Powermatic 3520A User Manual

20" WOODTURNING LATHE

Model 3520A

Instruction Manual & Parts List

M-0460221

(800) 248-0144

www.powermatic.com

This manual has been prepared for the owner and operators of a Powermatic Model 3520A Lathe. Its purpose, aside from proper machine operation, is to promote safety through the use of accepted correct operating and maintenance procedures. Completely read the safety and maintenance instructions before operating or servicing the machine. To obtain maximum life and efficiency from your lathe, and to aid in using the machine safely, read this manual thoroughly and follow all instructions carefully.

Warranty & Service

WM H Tool Group warrants every product it sell s. If one of our tool s needs service or repair, one of our Authorized Repair Stations located throughout the United States can give you qui c k servi c e.

In most cases, any one of these WMH Tool Group Repair Stations can authorize warranty repair, assist you in obtaining parts, or perform rout ine maintenance and major repair on your J E T, Performax, Powermatic or Wilton tools.

For the nam e of an Authorized Repair Station in your area, call 1-800-274- 6848.

More Information

WM H Tool Group is consistently adding new products to the li ne. For complete, up- to-date product informati on, check with your local WMH Tool Gr oup distribut or or vi si t wmhtoolgr oup.com.

Limited Warranty

WM H Tool Group (including JET, Performax, Powerm atic and Wilton brands) mak es every ef fort t o assure that its products meet hi gh quality and dur ability standards and warrants to the or iginal retail consum er /purchaser of our products that each product be free from defects in mat erials and workmanship as fol lows: 2 YEAR LIMITED WARRANTY ON THIS P OWERMATIC PRODUCT. This warranty does not appl y to defects due direc tly or indirectly to mi suse, abuse, negligence or accidents, normal wear-and-tear, repair or alt er ations outside our f ac ilities, or to a lack of mai ntenance.

WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE, FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTI B I LI TY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. WMH TOOL GROUP SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE O F OUR PRODUCTS . SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATIO N OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

To take advantage of this warranty, the product or part must be returned for ex amination, postage prepaid, to an Authorized Repai r Station designated by our office. P r oof of pur chase date and an explanation of the complaint must accompany the merchandise. If our inspecti on discloses a defect , W M H Tool Group will either repair or replace the pr oduc t, or refund the purchase pric e if we cannot readily and quickly pr ovi de a r epair or replacem ent, if you are willing to accept a refund. WMH Tool Gr oup will return repaired product or replac ement at our expense, but if it is deter mined ther e is no defect , or that the defect r esul ted from causes not within t he scope of our warranty, then the user must bear the cost of storing and returning the product. This warranty gives you specific legal rights; you may al so have other r ights, which vary fr om state to state.

WM H Tool Group sells through distributors only. W M H Tool Group reserves the right to effect at any tim e, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem nec essary for any reason whatsoever.

TABLE OF CONTENTS

Safety Rules.........................................................................................................................................4-5

Safety: Decals.........................................................................................................................................6

Specifications..........................................................................................................................................7

Receiving ................................................................................................................................................8

Installation...............................................................................................................................................8

Power Connection............................................................................................................................8

Inverter Drive System...................................................................................................................... 8

Maintenance............................................................................................................................................ 8

Adjustments:

Belt Adjustment ...............................................................................................................................8

Tool Support....................................................................................................................................8

Spindle............................................................................................................................................ 9

Speed Range Adjustment ................................................................................................................9

Table 1: Wood T ur ning Lathe Speeds ......................................................................................................9

Tools....... ..............................................................................................................................................10

Operating Instructions............................................................................................................................10

Spindle Turning.....................................................................................................................................10

Stock Selection..............................................................................................................................11

Mounting Stock..............................................................................................................................11

Cutting Techniques........................................................................................................................12

Roughing Out.........................................................................................................................12

Beads ....................................................................................................................................12

Coves....................................................................................................................................12

"V" Cuts.................................................................................................................................12

Parting Off.............................................................................................................................13

Sanding & Finishing...............................................................................................................13

Face Plate & Bowl Turning ....................................................................................................................13

Mounting Stock..............................................................................................................................13

Faceplate or Chuck?......................................................................................................................14

Wood Selection .............................................................................................................................14

Checks & Cracks....................................................................................................................14

Distortion ...............................................................................................................................14

Tools for Bowl Turning...................................................................................................................14

Bowl Turning Techniques ...............................................................................................................14

To Shape Outside of Bowl......................................................................................................14

To Shape Interior of B owl.......................................................................................................15

Sanding & Finishing...............................................................................................................15

Trouble-Shooting...................................................................................................................................16

Parts Lists & Exploded Views:

Headstock Assembly.................................................................................................................17-19

Stand & Bed Assembly .............................................................................................................20-21

Optional Accessories: Indexer & Bed Extensions......................................................................22-23

Optional Accessories: Tool Supports..............................................................................................24

Optional Accessory: Out boar d Turning St and.................................................................................25

Optional Accessories .....................................................................................................................26

Electrical Sc hematics:

3520A............................................................................................................................................27

3520A w/ Remote On/Of f Switch ..............................................................................................28-29

3520A School Lathe (#1352002)....................................................................................................30

3520A School Lathe – 2330009 K it................................................................................................31

AC Inverter Readi ngs ............................................................................................................................32

Instructions for Mounting Indexing Assembly ( Optional Accessory)........................................................33

SAFETY RULES

As with all machines, t her e is a certain amount of hazard involved wit h the use of thi s l athe. Use the mac hine with the respect and caution demanded where safet y pr ecautions are concerned. When normal safety precautions are overlooked or ignor ed, personal injury to the operator can result.

Read, understand and follow the safet y and oper ati ng i nstruct ions f ound i n thi s m anual . Know the l i m i tat ions and hazards associated with t his machine. A warning dec al is placed on each machi ne as a reminder of basic safet y practice.

Electrical grounding. Make certain that the machine frame is electrically grounded and that a ground lead is included in the incoming electrical service. In cases where a cord and plug are used, make certain that the grounding plug connec ts to a suitable ground. F ollow the grounding proc edure indicated in the National El ectrical Code.

Eye safety. W ear an approv ed safety shield, goggles, or glasses to protect eyes. (NOTE: Comm on eyeglasses are only impact-r esi stant, they are not safety glasses.)

Personal protection. Before operating t he m achi ne, rem ove ti e, r ings, watch and ot her j ewelry and rol l up sl eev es above t he elbows. Remov e al l l oose outer clot hing and conf ine long hair . Protecti v e type foot wear should be used. Wher e the noise exceeds the l evel of ex posure allowed in Sect ion 1910.95 of the OSHA Regul ations, use hearing protecti ve devic es. Do not wear gloves.

Guards. Keep the machine guards in pl ace, m ake cert ain they ar e operable, and use them at all ti mes. DO NOT operate the m achine with guards off.

Don't Overreach. Maintain a balanced stanc e and keep your body under contr ol at all times. Do not overreach or use excessive force to perform any operation.

Maintain Tools in Top Condition. Keep tools sharp and clean for safe and best performance. Dull tools can grab in the work and be jer k ed from the operator`s hands causing serious i njury.

Check the condition of the stock to be tur ned. Make sure it is free of knots, warpage, check ed ends, improper ly made or cured glue joints and other condit ions which can cause it t o be thrown out of the lathe.

Securely fasten spur centers to the material being used. Check centers and center sockets i n the headstock and tai lstock to be sure they are free of dirt or rust and oil

lightly bef or e inserting centers. Test each set-up by revolving the work by hand to insure it cl ear s the work r est and bed and c hec k setup at the

lowest speed before inc r easi ng it to the operating speed.

Use the correct cutting t ool for the operation to be performed and keep all tools in a sharpened condition. Use low speeds for r oughing and for long or large diameter work. If vibr ation occurs, stop the machi ne and c or rect

the cause. See Table on page 9 for speed recommendations. When sanding, remov e the tool rest from the machi ne, apply l ight pressure, and use a slow speed to avoid heat

build up. When turn ing larg e diameter pieces, such as bowls, always operate the lathe at low speeds. See Table 1 for

speed recomm endations. Never use dull turni ng tools - sharp tools help to prev ent the tool from gr abbing in the work and being jerked from

the operator's hands. Take measuremen t s on the part only with the spindle stopped.

Do not attempt to engage the spindle lock pin until t he spi ndle has stopped. If leaving the machine area, turn it off and wait until the spindle stops before departing.

Give the work you are doing your undivided attention. Looking around, c arrying on a conversation and "horseplay" are car eless acts that can result in serious inj ur y .

Make no adjustments excep t speed change with t he spindle rotati ng and always disconnect machine from power source when performing maintenance to avoid accidental star ting or elec trical shock.

Provide for adequate surrounding work space and overhead non-glar e lighting. Powermat ic recom mends the use of non-skid floor strips on the floor area where the operator normally stands and marking off a work area f or each machi ne.

Don't stand in line with any lar ge diameter par t being turned or allow anyone else to do so. When stopping the lathe, never grab the par t or face plate to slow it down. Let the work coast to a stop. Use only Po wermatic or factory aut hor ized replac ement parts and acc essories, otherwise the warranty and

guarantee are null and v oid.

Drugs, alcohol, medication. Do not operate tool while under the inf luence of dr ugs, alcohol, or any medication. Do not use this Powermatic wood lathe for other than its int ended use. If used for other purposes, Powerm atic

disclai ms any real or impl ied warranty and holds i tself harmless fr om any injury that may result from that use. Health Hazards. Some dust cr eated by power sanding, sawing, grinding, drilling and other construction activi ties

contains chemicals known to cause cancer , birth defects or other r epr oduc tive harm. Some exampl es of these chemic als are: * Lead from lead-based paint . * Crystalline silica from bricks and cement and other masonry products. * Arsenic and chromium from chemi c ally-treated lumber. Your risk f rom these exposures v aries, dependi ng on how often y ou do this type of work. To reduce your exposure to these chemi cals, work in a well-v entilated area, and work with appr oved safety equi pment, such as those dust masks that are speci fically designed to fi lter out microscopic parti c les.

Familiarize yourself with the following safety notices used in this manual:

CAUTION: (This m eans that if pr ec autions are not heeded, it may r esult in minor or moderate injury

and/or possible machine dam age)

WARNING: (Thi s means that if precautions are not heeded, it could result in serious injury or

possibly even death).

SAFETY: DECALS

Familiarize yourself with the location and content of this decal on your machine.

6294773

SPECIFICATIONS: 3520A Lathe

Table with standar d extensions..................................................................................................................... 28” x 38”

Distance Between Centers............................................................................................................................. 34-1/2"

Swing Over Bed ....................................................................................................................................................20"

Ov er all Length.....................................................................................................................................................50"

Spindle Speeds .......................................................................................................................0-1200 / 0-3200 RPM

Motor........................................................................................................................................................2HP, 220V

Lathe Power Requirements...........................................................................................................220V, 3P H or 1P H

Spindle T hread Size .........................................................................................................................1-1/4" x 8 T.P.I.

Head/Tailstock Taper..................................................................................................................................#2 Morse

Height...............................................................................................................................................44" (Adjustable)

Weight........................................................................................................................................................... 650 lbs

Tailstock Quill Travel.................................................................................................................................... Over 4"

3" Faceplate................................................................................................................................................standard

14" Toolrest.................................................................................................................................................standard

Drive System....................................................................................................................Poly V Belt, Inverter Drive

Spindle Lock................................................................................................................................................standard

Knock Out Rod............................................................................................................................................standard

Drive Center................................................................................................................................................standard

Ball Bearing (liv e) Center...............................................................................................................................standard

Hole through Tail St oc k S pindle............................................................................................................................3/8"

Hole through Head St oc k Spindle .........................................................................................................................5/8"

Footprint of stand...................................................................................................................................50" L x 24" W

NOTE: T he above speci fications were current at the time this m anual was published, but because of our policy of continuous improvement, Powermatic reserves the right t o c hange specifications without notice and without incurring obligat ions.

RECEIVING

Remove the lathe from the shippi ng c ontainer and check for damage. Report any damage to your distributor im mediately. Acc essories are pac k aged in a separate carton which will be on the shelf of the machine stand. Clean protec tive coati ng from the bed, spindles, work rest and face plat e wi th kerosene or a good commercial solv ent. Read the i nstr uc tion manual t horoughly for assembly, maintenanc e, operation and saf ety instructions.

INSTALLATION

Install the four lev eling screws in the l egs, adjust to a stable, level position and t ighten the jam nuts to lock in place. Insert the guard support r od in the guard m ounting bracket at t he rear of t he headstoc k . Positi on a locking collar on eac h si de of the mounting brac k et so that the l oc k pin lines up with the holes in the guard pivot rod, one for guard position and one for load position. The spring loaded lock pin will hold the guard in each posit ion.

Power Connection The lathe will operate on single phase or t hr ee phase 230 volt power supply. A t hr ee wir e pigtail for use on 230 volt single phase power is att ac hed to the inverter and may be hard wired to the power source or connected to a receptacle pl ug. Connect the 230 volt supply to the black and white leads and ground t he green lead. If t hr ee phase power is used, i t will be necessary to replace the pigtail wire with a 12/4 wire and c onnec t the three hot leads to the inverter at R, S and T as shown in the wiring diagr am. Al ways connect the ground lead. Before connec ting to t he power source make sure the on/off switch is i n the off positi on and turn the speed dial count erclockwise. I f the switch is in the on position when the power is connect ed, the inverter will trip out. If this happens, disconnect power, turn switch off, wait 30 seconds and then reconnec t power.

NOTICE: IF THERE IS A POWER OUTAGE WHILE OPERATING THE L ATHE, T URN THE SWITCH TO THE OFF POSITION, DISCONNECT POWER SOURCE, WAIT 30 S E CONDS THEN RE CONNECT POWER SOURCE AND RESUME NORMAL OPERATION.

Inverter Drive Syst em

The model 3520A lathe utilizes the latest technology in A.C. inverter dri ves to provi de infinitely v ar iable spindle speeds. The invert er c ontrols the speed of the motor by var ing the f r equency of t he vol tage supplied to the motor. The inverter provi des an

acceleration ramp that eli minat es the shock of normal across the line starting. Also a braking feature eliminates long c oasting periods when the lat he is turned off. The 2 HP mot or is speciall y desi gned for use with inverter drives, and is balanced to reduc e noise and minimi z e vi bration. The A.C. I nverter does not require any pr ogr amming, it is pre- pr ogr ammed from the fact or y . The buttons

on the face of the inverter shou ld never be pushed at any time. Use only the controls on the

front of the headstock .

MAINTENANCE

Maintenance on t he 3520A lathe should be performed at periodi c intervals to insure that the machine is in proper working order, that all fasteners are tight, and the machine is in adj ustment. The more use the machine is subjected to, the more often it should be inspected and maintained. Inspection and maint enanc e should be performed at least twice a year.

WARNING: To prevent accid ental starting or electrical sh ock, disconnect machine from

power source before performing any maintenance.

Periodic cleaning of the l athe is important to k eep the lathe in pr oper working order. T he lathe bed should be cleaned and oiled periodi c ally so that headstoc k , tailstock, and tool support will slide properly. With air hose periodically blow out headstock to keep saw dust and chips from collecting on belt and sheaves, and blow off dust and chips that c ollect on inv er ter (DO NOT DISASSEMBLE INVERTER TO CLEAN).

ADJUSTMENTS

Belt Adjustment

The drive belt sheaves are initally ali gned at the factor y , but if any service i s performed that af fects their al ignment it is very i mportant that they be realigned. To reali gn them, loosen the two set screws on the spindle sheave and slide it in the proper position. Use of a straight edge along the edge of both sheaves will simplify the positioning. When properly aligned, ther e shoul d be no pulsing sounds or noise coming from the belt .

Tool Support

The tool support (shown in Figure 5), i s designed to allow adj ustment f or height, position on the bed, and angle to the work. Y our 3520A lat he comes standard with the 14" tool support. Other supports are available; consult the "Optional Equipment" list on page 24. Periodic ally t he tool rest should be disassembled and the parts cl eaned and oi l ed to provi de f ree m ovem ent of the parts to insure good clamp action.

Spindle

The spindle bearing preload i s set at the factory for general turning applic ations. There shoul d be no " end play" of spindle l ooseness along i ts axis. If any looseness ever occur s i t may be removed by tightening the bearing lock nut on the left end of the spindle. Be very c ar eful not to ov er tighten the lock nut or the spindle bearings will overheat. It should be tightened just enough to rem ove the end play and the spindle should rot ate ver y freel y .

TABLE 1: WOOD TURNING LAT HE SPEEDS

DIAMETER OF WORK ROUGHING RPM

Speed Rang e Adjustment

To provide the maxi mum hor sepower to the spi ndle at the v er y slow speeds, set the driv e belt in the low range.

To change speed ranges, open the access door in front of the headstock , loosen the pivot lock handle located i n the motor tension slot, r aise the motor up by lifti ng up on the motor plate handle and r elock the lock handle to hold the motor up. T her e should be sufficient sl ac k in the belt to reposition it t o the other step. Loosen the tension l oc k handle and lower the motor t o tension the belt. Be sure that the Poly-V grooves of the belt seat properly in the corresponding groove of the pulley. Do not overtension; a very light pressure on the motor plate handle is adequate to prevent belt slippage.

GENERAL CUTTING

RPM

FINISHING RPM

Under 2" 1520 3000 300 0

2 to 4" 760 1600 2480 4 to 6" 510 1080 165 0 6 to 8" 380 810 1240

8 to 10" 300 650 1000 10 to 12" 255 540 830 12 to 14" 220 460 710 14 to 16" 190 400 620

16" to 20" 175 325 500 20" to 24" 175 260 400

TOOLS

If possible, select only quali ty, high speed steel turning tools. High speed tools hol d an edge and last longer t han ordinary car bon steel. As one becomes proficient in t ur ning, a variet y of specialty tool s for specific appl icati ons can be acquired. The fol lowing tools provide the basics for most woodturning projects:

Large Roughing Gouge - 1" to 1-1/4", used to elimi nate waste wood. Skews - 1-1/2" and 1" or 1- 1/4", used to m ak e finishing cuts and detai ls. Spindle Gouges - 1/4", 3/8", 1/2", used to turn beads, coves and other details. Square Scraper - 1/2", used to create square shoulders. Large Domed S craper - 1-1/2", used to r educ e r idges on interior of bowls. Parting Tool - 1/8", used to set diameters for sizing. Deep Fluted Bowl Gouge - 1/4", 3/8" and 1/2", used for turning bowls & plates.

For safety and best performance, keep t ools sharp . If a tool stops cutting or requires excessiv e pr essure to make a cut, it needs to be sharpened. A number of brand name sharpening ji gs and fixtures are available, however , a woodturner should learn t o sharpen t ools freehand. For best results, use a slow speed grinder (1800 rpm) fitted with a 60-grit wheel ( for shaping) and a 100-grit wheel (for final sharpeni ng and touchup). The gr inder should be located near your lat he and at a comfortable height. A diamond dresser will keep the wheels true and eli minat e glazing. Never allow the tool to rest in one place on the wheel, keep it m ovi ng and use a l ight touch.

Carbon steel tools can overheat easily and should be c ooled frequently. If the edge turns blue, i t has lost its temper and should be ground past the blue ar ea. High-speed steel tools are not as lik ely to overheat, but can be damaged if allowed to get r ed hot. High speed steel t ools should not be quenched for cooli ng. Honing with a diamond lap or slipstone will save trips to the grinder and keep the edge fresh.

OPERATING INSTRUCTIONS

Before operating the lathe, check eac h tim e that everythi ng is in proper working or der :

1. Lev el your m ac hine: use the adjustable levelers to help reduce vibration.

2. Check bearings: adjust only i f endplay exists.

3. Check belt s: shoul d be snug but not over ly ti ght.

4. Ways - keep clean, use steel wool and wax to prevent buildup of rust and finishes.

5. Toolrest - use mill file to remove nicks and dings.

6. Spindl e tapers - should be clean and free of dust and chips for pr oper seat ing of t aper s. Clean with scotchbrit e or taper cleaner.

7. Tailstock - cl ean and lubricate ram and l oc k ing device.

8. Lighting - proper lighting is essential.

9. Dust extr actor - to remove excess sanding dust.

10. Anti- fatigue mat - will help make long hours in fr ont of t he lathe mor e c omf or table.

SPINDLE TURNING

Spindle t urning takes plac e between the centers of the lathe. It requir es a spur or drive center in t he headstoc k and a revolving or live center in the tail st oc k . A cup center rather than a cone cent er will reduce the risk of splitting the stock. Figure 2 shows the basic profi le shapes in spindle turning.

FIGURE 2

STOCK SELECTI O N

Stock for spindles should be straight grained and free of checks, crack s, k nots and other defec ts. It should be cut 1/8" to 1/4" larger than the finished diamet er and may require additional length to remove ends if requir ed. Larger stock should have the corners remov ed to produce an octagon making the piece easier to rough down to a cylinder.

1. With a combinati on square or plastic center finder, loc ate and mark c enter on each end of stoc k . Accuracy is not crit ical on full rounds but extremely import ant on stock where square sections are to remain. P ut a dimple in the stock with an awl or nai l, or use a spring-loaded automat ic center punc h.

2. Extremely har d woods may r equire kerfs cut into the spur drive end of stoc k, Figur e 3, or may need to have the spur center driven i nto the stock with a wood m allet or dead blow hammer , Figure 4. NOTE : Never use a steel face

hammer and never drive stock o nto spur while it is mounted in t he lathe spindle.

FIGURE 3 FIGURE 4

MOUNTING ST OCK

1. Install workpiece by inserting the att ac hed spur center into the spindle taper on the headstoc k .

2. Bring tailstock into position, lock it to the bed, and advance the spindle with the handwheel in order t o seat the cup center into the workpiece.

3. Move tool support i nto position. It should be parallel to the workpiece, just below the cent er line and approxim ately 1/8" to 1/4" from the corners of the workpiece to be t ur ned, as in Figure 5. Lock tool support to bed.

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