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BobsCNC Evolution 4 Assembly Manual Download Page 13

12 

 

Z Carriage Assembly 

The Z Carriage Assembly holds the Router securely in a carriage that travels 
up and down the Z-axis on a set of Rails.  These first steps will show you 
how to build the Spindle (Router) Mount. 

NOTE: The Z Frame has alignment marks that are used to snug the SG20U 
Bearings to the Rails and later to tram the Router.  When assembling the Z 
Carriage, it is important that the adjustment marks face toward the Spindle 
Mount as shown in the following photos. 

 

Step 1

 

Attach Spindle Bottom Mount (Z4) to the Z Frame (Z3) with 

three M4 x 16 Machine Screws and Nuts as shown. 

 

 

 

 

 

 

Summary of Contents for Evolution 4

Page 1: ...Evolution 4 Assembly Manual Rev 1 06 ...

Page 2: ...e your success in assembling the Evolution 4 CNC Router and provides all the information you need to get your machine up and running Before beginning the assembly take the time you need to completely review the manual It s good to be familiar with the entire assembly process before diving in Be sure to check out the recommended tools you ll need for the assembly Welcome to the BobsCNC family It s ...

Page 3: ...9 Required Hardware 10 Z Carriage Assembly 12 Y Carriage Assembly 22 Required Wood Components 22 Required Hardware 23 Illustrated Step by Step Instructions 31 Gantry Assembly 38 Required Wood Components 38 Required Hardware 39 Illustrated Step by Step Instructions 42 Front View Right Hand Side Completed 57 X Frame Instructions 82 Required Wood Components 82 Required Hardware 83 Illustrated Step by...

Page 4: ...ns 93 Spoilboard installation optional 126 Completed Views 128 Tramming 133 Congratulations You Just Completed the Assembly of Your Evolution 4 135 Appendix 136 Evolution 4 Firmware Values 136 Evolution Washer Dimensions 137 Evolution 4 Spoilboard Drawing 138 ...

Page 5: ...oof steel Rails with SG20U Bearings GT2 Belt Drive on X and Y axis 2 mm pitch 4 start Acme Threaded Rod on Z axis Home Switches with Self Squaring Gantry MDF Spoilboard with Inserts Optional Accuracy 002 to 004 inch The assembled footprint Length 32 838 mm Width 39 994 mm Height 20 9 530 mm Assembled Weight 48 lbs Cutting Area X 24 610 mm Y 24 610 mm Z 3 3 85 mm ...

Page 6: ...low this instruction WARNING Indicates the possible damage to the machine its components the work piece or injury that can result from failure to follow this warning DANGER Indicates a serious risk of bodily harm injury and death This is a serious warning and should not be ignored Any work must be carried out with extreme caution TIPs Contains helpful information shortcuts and hints to simplify as...

Page 7: ...ngs bracelets watches necklaces before using the machine Wear snug fitting clothing and or roll up long sleeves to prevent snagging Use appropriate personal protective equipment PPE when operating machine including safety glasses and hearing protection Keep hands hair and clothing away from the moving parts of the machine Do not operate the machine when under the influence of alcohol or prescripti...

Page 8: ...t sandpaper to remove laser marks on wood pieces if desired LOCTITE 242 thread lock fingernail polish can be used as a substitute Set of Metric Sockets and SAE Wrenches Set of Metric and SAE Allen Wrenches To Operate the EVOLUTION 4 CNC Router you need will need Computer with control software for GRBL Materials for Projects 1 4 Shaft Router bits Recommended for the electronic setup include Multime...

Page 9: ...provide extra protection to the wood components Try using strips of 1 inch blue painters tape behind the T Slots to help hold the Nuts in place during assembly Lock Nuts are never used to secure components that have T Slots They are only used to mount components where the Nut is not held in a T Slot CAUTION This kit contains numerous small components that pose a choking risk for small children and...

Page 10: ...9 Z Spindle Mount Assembly Required Wood Components Part Description Qty Photo Z1 Frame Mount Support 2 Z2 Z Frame Support 2 Z3 Z Frame 1 Z4 Spindle Bottom Mount 1 ...

Page 11: ...10 Z5 Spindle Interlock Bottom 1 Z6 Spindle Interlock Top 1 Z7 Spindle Top Mount 1 Z8 Spindle Support 1 Required Hardware Part Description Qty Photo ZD2 Acme Block Nut 1 H31 8 Zip Tie 1 ...

Page 12: ...ine Screws 4 H18 M6 Locknuts 4 H40 Eccentric Adjustment Spacer 4 H41 Eccentric Washer 4 H42 Bearing Fender Washer 4 H44 SG20U Bearings 4 H38 M4 x 30 Machine Screws 2 H14 M4 x 16 Screws 25 H15 M4 Nuts 25 H47 M4 Lock Nuts 2 ...

Page 13: ...the Spindle Router Mount NOTE The Z Frame has alignment marks that are used to snug the SG20U Bearings to the Rails and later to tram the Router When assembling the Z Carriage it is important that the adjustment marks face toward the Spindle Mount as shown in the following photos Step 1 Attach Spindle Bottom Mount Z4 to the Z Frame Z3 with three M4 x 16 Machine Screws and Nuts as shown ...

Page 14: ...h Spindle Interlock Bottom Z5 to the Z Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown Step 3 Attach Spindle Interlock Top Z6 to the Z Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown ...

Page 15: ...indle Top Z7 to the Z Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown Step 5 Secure the Spindle Bottom Supports together with two M4 x 30 Machine Screws and Locknuts as shown Do not fully tighten the nut ...

Page 16: ...Attach the Z Frame Support Z2 to the Spindle Assembly with four M4 x 16 Machine Screws and Nuts as shown Step 7 Fit the tabs on the Acme Block Nut A into the slots on the back side of the Frame Assembly as shown ...

Page 17: ...Top Plate Assembly with four M4 x 16 Machine Screws and Nuts as shown Be careful to keep the Acme Block Nut securely in place Step 9 Wrap an 8 Zip Tie around the Frame Supports as shown Make sure the Zip Tie Lock is positioned on the Router side of the Assembly ...

Page 18: ...ening Remove the Router after dry fitting is completed Step 10 Attach four SG20U Bearing Assemblies to the Z Frame When putting the Bearing Assembly together make sure the hub on the Bearing faces the wood IMPORTANT The Screw must be oriented so that the Nut is visible when looking at the back of the carriage see photo below TIP T TIP T Hub ...

Page 19: ... Bearing Washer Bearing Washer Eccentric Washer Eccentric Adjustment Spacer Locknut Prior to putting the Bearing Assembly together mark the point of the inboard edge of the Eccentric Adjustment Spacer using a permanent marker as shown below This mark will help orient the Nut for tramming TIP T Mark this inboard point ...

Page 20: ...19 1 2 3 4 ...

Page 21: ...two Z1 Frame Mount Supports to the Z8 Spindle Support and secure with two M4 x 16 Machine Screws and Nuts Step 12 Attach the Spindle Support Assembly to the Z Frame Assembly with six M4 x 16 Machine Screws and Nuts as shown ...

Page 22: ...21 The finished Z Assembly should look like this ...

Page 23: ...embly Required Wood Components Part Description Qty Photo Y1 Z Stepper Motor Mount 1 Y2 Rail Top Support 1 Y3 Bearing Retainer Plate 1 Y4 Carriage Frame 1 Y5 Y Carriage Side Support 2 Y6 Belt Retainer 1 Y7 Z Rail Stop 1 ...

Page 24: ...Bottom Support 1 Y9 Rail Supports 2 Required Hardware Part Description Qty Photo H42 Bearing Retainer Washers 3 CB11 Stepper Motor 1 ZD5 Aluminum Helical Coupler 1 H44 SG20U Bearings 4 ZD1 Acme Rod 1 H66 Shim Washer 2 ...

Page 25: ...ustment Spacer 2 H41 Eccentric Washer 2 H42 Bearing Fender Washer 6 H47 M4 Lock Nuts 9 H14 M4 x 16 Machine Screws 37 H15 M4 Nuts 28 ZD3 626 2RS Bearing 1 ZD4 6mm Split Locking Collar 1 H54 Stress Proof Steel Z Rails 2 H27 M2 5 x 16 Machine Screws 2 H43 M2 5 Lock Nut 2 ...

Page 26: ...etainer Y6 to the front side of the Y Carriage Frame Y4 and secure with four M4 x 16 Machine Screws and Lock Nuts as shown below Make sure the UP mark is visible and oriented toward the top of the Y Carriage Frame NOTE The Eccentric Bearing adjustment marks are on the opposite side of the Y Carriage Frame as shown ...

Page 27: ...sher Bearing Washer Plywood Bearing Washer secured with a Lock Nut 2b Attach the two lower SG20U Bearings to the Y Carriage Assembly as shown NOTE The assembly order for the Lower Bearing is Machine Screw SG20U Bearing hub facing toward the Bearing Washer Bearing Washer Plywood Eccentric Washer Eccentric Adjustment Spacer secured with a Lock Nut Upper Bearing Assembly Lower Bearing Assembly with E...

Page 28: ...27 Step 3 Attach the Carriage Bottom Support Y8 to the Y Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown Upper Bearing Lower Bearing ...

Page 29: ...ch one Rail Support Y9 to the Y Frame Assembly with three M4 x 16 Machine Screws and Nuts as shown Step 5 Attach the second Rail Support Y9 to the Y Frame Assembly with three M4 x 16 Machine Screws and Nuts as shown ...

Page 30: ...tach the Rail Top Support Y2 to the Y Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown Step 7 Attach the Z Rail Stop Y7 to the Y Frame Assembly with two M4 x 16 Machine Screws and Lock Nuts as shown ...

Page 31: ... Support Y5 to the Y Frame Assembly with seven M4 x 16 Machine Screws and Nuts as shown Step 9 Follow the same process to attach the second Y Carriage Support Y5 to the Y Frame Assembly using seven M4 x 16 Machine Screws and Nuts as shown ...

Page 32: ...ns WARNING Prior to installing the Lower Rails adjust the Eccentric Spacers so that the lower Bearing Assemblies are at their outboard position Step 1 Lay the Y Carriage Assembly with the Bearings facing down Set Z Carriage Assembly into Y Carriage Assembly as shown ...

Page 33: ...it behind the upper SG20U Bearing as shown Gently thread the Rod through the Rail Support and behind the lower SG20U Bearing through the second Rail Support finally seating the Rod into the Lower Rail Support and Rail Stop Assembly Step 3 Repeat to install the second Rail The finished Assembly should look like this ...

Page 34: ...33 Step 4 Attach the Stepper Motor to the Z Stepper Motor Mount Y1 using four M3 x 10 Machine Screws Step 5 Thread the Stepper Motor wiring harness through the Motor Mount as shown ...

Page 35: ...nsert 2 shim washers and secure in place with the 6mm Split Locking Collar by holding the Locking Collar tightly against the Bearing then tighten the Set Screw as shown Step 7 Insert the Acme Rod through the hole in the Rail Top Support and thread into the Acme Nut as shown ...

Page 36: ...e M4 x 16 Machine Screws Bearing Retainer Washers and Lock Nuts NOTE Washers must be placed so that they cover the Outer Bearing Race to secure it in place as shown Once installed spin the Acme Rod to confirm the Washers do not interfere with the rotation of the Locking Nut Bearing Outer Race ...

Page 37: ... keep it from rotating off the flat but loose enough so that it can slide up and down Step 10 Slide the Aluminum Helical Coupler so that it is centered top and bottom between the Locking Collar and bottom of the Z Stepper Motor Mount and tighten the upper and lower Set Screws Secure the Z Motor Mount to the tabs of the Y Carriage Assembly using four M4 x 16 Machine Screws and Nuts ...

Page 38: ... Z Carriage Home Switch in the upper left inside corner of the Y Carriage Assembly using two M 2 5 Machine Screws and Lock Nuts as shown Note Do not overtighten the Screws Step 12 Route the Home Switch Wires as shown below ...

Page 39: ...scription Qty Photo G1 Gantry Frame 1 G2 Gantry Side Support 4 G3 Gantry Cross Brace 4 G4 Y Rail Support 7 G5 Controller Mount 1 G7 Gantry Back Brace 2 G8 Gantry Back Support 2 G9 Gantry Top Botto m Brace 2 G10 Gantry Side 2 G11 Y Stepper Motor Mount 1 ...

Page 40: ...e 2 Belt Gauge 1 Required Hardware Part Description Qty Photo H37 M3 X 10 Machine Screws 12 H39 M6 X 30 Machine Screws 8 H27 M2 5 x 16 Machine Screws 6 H43 M2 5 Lock Nuts 6 H18 M6 Lock Nuts 8 H40 Eccentric Adjustment Spacer 4 H41 Eccentric Washer 4 H42 Bearing Fender Washer 12 ...

Page 41: ...Machine Screws 112 H15 M4 Nuts 113 H26 Small 4 Zip Ties 30 H48 M5 x 30 Machine Screw 3 H64 M5 Nut 3 H49 M5 Lock Nuts 3 H50 Idler Fender Washer 6 H51 Flanged Bearing F625Z 6 H55 GT2 Pulleys 3 H42 Bearing Retainer Washers 1 CB8 USB Cable 1 ...

Page 42: ...41 CB11 Stepper Motors 3 CB12 Power Supply with Cord 1 H31 8 Zip Tie 1 CB16 Controller 1 CB13 Home Switches 3 ...

Page 43: ... one Gantry Side G10 Secure with five M4 x 16 Machine Screws and Nuts as shown NOTE Make sure the side with the alignment markings is facing up Step 2 Align and insert the tabs of the second Gantry Side Support G2 to the slots of the Gantry Side G10 and secure with five M16 Machine Screws and Nuts as shown Alignment Marks ...

Page 44: ...ots of the Gantry Side Lower Brace G14 and secure with three M4 x 16 Machine Screws and Nuts as shown Step 4 Align and insert the tab and slots of one Gantry Cross Brace G3 as shown and secure in place with two M4 x 16 Machine Screws and Nuts ...

Page 45: ...nsert the tab and slots of the second Gantry Cross Brace G3 as shown and secure in place with two M4 x 16 Machine Screws and Nuts Step 6 Repeat process to assemble second side NOTE Both sides will mirror each other as shown ...

Page 46: ...y together note that the four 12mm holes at the bottom of the Gantry Frame G1 must be oriented on the bottom of the Gantry Assembly They provide access to adjust the Y Carriage Bearings in a later step Bearing Adjustment Access Holes TIP T ...

Page 47: ...46 Step 7 Align and insert the tabs of the seven Y Rail Supports G4 into the slots in the G1 Gantry Frame and secure with fourteen M4 x 16 Machine Screws and Nuts Finished Assembly should look like this ...

Page 48: ... Machine Screws and Nuts as shown NOTE The Bearing Adjustment Access Holes in the Gantry Frame are at the bottom Step 9 Align and insert the tabs of the Gantry Back Support G8 into the slots of the Gantry Frame Assembly and secure with two M4 x 16 Machine Screws and Nuts Repeat at the opposite end of the Gantry as shown Left Side Right Side ...

Page 49: ...48 Step 10 Align and insert the tabs of the Controller Mount G5 into the slots of the Gantry Frame Assembly and secure with two M4 x 16 Machine Screws and Nuts as shown ...

Page 50: ...49 Step 11 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Gantry Top Brace G9 and secure with twenty one M4 x 16 Machine Screws and Nuts as shown ...

Page 51: ... with three M4 x 16 Machine Screws and Nuts as shown Repeat to install the second Brace Step 13 Build three Idler Bearing Sub Assemblies 13a Slide two F625Z Flanged Bearings on a M5 x 30 Machine Screw as shown NOTE install the flanges of the Bearings so that each flange is oriented to the outside from the other as shown ...

Page 52: ...51 13b Thread a M5 Nut onto the Machine Screw snug against the Bearings as shown 13c Slide an Idler Fender Washer onto the Machine Screw against the M5 Nut ...

Page 53: ...r Mount G12 and secure with an Idler Fender Washer and M5 Lock Nut as shown 13e Place a 1 strip of painter tape on one side of the Y Belt Adjuster Insert a M4 Nut and a Bearing Retainer Washer in the appropriate slots and cover with another length of tape ...

Page 54: ...to the hex shaped hole in the Y Belt Adjuster G13 Secure in place by threading an 8 inch Zip Tie through the slots as shown NOTE The Idler Support Assembly should slide up and down the Y Belt Adjuster while keeping the Lock Nut secure ...

Page 55: ...slots of the Gantry Frame Assembly as shown Secure the Adjustment Assembly in place with one M4 machine Screw and Nut as shown In the photo below the Bearing Adjustment Access Holes are oriented to the top to simplify installation TOP BOTTOM Right Hand Side ...

Page 56: ...per Motor Mount G11 into the slots of Gantry Frame Assembly and secure with one M4 x 16 Machine Screw and Nut as shown In the photo below the Bearing Adjustment Access Holes are oriented to the bottom to simplify installation BOTTOM TOP Left Hand Side ...

Page 57: ...bs of the Gantry Frame Assembly into the slots of the left Gantry Side Assembly and secure with seven M4 x 16 Machine Screws and Nuts NOTE The Stepper Motor Mount will be secured in a later step Left Front View Completed Left Hand Side ...

Page 58: ...o the slots of the Right Gantry Side Assembly and secure with seven M4 x 16 Machine Screws and Nuts NOTE The Stepper Motor Mount will be secured in a later step Photo is taken from the back of the Assembly to illustrate tabs and slots Front View Right Hand Side Completed ...

Page 59: ...58 Step 18 To install the lower Eccentric Bearing Assembly on the Gantry Side Assembly turn the Gantry Assembly so that it is resting on the top side as shown ...

Page 60: ...59 18a Lower Bearing Order M6 x 30 Machine Screw SG20U Bearing with hub facing toward the Bearing Washer Bearing Washer Plywood Eccentric Washer Eccentric Adjustment Spacer secured with M6 Lock Nut ...

Page 61: ...18b Upper Bearing Order M6 x 30 Machine Screw SG20U Bearing with hub facing toward the Bearing Washer Bearing Washer Plywood Bearing Washer secured with a M6 Lock Nut 18c Install the Idler Bearing as shown ...

Page 62: ...e Assembly as shown Step 20 Install the Arduino Controller to the Gantry Assembly using four Zip Ties as shown NOTE when threading the Zip Ties through the attachment holes do not tighten until all four Zip Ties are installed Do not over tighten Once installed clip the loose ends of the Zip Ties ...

Page 63: ...ling the X1 Home Switch 21a The X1 Home Switch is located to the right of the Controller when viewed from the back Begin by labeling the pin cover using easy to read tape or other label material Mark the label as H X 1 ...

Page 64: ...ry Side Assembly through the access hole at the bottom of the Gantry Back Brace through the Home Switch HS opening in the Controller Mount and thread in the Gantry Back Brace 21c Connect the X1 Plug to the X Pin location on the Arduino Shield as shown Viewed from the back ...

Page 65: ...64 21d Mount the X1 Home Switch using two M2 5 x 16 Machine Screws and Lock Nuts Secure the Home Switch Wires with a Zip Tie as shown X1 Home Switch Installed Zip Tie ...

Page 66: ...he pin cover using easy to read tape or other label material Mark the label as H X 2 22b Route the X2 Home Switch Wire through access hole in the bottom of the Gantry Side Assembly through the access hole at the bottom of the Gantry Back Brace and through the Home Switch HS opening in the Controller Mount The X2 plug will be connected in a later step ...

Page 67: ...66 22c Mount the X2 Home Switch using two M2 5 x 16 Machine Screws and Lock Nuts Secure Home Switch Wires with a Zip Tie as shown X2 Home Switch Installed Zip Tie ...

Page 68: ... back Begin by labeling the pin cover using easy to read tape or other label material Mark the label as H Y 23b Route the Wire through access slot in the top of the Gantry Side Assembly through the access hole in the top of the Gantry Side Support through the Gantry Side Assembly through the access hole in the top of the Gantry Back Brace and through the Home Switch HS opening in the Controller Mo...

Page 69: ...68 23c Mount the Y Home switch on the top right side of the Gantry using two M2 5 x 16 Machine Screws and Lock Nuts as shown ...

Page 70: ...69 23d Connect the Y Home Switch plug to the Y pin on the Arduino Controller as shown ...

Page 71: ...on the Motor Housing Insert the Pulley onto the Motor shaft Snug one of the Set Screws against the flat on the shaft and lift the top flange of the Pulley against the top of the gauge opening as shown Securely tighten both Set Screws using Locktite 242 or a suitable substitute Repeat for remaining two Stepper Motors ...

Page 72: ...r Mount from the back side of the Gantry Assembly Make sure the Stepper Motor Wires are oriented toward the top of the Gantry as shown Secure the Stepper Motor in place with four M3 x 10 Machine Screws 25b Route the Y Stepper Motor Wire Harness through the Back Brace and the Y Slot in the Controller Mount as shown Back View ...

Page 73: ...re Wires to the Controller Board with a Zip Tie as shown NOTE The color code orientation must be as shown Step 26 Installing the X1 Stepper Motor Assembly 26a Insert the X1 Stepper Motor Assembly into the left side of the Gantry Assembly when facing the front and secure with four M3 x 10 Machine Screws ...

Page 74: ...73 26b Route the Stepper Motor Wires up through the Gantry Side Assembly as shown 26c Continue routing the Stepper Motor Wires across the Gantry and through X1 Wire slot in the Controller Mount as shown ...

Page 75: ...he Driver as shown NOTE follow the color orientation of the X1 plug as shown Step 27 Installing the X2 Stepper Motor Assembly 27a Insert the X2 Stepper Motor Assembly into the right side of the Gantry Assembly when facing the front and secure with four M3 x 10 Machine Screws ...

Page 76: ... 27b Route the X2 Stepper Motor Wires up through the Gantry Side Assembly as shown 27c Continue routing the Stepper Motor Wires across the Gantry and through X2 Wire slot in the Controller Mount as shown ...

Page 77: ... 27d Connect the X2 Plug to the pins located to the left of the X2 Driver as shown Step 28 Installing the Power Supply and USB Cable 28a Tuck the Power Supply into the back of the Gantry Assembly as shown ...

Page 78: ...77 28b Route the Power Wire through the Controller Mount as shown ...

Page 79: ...o the Power Terminal on the Arduino Uno Secure the Power Cord to the Controller Mount with a Zip Tie as shown WARNING Polarity is important Ensure proper connection as illustrated in the steps below or you will damage your Controller ...

Page 80: ...Route the Power Cord as shown and secure with Zip Ties shown 28e Connect the USB Cable to the Arduino Uno and route the Cable through the back of the Gantry and secure to the Gantry Side with Zip Ties as shown ...

Page 81: ...80 28f Wire Management Bundle and secure the Stepper Motor Wires to the back of the Gantry Back Support with a Zip Tie as shown ...

Page 82: ...81 ...

Page 83: ...ons Required Wood Components Part Description Qty Photo X1 Rail Supports 8 X2 Frame Corner Braces 4 X4 Frame Mid Support 4 X5 Frame Side Support 2 X6 Frame End Support 2 X7 Wire Harness Support 2 X8 Frame Corner Support 4 ...

Page 84: ...Screws 84 H15 M4 Nuts 84 Illustrated Step by Step Instructions Step 1 Align the tabs of four Rail Supports X1 into the slots in the Frame Side Support X5 Secure with three M4 x 16 Machine Screws and Nuts for each Rail Support as shown Repeat for both Frame Side Supports ...

Page 85: ...84 Step 2 Align the tabs of the four Frame Corner Supports X8 into the lower slots of the Frame Side Assembly and secure with eight M4 x 16 Machine Screws and Nuts as shown ...

Page 86: ...ep 3 Align the tabs of the four Frame Corner Braces X2 into upper slots of the Side Assembly on the outside as shown and secure with eight M4 x 16 Machine Screws and Nuts as shown All four corners completed ...

Page 87: ... Using two of the Frame Mid Supports X4 align the tabs of the Wire Harness Support X7 to the slots at both ends of the Frame Mid Supports and secure with two M4 x 16 Machine Screws and Nuts for each end as shown ...

Page 88: ...87 Step 5 Align the tabs of the Mid Frame Assembly into the slots of each Side Assembly as shown Secure with two M4 x 16 Machine Screws and Nuts for each Rail Support as shown ...

Page 89: ... slots of the Frame Assembly and secure with two M4 x 16 Machine Screws and Nuts for each end as shown Step 7 Insert the tabs of the fourth Mid Frame Support X4 into the slots of Frame Assembly and secure with two M4 x 16 Machine Screws and Nuts for each end as shown ...

Page 90: ...89 Step 8 Align the tabs of the Frame Assembly into the slots of the opposite Frame Side and secure with eight M4 x 16 Machine Screws and Nuts for each end as shown ...

Page 91: ...90 Step 9 Align the tabs of the Frame Assembly into the slots of the Frame End Support and secure with twelve M4 x 16 Machine Screws and Nuts for each end as shown ...

Page 92: ...ner Short 2 X10 Belt Retainer Long 2 X3 Rail Stop 4 X11 Belt Adjusting Plate 2 G6 Rail Stop 2 Required Hardware Part Description Qty Photo OO Heat Shrink Tubing 4 CB15 Pin Connector 1 H56 GT2 Belts 3 H52 Stress Proof Steel X Rails 4 H53 Stress Proof Steel Y ails 2 H39 M6 x 30 Machine Screws 4 ...

Page 93: ...92 H60 M6 Nuts 8 H38 M4 x 30 Machine Screw 5 H15 M4 Nuts 4 R2 R3 Makita or DeWalt Router 1 ...

Page 94: ...93 Illustrated Step by Step Instructions Step 1 Carefully position the Gantry Assembly on the X Frame Assembly as shown ...

Page 95: ...ully insert the upper Stress Proof Steel X Rail into the X Frame Assembly through each of the upper Rail Supports and beneath each of the Upper Bearings of the Gantry Side Assembly as shown Repeat this for other side ...

Page 96: ... are at their lowest position Step 3 Observe the SG20U Bearing while turning the hex head of the Eccentric Adjustment Spacer until you see that the Bearing is set to its lowest position Do this for all four of the lower Bearings Using a Sharpie mark the hex point closest to the outermost adjustment mark as shown ...

Page 97: ...Carefully insert the lower Stress Proof Steel X Rail into the X Frame Assembly through each of the Rail Supports and above each of the Upper Bearings of the Gantry Side Assembly as shown Repeat for the other side ...

Page 98: ...ers NOTE To raise the SG20U Bearing against the Rail on the Left Side rotate the Eccentric Adjustment Spacer clockwise To raise the Bearing on the Right Side rotate the Eccentric Adjustment Spacer counterclockwise Clockwise Counterclockwise ...

Page 99: ...y to turn the Bearing The Bearing should only move if the Gantry moves Note the position of the mark that was made on the right side Eccentric Adjustment Spacer Count the number of adjustment marks between the lowest position and the final tightened positioned Make a corresponding adjustment mark on the left side Adjustment Marks ...

Page 100: ...n the left lower Bearing The Bearing should only move if the Gantry moves Once the Bearings are snug against the rail tighten the Locknut with a 10mm wrench and Phillips Head screwdriver as shown NOTE There are access holes located at the bottom of the Sides of the X Frame to help you tighten the Bearings ...

Page 101: ...f the Belt into the X9 Short Belt Retainer X9 6c Next thread the free end of the GT2 Belt through the Rail Stop X3 NOTE In the photo the Rail Stop has been rotated so that the slot is oriented toward the bottom of the Rail Stop Pull the belt through and insert the Short Belt Retainer through the Rail Stop as shown ...

Page 102: ...101 6d Insert the free end of the Belt through the lower slot of the X Frame Assembly and pull the Belt through ...

Page 103: ...ry Assembly in front of the square access hole This opening provides the access you need to loop the Belt around the Idler and Flange Bearings We suggest that you watch the short video demonstrating how to correctly route and install the Belts around the Flange and Idler Bearings https youtu be SAz9UjGeOa0 ...

Page 104: ...on the belt are facing outboard The following photos illustrate the proper path for routing the Belt The photos were taken before the Gantry was installed on the X Frame for Illustration purposes only The Gantry Assembly must be installed on the X Frame Assembly before attempting to install the Belts TIP T ...

Page 105: ...104 6g Loop the Belt over the Belt Pulley so that the Belt teeth engage the teeth of Pulley 6h Repeat for the other X Belt Finished Belt Routing viewed through the access port ...

Page 106: ...105 Step 7 Securing the X1 and X2 Belts 7a Insert two M6 x 30 Machine Screws through the Belt Adjustment Plate X11 and secure with a M6 Nut 7b Add one M6 Nut to each Machine Screw as shown ...

Page 107: ...106 7c Insert the Long Belt Retainer X10 through the Belt Adjusting Plate into the Rail Stop X3 as shown 7d Insert the Belt Tightening Assembly into the upper slot of the X Assembly as shown ...

Page 108: ...e Belt completely in the Retainer as shown Step 8 Attaching the Y Carriage Assembly and Y Axis GT2 Belt 8a Insert the upper Y Axis Stress Proof Steel Rail into the Gantry Side and carefully thread the Rail through the upper Rail Supports and into opposite Gantry Side as shown ...

Page 109: ...08 8b Cut one of the GT2 Belts to 56 1 2 inches 8c Lay the Y Carriage Assembly on the X Frame Assembly and insert the ends of the Y Axis Belt into the Belt Retainer making certain the Belt is not twisted ...

Page 110: ...d the Y Carriage Assembly making sure the ends remain secure in the Y Belt Retainer Then hang the upper Bearings of the Y Carriage Assembly onto the upper Y Rail as shown being careful to keep the Belt between the upper and lower Bearings ...

Page 111: ...il through the Gantry Side through the lower Rail Supports over the lower SG20U Bearings and across into the opposite Gantry Side 8f Attach the Rail Stops to each end of the Gantry Side using two M4 x 30 Machine Screws and Nuts for each side as shown ...

Page 112: ...e Idler Pulley as shown Make sure the Belt is not twisted and that the Belt teeth are oriented as shown 8h Loop the other end of the Belt over the Belt Pulley as shown Make sure the teeth in the Belt engage the teeth of the Pulley ...

Page 113: ...sides using the alignment marks to tighten Bearings against the Rail as shown 8j Align the access hole in the Gantry with the Bearing Screw Using a 10mm socket and a Phillips Screwdriver tighten the Locknut to secure the Bearing position Clockwise Counterclockwise ...

Page 114: ...he Self Squaring Gantry 9a Separate the red and black Wire on the X2 Home Switch Wire as shown 9b Turn the pin connector over to view the locking mechanism that holds the wires in place Completed Y Axis Belt Installation ...

Page 115: ...114 9c Using the sharp point of a thin blade Insert the blade beneath the wire lock and gently lift to remove the black wire 9d Repeat these steps with the Z Home Switch ...

Page 116: ...me Switch Wire using the Pin Connecter as shown 9f Cover the splice with the heat shrink tubing Using a lighter or heat gun carefully heat the tubing so that it shrinks securely around the pin connector as shown Insert the remaining wire into the black 2 pin connector ...

Page 117: ...116 9g Plug the connector to the Z pin terminal on the controller and secure the spliced wires with a Zip Tie 9h Plug the Z Stepper Motor connector to the Z Driver and secure with a Zip Tie as shown ...

Page 118: ...l shows installing a Makita RT0701C Router The same steps will be followed to install the DeWalt 611 Router 10a Insert the Router into the Holder and with downward pressure gently twist the Router body until it is fully seated in the Holder as shown ...

Page 119: ...h one of the elongated access holes in the back of the Gantry Note In order to align the access hole with the Phillips head screws it will be necessary to raise or lower the Z Carriage This can be done by manually rotating the Helical Coupler at the top of the Z Axis as shown ...

Page 120: ...Carriage and Gantry first lower the Router Carriage as low as possible Use Zip Ties to secure the Router power cord to the top of the Router Carriage Assembly as shown Be careful to route the Cord without putting stress on the stress relief as shown ...

Page 121: ...ntry Back Side as shown then through the side access hole 10e Facing the back of the Gantry slide the Router Carriage all the way to the right Allow enough slack in the cord so that the Router Carriage can travel from the right side of the Gantry to the left without binding as shown ...

Page 122: ... side of the Gantry as shown Then tie them together and secure them to the Gantry Lower Side Brace as shown In the same way tie the USB Cord to its Wire Harness Support as shown Cord length estimated from the right side Cord length estimated from the left side ...

Page 123: ... closest to the Belt Adjusting Plate is tight Using a 10mm wrench hold the adjustment Nut and turn the machine screw to tighten the Belt Be sure to adjust both Screws the same amount until the Belt is tight Power cord secured along the edge of the Gantry side ...

Page 124: ...123 Repeat these steps to tighten the X2 Belt Step 12 Tighten the Y Belt 12a Insert the M4 x 30 Machine Screw through the large hole in the Y Rail Stop as shown Thread the Screw into the ...

Page 125: ...ghten the Screw on the Idler Pulley to secure Belt tension as shown Make sure the Nut closest to the Belt Adjusting Plate is tight Using a 10mm wrench hold the adjustment Nut and turn the Machine Screw to tighten the Belt Be sure to adjust both Screws the same amount until the Belt is tight ...

Page 126: ...125 Step 13 Secure Power and USB Cords 13a Secure the Power Cords to the Wire Harness Support with four Zip Ties as shown 13b Secure the USB cord to the Wire Harness Support with four Zip Ties as shown ...

Page 127: ...oilboard NOTE Whether you are installing the Spoilboard from BobsCNC or one of your own design you should follow the same basic steps Step 1 Insert 24 M4 Nuts into the Frame Support Use 1 strips of painter s tape to hold them in place as illustrated below ...

Page 128: ...127 Step 2 Carefully slide the Spoilboard onto the X Frame Assembly and align the mounting holes with the M4 Nuts already in place Secure the Spoilboard with 24 M4 X 16 Machine Screws and Nuts ...

Page 129: ...128 Completed Views Front View Back View ...

Page 130: ...129 X1 Home Switch X1 Side View ...

Page 131: ...130 X2 Home Switch X2 Side View ...

Page 132: ...131 Z Home Switch Y Home Switch ...

Page 133: ...132 ...

Page 134: ...er so it is perpendicular to the spoilboard The simplest method to do this is to use a square as shown If the Spindle is not perpendicular the Evolution Series CNC Routers can be trammed on the X axis by adjusting the four Eccentric Adjustment Spacers on the Z Carriage ...

Page 135: ... Router can be trammed on the Y axis by placing shims behind the SG20U Bearing Fender Washer Placing the shim on the top will tilt the axis clockwise Placing the shim on the bottom will tilt the axis counterclockwise ...

Page 136: ...135 Congratulations You Just Completed the Assembly of Your Evolution 4 Please review our Software Setup Guide for Software installation and setup ...

Page 137: ... status report mask 00000011 11 0 01 junction deviation mm 12 0 002 arc tolerance mm 13 0 report inches bool 20 1 soft limits bool 21 0 hard limits bool 22 1 homing cycle bool 23 3 homing dir invert mask 00000011 24 250 homing feed mm min 25 2000 homing seek mm min 26 250 homing debounce msec 27 5 homing pull off mm 30 1000 Maximum spindle speed RPM 31 0 Minimum spindle speed RPM 32 0 Laser mode e...

Page 138: ...vel millimeters 131 610 Y axis maximum travel millimeters 132 85 Z axis maximum travel millimeters Evolution Washer Dimensions Part number Description ID OD Thickness min Thickness max H41 Eccentric Washer 0 453 0 750 0 059 0 063 H42 Bearing Fender Washer 0 250 0 750 0 060 0 090 H50 Idler Fender Washer 0 203 0 750 0 043 0 051 H57 Bearing Retainer Washer 0 172 0 050 0 050 0 080 H66 Small Shim Washe...

Page 139: ...lution 4 Spoilboard Drawing The recommended Spoilboard material is MDF M4 x 16 mm Machines screws will work with a 10mm deep counter bore Other holes shown are for threaded inserts and can be placed as desired ...

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