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Version 2.6

Mechanical System

K L7 4 4

MANUAL 5 of 8

Summary of Contents for KL744

Page 1: ...Page 1 Version 2 6 Mechanical System KL 744 MANUAL 5 of 8 ...

Page 2: ... 23 Installing the Y Bell Everman Dynamic Belt 24 26 Preparing the Drag Chain 27 29 Attaching the Cable Drag Chains 30 32 Cable Routing of the Servo Motor Wires Cables 33 43 Preparing for the Home Switch Installation 44 Installing the Z Home Switch 45 46 Installing the Y Home Switch 47 Installing the X Home Switches 49 51 Securing Trimming and Managing the Excess Wire 52 Tightening the Bell Everma...

Page 3: ...oto H24 Tape roll 1 H8 T5 Timing Belt Roll 10M 1 10 24 x 3 4 Hex Head Screws 4 M5 Washer 12 M5x30 Socket Head Bolt 4 H3 5 16 x 1 1 4 Machine Screw 6 H5 5 16 Lock Nuts 6 H6 Large Zip Ties 50 20 Extension Cord 1 DeWalt 611 Router 1 Drag Chain 2 H4 5 16 x 1 Hex Head Bolt 1 ...

Page 4: ...Page 4 Part Description Qty Photo H24 Adjustment Tool 1 Vacuum Shoe 1 Vacuum Shoe Retainer ...

Page 5: ...w this warning CAUTION Indicates a serious risk of bodily harm possible injury and death This warning box is to be taken seriously Any work must be carried out with extreme caution Please review each assembly manual before beginning to assemble the KL7 series CNC Router Safety Information and Hints Hints will provide needed information shortcuts and insights that will make assembly and machine ope...

Page 6: ...Static Belt beneath the Idler Pulleys and driven by the Dynamic Belt as its teeth are engaged by the Timing Pulley Hint Clean the Belt Support surfaces using denatured alcohol and a clean paper towel or lint free cloth as shown NOTE The 3M double sided tape supplied with your kit was specifically designed to adhere to a polyurethane surface Before proceeding make sure you applied two coats of poly...

Page 7: ...hown The tape will be placed from one end to the other and cover the length of the Belt Support NOTE You will have to roll the gantry past the tape you have applied to finish the entire Belt Support Surface Repeat the process to install the tape on the Gantry Belt Support After applying the tape press it firmly onto the wood surface being careful not to remove the paper cover from the tape ...

Page 8: ...tep 3 Measure a length of belt approx 1 8 shorter than the Belt Support Using snips cut the belt to length Step 4 Clean any oil dust and dirt from the back of the belt with denatured alcohol and a lint free rag ...

Page 9: ...position the belt so its edge is flush to the edge of the Belt Support as shown Working from one end to the other carefully position the Belt along the edge of the Belt Support After the belt is set firmly press it into the tape for maximum adhesion Repeat for the remaining 2 belts ...

Page 10: ...d the Servo Motor and Encoder Wires through the Left side of the Gantry as shown Installing the X1 and X2 Servo Motors Step 2 Secure the Bell Everman assembly in place with four 1 1 4 Machine Screws and Lock Nuts as shown ...

Page 11: ...Page 11 Step 3 Remember Wire Management Bundle the Servo Motor and Encoder wires together Secure with Zip Ties as shown Repeat procedure to install the X2 Servo Motor on the right side ...

Page 12: ...d a 5 16 Nut onto the 5 16 18 x 1 Hex Head Bolt as shown and insert it in the Rail Support as shown NOTE In this step thread the nut until it touches the head of the bold This bolt will be used to tighten the Y axis belt in a later step Installing the Y Servo Motor to the Y Carriage ...

Page 13: ...Page 13 Step 2 Route the Servo Motor and Controller cable through the back of the Y Carriage Assembly as shown ...

Page 14: ...Page 14 Step 3 After carefully pulling all the cables through the Y Carriage loop the excess wire and secure it with two zip ties Hang it over the back of the Carriage Mount Top ...

Page 15: ...Page 15 Step 4 Set the Servo Motor and Bell Everman Assembly onto the Adjustment Plate and secure with four 5 16 x 1 1 4 Machine Screws and Lock Nuts circled in red Back view Front view ...

Page 16: ... the Servo Motor shaft with the opening in the Spider Coupler as shown Secure the Servo Motor with four 10 24 x 3 4 Socket Head Bolts tighten with a 4 mm Allen Wrench Installing the Z Servo Motor to the Ball Screw Assembly ...

Page 17: ...Step 2 Tighten Spider Coupler to the shaft using an 2 5 mm Allen Wrench as shown NOTE Remember Wire Management Bundle the excess wire and secure with two zip ties and loop the wire over the Servo Motor as shown ...

Page 18: ...t the back left of the X1 axis align and mesh the ends of the belts together Secure with the a X9 Belt Holder and one 5 16 x 1 1 4 Machine Screw and Lock Nut as shown Installing the X1 and X2 Dynamic Bell Everman Belts ...

Page 19: ...Page 19 Step 2 Pull the Bell Everman Assembly up so that there is a gap between the Idler Pulleys and the Static belt Step 3 Slip the Dynamic Belt beneath the two back Idler Pulleys ...

Page 20: ... then route it beneath the two front Idler Pulleys Remove excess slack from the Belt Pully and Push the Bell Everman Assembly down so that the belt is meshed as shown The belt will not be tight at this step in the process The belts will be tightened in a later step ...

Page 21: ...e X2 Dynamic Belt Step 5 Trim the belt to length and secure with a X9 Belt Holder and one 5 16 x 1 1 4 Machine Screw and Nut Step 6 Tighten the four screws holding the Bell Everman Assembly in place making certain the belts are meshed Step 7 ...

Page 22: ...Page 22 Installing the Y Carriage on the Gantry Step 1 Hang the two upper bearings on the upper Y rail on the Gantry as shown Upper Bearing hanging securely on upper rail ...

Page 23: ...inst the lower Rail by adjusting the Set Screw in the bottom of the Y Carriage Tighten in place with the 2mm Allen Wrench The Bearings should only roll as the Carriage Assembly moves Step 3 Tighten the four 5 16 Nuts to secure the SG25U Bearings ...

Page 24: ...ether Secure with a G15 Belt Holder and one 5 16 x 1 1 4 Machine Screw and Lock Nut as shown Installing the Y Bell Everman Dynamic Belt Step 2 Route the Dynamic Belt beneath the two back Idler Pulleys with the Bell Everman Assembly in the upward position Viewed from behind through the Gantry ...

Page 25: ...t Idler Pulleys as shown Step 4 Remove excess slack from the Belt Pully and push the Bell Everman Assembly down so that the belt is meshed Tighten the 4 Machine Screws as shown The Belt will not be tight at this step in the process The Belts will be tightened in a later step ...

Page 26: ...Page 26 Step 5 Trim the Belt to length Step 6 Secure with a G15 Belt Holder and one 5 16 x 1 1 4 Machine Screw and Nut ...

Page 27: ...ing link The other end cap fits around the outside of the adjoining link This end cap snaps within the adjoining link This end cap snaps around the adjoining link Step 1 Preparing the Drag Chain Turn this end cap on its back and gently remove the connecting tab as shown This end cap snaps around the adjoining link ...

Page 28: ...Page 28 Turn the end cap on its back and remove the connecting tab as shown Disconnect and remove the end link Turn it over and reconnect to the adjoining link as shown ...

Page 29: ...Page 29 NOTE Proper orientation of the Drag Chain ends ...

Page 30: ... 30 Attaching the Cable Drag Chains Step 1 Attach the Left Side Drag Chain to the G8 Drag Chain Mount on the Left Side of the Gantry Assembly using two 10 24 x 3 4 Socket Head Bolts and M5 Washers as shown ...

Page 31: ...Page 31 Step 2 Attach the other end of the Drag Chain to the X4 Drag Chain Support using two 10 24 x 3 4 Socket Head Bolts and M5 Washers as shown ...

Page 32: ... Step 2 Attach the Y Axis Drag Chain to the Y1 Carriage Top Mount and the G10 Gantry Top Support using four 10 24 x 3 4 Socket Head Bolts and M5 Washers as shown Finished View from Front Finished View Top Left ...

Page 33: ...2 Use a crescent wrench for leverage and GENTLY remove the upper connecting tabs on the Drag Chain as shown to the point where the chain loops back Only remove the upper tabs Keep the tabs in a safe place for reinstallation later When removing the connecting tabs DO NOT remove the upper and lower tabs of a single link or the drag link will separate Hint ...

Page 34: ...Page 34 Step 3 Remove the upper tabs until you reach the bend ...

Page 35: ...Page 35 Leave one tab on the front of the bend Leave three tabs on the back of the bend ...

Page 36: ...The Encoder Connector has five pins the Servo Motor Connector has six Tape the Cables of each axis pair together and label as shown Each set of Cables will need to be routed neatly through the structure and appropriate Drag Chain Make sure the Cables are not kinked or rubbing against any sharp corners ...

Page 37: ...ough the square access hole to the right of the X1 Servo Motor Route the Cables through the Drag Chain so that they run past the Drag Chain Mount There will be excess Cables once they are routed through the Drag Chain Be sure to protect the Cables and connectors from damage ...

Page 38: ...Page 38 Step 4 Route the Y Servo Motor and Encoder Cables across the Y1 Carriage Mount Top and into the Y Z Drag Chain as shown ...

Page 39: ...Page 39 Continue routing the Cables through the Left Gantry Side and Drag Chain as shown Bundle the excess Cables once they are routed and to protect the Cables and connectors from damage ...

Page 40: ...rough the Right Gantry Side and across the back of the Gantry Assembly through the Left Side Gantry Assembly and into the Drag Chain as shown Step 5 Repeat to route the Z Servo Motor and Encoder Cables following the same path used for the Y Servo Motor and Encoder Cable ...

Page 41: ...Page 41 Continue routing the Cables through the entire Left Gantry Side and Drag Chain There will be excess cables once they are routed Be sure to protect the cables and connectors from damage ...

Page 42: ... the Servo Motor and Encoder Cables Starting from the connectors measure back 24 inches and bundle the Cables together with a Zip Tie Then every 4 to 6 inches add a Zip Tie until the Cables enter the Drag Chain Step 7 24 ...

Page 43: ...refully pull all the excess Cables back through the Drag Chain and the left side of the Gantry then organize and Zip Tie the excess Cables as shown Wire routing and management for the back of the Gantry Assembly ...

Page 44: ...possible to minimize electronic interference noise which can adversely affect machine performance WARNING Preparing for the Home Switch Installation Step 1 Separate and label the Home Switch cables X1 X2 Y and Z Step 2 Remove the Nut and one of the Lock Washers from the all 4 of the Home Switches ...

Page 45: ...sher Plywood Lock Washer Lower Nut Snug in Installing the Z Home Switch Place the home switch so that the end of the barrel measures at least 1 2 inch from the Home Switch Mount surface NOTE The mounting distance can be adjusted once the CNC is ready for operation This will be done to maximize the amount of travel on the Z axis Hint 1 2 ...

Page 46: ...Page 46 Step 2 Route the Z Home Switch into the Y Drag Chain and through the upper access hole in the Left Gantry Side as shown Finish by routing the Z Home Switch Wire through the X Drag Chain ...

Page 47: ... hole Secure with the Nut and Lock Washer Place the home switch so that the end of the barrel measures at least 1 4 inch from the Home Switch Mount surface NOTE The mounting distance can be adjusted once the CNC is ready for operation This will be done to maximize the amount of travel on the Y axis Hint ...

Page 48: ...Page 48 Step 2 Finish by routing the Y Home Switch wire down and through the Drag Chain ...

Page 49: ...witch Mount as shown Place the home switch so that the end of the barrel measures at least 1 2 inch from the Home Switch Mount surface NOTE The mounting distance can be adjusted once the CNC is ready for operation This will be done to maximize the amount of travel and the gantry is square with the X axis Hint ...

Page 50: ...50 Step 2 Route the X2 Switch Wire up through the Gantry Bottom Support and out the back as shown Step 3 Route the X2 Switch Wire through the Gantry Frame and along the bottom of the Gantry Assembly as shown ...

Page 51: ...Page 51 Step 4 Route the X2 Home Switch Wire up through the Left Gantry Side into and through the Drag Chain as shown Follow the same process to install the X1 Home Switch Step 5 ...

Page 52: ...r Cables Once trimmed bundle the X1 X2 Y and Z Home Switch Wires together with Zip Ties placed 6 inches apart Step 1 Securing Trimming and Managing the Excess Wires Be careful to protect the connectors from damage The connections to the Controller will be completed in a later step ...

Page 53: ...se the bolt head Raising the Bolt head will force the Y Servo Motor upward and tighten the belt Step 1 Do not overtighten the Dynamic belt The Dynamic belt should be tightened to remove any slack between the timing and idler pulleys and ensure that the mesh has contact resulting in minimal backlash WARNING ...

Page 54: ...Page 54 Once the Belt has been tightened then tighten the four Y Servo Motor mounting Screws as shown Step 2 Loosen the 5 16 Hex Bolt so that it no longer touches the Y Servo Motor Step 3 ...

Page 55: ...Page 55 Step 4 Assemble the X Servo Belt Tension Tool Insert a 5 16 Nut and the 5 16 x 1 Hex Head Bolt as shown Position the tool parts and secure with 5 16 x 1 1 4 Machine Screw and Nut as shown ...

Page 56: ...and raise the head of the Bolt until it touches the Motor Assembly Using a 1 2 open end wrench gently adjust the Bolt up against the motor housing until the Belt is properly tightened Remove the slack between the Timing and Idler Pulleys Repeat process for the X2 Stepper Motor ...

Page 57: ...Page 57 Properly tightened belt with teeth fully engaged beneath the Idler Pulleys ...

Page 58: ...ly by holding one side of the Bearings against the Rod and rotating the Assembly into position as shown Step 1 Attaching the Z Assembly Screw the 8 32 Inserts inward to push the Bearings snug up against the Rails as shown Step 2 ...

Page 59: ... the Z Assembly and align the four mounting holes with the Ball Screw Nut Housing Step 3 Tighten the Z Assembly to the Ball Screw Nut Housing using four M5 X 30 Socket Head Screws with the M5 washers as shown Step 4 ...

Page 60: ...n Cord through the Left Side Gantry Frame Assembly and Drag Chain Step 1 Routing the Extension Cord and Attaching the Spindle The female end of the Extension Cord should be positioned at the entrance of the Y Drag Chain as shown ...

Page 61: ...s gently pulled through the access hole in the Z Assembly as shown Step 2 Route the Spindle Cord through the Z Assembly and mount it with Zip Ties leaving excess for Z axis motion Step 3 Gently turn the Router as you feed the strain relief and power cord through the access hole ...

Page 62: ...Page 62 Plug the Router into the Extension Cord as shown Step 4 ...

Page 63: ...Page 63 Re install the Drag Chain Clips for Both Drag Chains Be careful not to damage any of the Cables Step 1 Wire Management ...

Page 64: ...Page 64 Wire Management Pictures NOTE Bundle the Cables together and secure them to the frame components to eliminate excess movement and prolong the life of the wiring components ...

Page 65: ...Assembling and Mounting the Vacuum Brush Shoe Using a slotted screw driver insert the 2 Brush material securely into the groove of the Shoe Plate until the brush completely surrounds the plate and trim to length NOTE You may have to sand the inside channel to widen Step 2 ...

Page 66: ...ut is approximately 9 16 from the bottom of each Bolt Then thread the Bolts Assembly into the Threaded Inserts as shown Step 2 Insert the Brush Assembly around the Router body with the Bolts fitting up and through the access holes in the Router Base Plate as shown Step 3 ...

Page 67: ...Page 67 Lock the Brush Shoe Assembly in place by inserting the Shoe Retainer as shown Step 4 ...

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