
• Always clamp a straight piece of scrap
stock to your worktable surface for use
in holding your workpiece against the
fence during straight-line routing opera-
tions. Also use a long piece of scrap stock
to feed a narrow workpiece underneath
the guard to complete a cut.
• Use only Shopsmith parts and accesso-
ries on your Overarm Router. NEVER use
non-Shopsmith replacement parts or ac-
cessories. They are not designed like
Shopsmith parts. Using non-Shopsmith
parts may create a hazardous condition
and will void your warranty. Follow your
router manufacturer’s recommendations
as to replacement of router parts.
• Cut with the grain instead of against the
grain. You will get a smoother cut and
the operation will be safer.
• Avoid standing in-line with the
workpiece being fed. In the event of a
kickback you could be hit.
• Feed the workpiece slowly. Use extra care
in routing workpieces that contain fig-
ured grain or knots, as these may cause
kickbacks.
• Do not rout second-hand lumber. If you
hit a nail, screw, or other foreign object,
you could be hit by pieces of metal or
there could be kickback.
• When you are routing stock up to 10"
wide across the grain, use a piece of scrap
stock cut at a 90° angle to guide the
workpiece through the cut. The
workpiece must extend 5-1/2" away from
router bit.
• Do not “freehand” rout stock less than
12" X 12" or equivalent.
• Support long boards and sheet materials
with a roller stand(s) placed 1' -4' from
the worktable.
• When stop routing, always use stop
block(s) to control the length of cut. Fail-
ure to use stop block(s) could cause the
bit to grab and throw the workpiece.
• Avoid taking deep cuts. With the excep-
tion of single-pass dovetail cuts, limit
depth-of-cut to 1/4" for each pass when
using bits up to 1/2" diameter in hard-
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MARK V – MOUNTED OVERARM PIN ROUTER
• When routing oversize stock, always use speed steel bits are heat treated for extra
at least one push block to help control hardness and to hold keen cutting edges.
the workpiece firmly against the fence.
Carbide bits (solid or tipped) are the finest
bits available today. Although more expen-
sive, they will outlast high speed steel bits
at a 15 to 1 ratio on softwoods and are highly
recommended for use on hardwoods, plas-
tic laminates, plywood and particleboard.
• Do not work with stock that is too small
or too large to handle safely; that is
warped, bowed or cupped; or that has
loose knots or other defects.
• Plan the operation before you begin. If
you are in doubt about how to complete Router bits are generally classified into four
an operation safely, do not attempt it. You different categories — grooving bits, edge
can contact your Shopsmith Customer cutting bits, panel bits and laminate and ve-
Service Representative or Store person- neer trimming bits. (See Chart.)
nel for advice.
• Secure the router, overarm assembly,
CARE AND MAINTENANCE
depth stop rod, depth control handle,
You’ll enjoy longer use of your router bits if
worktable, accessories, safety devices,
you make it a point to handle, use and
fences, and fixtures before turning on the
sharpen them properly.
motor.
• Use your router bits only for the job they
are intended to do.
TYPES OF
• Make sure the bit is mounted rigidly in
ROUTER BITS
the collet.
Router bits come in a wide variety of shapes
and sizes designed to be used at very high
speeds.
• Learn to cut your workpiece at the proper
speed to prevent heat buildup that can
cause the loss of bit hardness.
• Between operations, set your bits in a safe
place where they will not fall or get hit.
Never use solvent on a bearing piloted
bit without first removing the bearing.
The part of the bit mounted in the router
chuck is called the shank and the rounded
extension beyond the cutter on some bits is
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