BobsCNC REVOLUTION Assembly Manual Download Page 13 | Manualshive

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Illustrated Step by Step Instructions

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.

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Summary of Contents for REVOLUTION

Page 1: ...Assembly Manual Rev 2 5 Rotating Axis CNC Router REVOLUTION ...

Page 2: ...olution 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 time to Unleash Your Creativity Versi...

Page 3: ...ired Wood Components 9 Required Hardware 11 Illustrated Step by Step Instructions 12 X Carriage Assembly 23 Required Wood Components 23 Required Hardware 24 Illustrated Step by Step Instructions 34 Chuck Assembly 43 Required Wood Components 43 Required Hardware 44 Illustrated Step by Step Instructions 45 Tail Stock Assembly 52 Required Wood Components 52 Required Hardware 53 Illustrated Step by St...

Page 4: ...s 71 Final Assembly 79 Wood Components 111 Required Hardware 111 Installing the X and A Axis Stepper Motors 116 Installing the Controller the X Axis Home Switch and the X and A Axis Stepper Motors 113 Completed Views 122 Tramming 145 Congratulations You Just Completed the Assembly of Your Revolution 148 Appendix 149 Revolution Firmware Values 149 ...

Page 5: ...f steel Rails with SG20U Bearings GT2 Belt Drive on X and A axes Longworth Self Centering Chuck 2 mm pitch 4 start Acme Threaded Rod on Z axis Home Switches on X and Z axes Accuracy 0 002 to 0 004 inch The assembled footprint Length 43 8 1113 mm Width 13 2 335 mm Height 24 0 610 mm Assembled Weight 30 lbs Cutting Area X 24 610 mm Z 3 3 85 mm A 6 4 165 mm diameter ...

Page 6: ...follow 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...

Page 7: ...emove rings 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 pr...

Page 8: ...lips screwdrivers to mount Home Switches and Stepper Motors 220 grit 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 Long Reach Allen Wrenches To Operate the REVOLUTION Rotating Axis Router you need will need Computer with control software for GRBL Materials ...

Page 9: ...ear coat will provide extra protection to the wood components You may wish to using strips of 1 inch blue painters tape behind the T Slots to help hold the Nuts in place during assembly A telescoping magnetic pickup tool can also be a handy way of placing and holding small Nuts during assembly Lock Nuts are never used to secure components that have T Slots They are only used to mount components wh...

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

Page 11: ...10 Z5 Z Spindle Interlock Bottom 1 Z6 Z Spindle Interlock Top 1 Z7 Z Spindle Top Mount 1 Z8 Z Spindle Support 1 ...

Page 12: ...e Block Nut 1 H31 8 Zip Tie 1 H39 M6 x 30 Machine Screws 4 H18 M6 Locknuts 4 H40 Eccentric 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: ...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 ...

Page 14: ...ews and Nuts or use LOCKTITE They will be tightened in a later step after the Router has been mounted Step 3 Loosely attach the Spindle Interlock Top Z6 to the Z Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown Do not tighten the Machine Screws and Nuts or use LOCKTITE They will be tightened in a later step after the Router has been mounted ...

Page 15: ...the Router has been mounted The Interlock Bottom and Top must be able to move slightly from front to back this allowance will make installing the Router easier You only need to make sure that the machine Screws and Nuts are engaged to keep the Screws from falling out Step 5 Loosely secure the Spindle Bottom Supports together with two M4 x 30 Machine Screws and Locknuts as shown Do not fully tighte...

Page 16: ...n the Acme Block Nut into the slots on the back side of the Frame Assembly as shown The ACME Block Nut tabs are designed to be a snug fit If the ACME Block Nut fit is too tight use sandpaper with block or a file to sand the outer faces of the rectangular slots as shown with the red arrows below until the Block fits snugly into the slots ...

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: ... Support Assembly as shown This will help align the interlocking center pieces prior to final assembly and tightening Remove the Router after dry fitting is completed Video Link https www youtube com watch v SkQ55V6ymEs t 69s TIP T ...

Page 19: ... 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 NOTE Bearing Assembly Order with Eccentric Adjustment Spacer M6 X 30 Machine Screw Head Bearing with hub facing toward the Bearing Washer Bearing Washer Eccentric Washer Eccentric Adjustment Spacer M6 Locknut TIP T ...

Page 20: ...g 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 21: ...20 1 2 3 4 ...

Page 22: ...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 23: ...22 The finished Z Assembly should look like this ...

Page 24: ...e Assembly Required Wood Components Part Description Qty Photo XR1 Z Stepper Motor Mount 1 XR2 Rail Top Support 1 XR3 Bearing Retainer Plate 1 XR4 Carriage Frame 1 XR5 Y Carriage Side Support 2 XR6 Belt Retainer 1 ...

Page 25: ...XR7 Z Rail Stop 1 XR8 Carriage Bottom Support 1 XR9 Rail Support 2 Required Hardware Part Description Qty Photo H57 Bearing Retainer Washer 3 CB11 Stepper Motor 1 ZD5 Aluminum Coupler 1 H44 SG20U Bearing 4 ...

Page 26: ...0 Machine Screw 4 H18 M6 Locknut 4 H40 Eccentric Spacer 2 H41 Eccentric Washer 2 H42 Bearing Fender Washer 6 H47 M4 Lock Nut 9 H14 M4 x 16 Machine Screw 37 H15 M4 Nut 28 ZD3 626 2RS Bearing 1 ZD4 6mm Split Locking Collar 1 HR1 Stress Proof Steel Z Rail 2 ...

Page 27: ...26 H27 M2 5 x 16 Machine Screw 2 H43 M2 5 Lock Nut 2 CB13 Home Switch 1 H37 M3 x 10 Machine Screw 4 H26 Small Zip Ties 2 ...

Page 28: ...side of the Y Carriage Frame XR4 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 X Carriage Frame as shown ...

Page 29: ...two upper SG20U Bearing Assemblies to the Y Carriage Assembly as shown NOTE The assembly order for the Upper Bearing Machine Screw SG20U Bearing with hub facing toward the Bearing Washer Bearing Washer Plywood Bearing Washer secured with a Lock Nut Upper Bearing Assembly ...

Page 30: ...ill be tightened in a later step NOTE The assembly order for the Lower Bearing Machine Screw SG20U Bearing hub facing toward the Bearing Washer Bearing Washer Plywood Eccentric Washer Eccentric Spacer secured with a Lock Nut Lower Bearing Assembly with Eccentric Spacer Upper Bearing Lower Bearing ...

Page 31: ... the Carriage Bottom support XR8 to the X Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown Step 4 Attach one Rail Support XR9 to the X Frame Assembly with three M4 x 16 Machine Screws and Nuts as shown ...

Page 32: ... the second Rail Support XR9 to the X Frame Assembly with three M4 x 16 Machine Screws and Nuts as shown Step 6 Attach the Rail Top Support XR2 to the X Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown ...

Page 33: ...the Z Rail Stop XR7 to the X Frame Assembly with two M4 x 16 Machine Screws and Lock Nuts as shown Step 8 Attach one X Carriage Side Support X5 to the Y Frame Assembly with seven M4 x 16 Machine Screws and Nuts as shown ...

Page 34: ...33 Step 9 Repeat for the other side Attach one X Carriage Side Support X5 to the Y Frame Assembly with seven M4 x 16 Machine Screws and Nuts as shown Completed X Carriage Assembly ...

Page 35: ...ARNING 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 X Carriage Assembly with the Bearings facing down Fit the Z Carriage Assembly into the X Carriage Assembly as shown ...

Page 36: ...r 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 Rotate each Rail as you guide them through each of the components This will help them to slide smoothly into place TIP T ...

Page 37: ...all the second Rail The finished Assembly should look like this Step 4 Attach the Stepper Motor to the Z Stepper Motor Mount XR1 using four M3 x 10 Machine Screws Note The Stepper Motor wires are facing towards the protrusion ...

Page 38: ...e Motor Mount as shown Step 6 Slide the 626 2RS Bearing onto the shaft of the ACME Rod Next insert 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 ...

Page 39: ...ough the hole in the Rail Top Support and thread into the ACME Block Nut as shown Step 8 Place the Bearing Retainer Plate XR3 over the Bearing and secure in place with three M4 x 16 Machine Screws Bearing Retainer Washers and Lock Nuts ...

Page 40: ... 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 41: ... keep it from rotating off the flat but loose enough so that it can slide up and down Step 10 Slide the Aluminum 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 42: ... Carriage Home Switch in the upper left inside corner of the X Carriage Assembly using two M 2 5 x 16 Machine Screws and Lock Nuts as shown Note Do not overtighten the Screws Step 12 Route the Home Switch Wires as shown below ...

Page 43: ...42 Step 13 Secure the Z Axis Stepper Motor and Home Switch wires with two Zip Ties to the Stepper Motor Mount as shown ...

Page 44: ...43 Chuck Assembly Required Wood Components L2 Outer Chuck Plate 1 L3 Chuck Pulley 1 L4 Inner Chuck Plate 1 ...

Page 45: ...quired Hardware H47 M4 Lock Nut 12 H74 M4x40 Hex Cap Screw 8 H57 Bearing Retainer Washer 16 H72 Chuck Gripper 8 H14 M4x16 Machine Screw 4 H71 12mm Chuck Shaft 1 H70 12mm Chuck Flange 1 H76 Round Foam Tabs 8 ...

Page 46: ...t protrude into the center to allow the insertion of the 12mm Chuck Shaft in a later step Align the holes of the 12 mm Chuck Flange with the screw holes in the Inner Chuck Plate and secure with four M4 x 16 Screws and Lock Nuts as shown Insert the Screws through the back of the Inner Chuck Plate so that the threaded end passes through the Flange and can be secured with the Lock Nuts as shown Do no...

Page 47: ...k Shaft through the back of the Inner Chuck Plate Assembly for alignment as shown Step 3 Remove the paper covering one side of the eight Round Foam Pads and carefully adhere them to the circular marks located on the Chuck Pulley L3 ...

Page 48: ...mbly Slip the Chuck Pulley L3 over the 12 mm Chuck Shaft Slide the Plates together being careful to keep the helical cutouts of the Chuck Pulley and those on the Inner Chuck Plate perfectly aligned Then press the discs firmly together as shown View from the flange side showing the alignment of the helical cutouts for both the Inner Chuck Plate L4 and the Chuck Pulley L3 ...

Page 49: ...ck Grippers and Outer Chuck Plate L2 to the Chuck Assembly 5a Align the Outer Chuck Plate L2 with the Chuck Assembly so the helical cutouts intersect as shown below and slide the Outer Chuck Plate L2 onto the 12mm Chuck Shaft ...

Page 50: ...al grooves as shown below The Chuck is designed to allow the two Chuck Plates to counter rotate As the Plates rotate the Grippers are guided along the helical cutouts either inward toward the shaft or outward to secure or release a workpiece If the Lock Nuts securing the Grippers are too tight the Plates will not slide against each other TIP T ...

Page 51: ...earing Retainer Washer 5c Slide the Chuck Gripper over the screw threads on the Chuck Assembly with the rounded shoulder against the wood and secure with a Bearing Retainer Washer and Lock Nut as shown Once the threads of the screw engage the nylon insert in the Lock Nut the screw should be snugged turn Repeat to install the remaining Chuck Gripper Assemblies Flat Edge Large Hole Hex Cap Bolt Wash...

Page 52: ...51 5d With the shaft end flush with the front chuck surface secure the chuck flange 4 machine screws The Completed Assembly ...

Page 53: ...od Components TS1 Tail Stock Side Plate 2 TS2 Tail Stock Top Plate 1 TS3 Tail Stock Bottom Plate 1 TS4 Tail Stock Top Brace 1 TS5 Tail Stock Bottom Brace 1 TS6 Tail Stock Guide 2 TS7 Tail Stock Tensioner 1 TS8 Tail Stock Nut Retainer 1 ...

Page 54: ...Description Qty Photo H77 5 16 x 3 Hex Cap Screw 1 H5 5 16 Nut 1 H14 M4 x 16 Machine Screw 14 H15 M4 Nut 12 H69 12mm Pillow Block Bearing 2 H78 12mm Live Center 1 H73 M6x20 Socket head Screw 4 H18 M6 Locknut 4 H47 M4 Lock Nut 2 ...

Page 55: ...shaped hole in the Tail Stock Nut Retainer TS8 It will be necessary to use a hammer hard mallet or handpress to press fit the Nut into the Retainer Step 2 Attach the Tail Stock Nut Retainer Assembly to the Tail Stock Bottom Plate TS3 and secure with two M4 x 16 Screws and M4 Lock Nuts ...

Page 56: ...thin the block making it self centering After sliding the 12mm Shaft through the first Bearing the second Bearing can be rotated within its Block as needed to pass a shaft through two Bearings Place the 12mm Pillow Lock Bearing through the hole in the Tail Stock Plate TS1 and secure with two M6 x 20 Socket head Screws with M6 Lock Nuts TIP T ...

Page 57: ...ws so that the Screw head rests against the wood Do not tighten completely until the live center in place This will aid in alignment of the pillow block bearings with the live center in a later step Step 4 Repeat the assembly for the remaining Tail Stock Side Plate TS1 Socket head Lock Nuts The Completed Assembly TIP T ...

Page 58: ...57 Step 5 Building the Tail Stock Tensioning Assembly 5a Attach the two Tail Stock Guides TS6 to the Tail Stock Side Plate Assembly and secure with two M4 x 16 Screws and Nuts ...

Page 59: ...f Tail Stock Bottom Brace TS5 into the slot in the Tail Stock Assembly 5c Insert the Tail Stock Tensioner TS7 into the slot in the Tail Stock Assembly centering the hex shaped hole with the hole in top of the Brace as shown ...

Page 60: ...ex shaped hole Holding the bolt in place with a piece of tape will aid in assemble in a later step 5e Insert the tabs of the Tail Stock Top Brace TS4 into corresponding slots in the Tail Stock Assembly and secure with two M4 x 16 Screws and Nuts TIP T ...

Page 61: ... them together with four M4 x 16 Screws and Nuts 5g Rotate the Tail Stock Assembly to align the tabs of the Tail Stock guides with the slots of the Tail Stock Top Plate TS2 Align the hole in the Tail Stock Top Plate to allow the 3 Screw to pass through Secure with four M4 x 16 Screws and Nuts ...

Page 62: ...rt so that the end of the 3 Screw can be threaded into the 5 16 nut Use the sprocket shape of the Tail Stock Tensioner to tighten the Bottom Plate Assembly and complete the Tail Stock Tensioning Assembly The Tail Stock Bottom Plate Assembly will be removed and reinstalled in a later step ...

Page 63: ...62 Step 6 Insert the 12mm Live Center into the Chuck on the opposite side of where the Tail Stock Tensioner TS7 protrudes out the furthest as shown Tighten the Set Screws to secure the Live Center ...

Page 64: ...Base Assembly Required Wood Components Part Descripti on Qt y Photo BA1 Base Frame 1 BA2 Base Tail Stock Guide 1 BA3 Front Base Support 1 BA4 Rear Base Support 1 BA5 Base Brace 8 BA6 Base Corner Bracket 2 ...

Page 65: ... Hardware Part Description Qty Photo H38 M4 x 30 Machine Screws 16 H14 M4 x 16 Screws 36 H15 M4 Nuts 52 Illustrated Step by Step Instructions Step 1 Lay the Base Tail Stock Guide BA2 on the Base Frame BA1 as shown ...

Page 66: ...tom insert the tabs of a Base Brace BA5 into the slots of the Base Frame BA1 and loosely secure with two M4 x 30 Machine Screws and Nuts Repeat with the remaining seven Base Braces BA5 Note Do not fully tighten the Screws and Nuts This will be done in a later step Bottom View Top View ...

Page 67: ...ort B3 to the Base Assembly using sixteen M4x 16 Screws and Nuts Step 4 Attach the Rear Base Support B4 to the Base Assembly using sixteen M4 x 16 Screws and Nuts Note When Both Sides are attached fully tighten the M4 x 30 Screws and Nuts ...

Page 68: ...67 Step 5 Attach the two B6 Base Corner Brackets to the Base Assembly using two M4 x 16 Screws and Nuts for each Both Sides Attached Bottom View Both Sides Attached Front View ...

Page 69: ...Wood Components GR1 Gantry Frame 1 GR4 X Rail Support 7 GR5 Controller Mount 1 GR7 Back Brace 2 GR8 Gantry Back Support 2 GR9 Gantry Top Bottom Brace 2 GR11 X Stepper Motor Mount 1 GR12 X Belt Idler Mount 1 GR13 X Belt Tensioner 1 ...

Page 70: ...cription Qty Photo H14 M4 x 16 Machine Screws 64 H15 M4 Nuts 65 H31 Large 8 Zip Ties 1 H48 M5 x 30 Machine Screw 2 H64 M5 Nut 2 H49 M5 Lock Nuts 2 H50 Idler Fender Washer 4 H51 Flanged Bearing F625Z 4 H57 Bearing Retainer Washers 1 ...

Page 71: ...gether note that the four 12mm holes at the bottom of the Gantry Frame GR1 must be oriented on the bottom of the Gantry Assembly They provide access to adjust the X Carriage Bearings needed in a later step TIP T Bearing Adjustment Access Holes ...

Page 72: ...by Step Instructions Step 1 Align and insert the tabs of the seven Y Rail Supports GR4 into the slots in the GR1 Gantry Frame and secure with fourteen M4 x 16 Machine Screws and Nuts Finished Assembly should look like this ...

Page 73: ...GR9 and secure with fifteen M4 x 16 Machine Screws and Nuts as shown Step 3 Align and insert the tabs of the Gantry Back Support GR8 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 Back Right Side Back ...

Page 74: ...tabs of the Controller Mount GR5 into the slots of the Gantry Frame Assembly and secure with two M4 x 16 Machine Screws and Nuts as shown These small holes must be positioned at the bottom to properly install the Controller Mount GR5 ...

Page 75: ...e Gantry Top Brace GR9 and secure with twenty one M4 x 16 Machine Screws and Nuts as shown Step 6 Align and insert the tabs of the Back Brace GR7 into the slots of the Gantry Frame Assembly and secure with three M4 x 16 Machine Screws and Nuts as shown Repeat to install the second Brace ...

Page 76: ...ide 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 7b Thread a M5 Nut onto the Machine Screw snug against the Bearings as shown ...

Page 77: ... Washer onto the Machine Screw against the M5 Nut 7d Insert the Bearing Assembly through X Belt Idler Mount GR12 and snug with an Idler Fender Washer and M5 Lock Nut as shown below The idler should able to slide with in the slot ...

Page 78: ...the appropriate slots and cover with another length of tape 7f Insert the M5 Lock Nut into the hex shaped hole in the X Belt Adjuster GR13 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 X Belt Adjuster while keeping the Lock Nut secure ...

Page 79: ...embly into the slots of the Gantry Frame Assembly as shown Secure the Adjustment Assembly in place with one M4 x 16 Machine Screw and Nut In the photo below the Bearing Adjustment Access Holes are oriented to the top to simplify installation ...

Page 80: ...Stepper Motor Mount GR11 into the slots of Gantry Frame Assembly and secure with one M4 x 16 Machine Screw and Nut In the photo below the Bearing Adjustment Access Holes are oriented to the bottom to simplify installation BOTTOM TOP Left Hand Side ...

Page 81: ... Attaching the Base and Gantry Assembly Required Wood Components Part Description Qty Photo GR2 A Axis Stepper Motor Mount 1 GR3 A Axis Stepper Motor Support 2 GR17 Left Gantry Side 1 L8 Dial Indicator 1 ...

Page 82: ...81 GR18 Right Gantry Side 1 GR20L GR20R Gantry Mid Vertical Support 2 ...

Page 83: ...82 GR21 Gantry Back Vertical Support 2 GR10 A Axis Belt Tensioner 1 GR14 Gantry Top Brace 2 GR15 Gantry Mid Brace 2 GR16 Gantry Bottom Brace 2 ...

Page 84: ...2 L5 Chuck Support 1 L6 Front Chuck Brace 1 L7 Rear Chuck Brace 1 Required Hardware Part Description Qty Photo H14 M4 x 16 Machine Screws 119 H15 M4 Nut 119 H42 Bearing Fender Washer 1 H69 12mm Pillow Block Bearing 2 H73 M6x20 Socket head Screw 5 ...

Page 85: ...84 M18 M6 Lock Nut 5 H9 20 X 2 Screw 1 H45 20 Wing Nut 1 H10 20 Nut 1 H75 Spacer 1 ...

Page 86: ... place This will aid in alignment of the pillow block bearings with the Chuck Shaft in a later step Step 1 Attach a 12mm Pillow Block Bearing to the Left Gantry Side GR17 and secure with two M6 x 20 Socket Head Screws and Locking Nuts Note the laser marking on the Left Gantry Side GR17 TIP T ...

Page 87: ...Assembly into the slots of the left Gantry Side Assembly and secure with eleven M4 x 16 Machine Screws and Nuts In this photo the Base was set on end to make it easier to align the tabs in the Base Assembly with the Left Side of the Frame Assembly Left Side ...

Page 88: ...87 Step 3 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Right Gantry Side Assembly and secure with seven M4 x 16 Machine Screws and Nuts ...

Page 89: ...bs of the Gantry Frame Assembly and base into the slots of the Right Gantry Side GR18 and secure with eighteen M4 x 16 Machine Screws and Nuts Photos below show both sides attached to the Gantry and Base Assemblies Front View Back View ...

Page 90: ...89 Step 5 Attaching the Left Side Assembly Components 5a Attach the Rear Chuck Brace L7 to the Gantry Mid Vertical Support GR20L and secure with one M4 x 16Screw and Nut ...

Page 91: ...90 5b Attach the Front Chuck Brace L6 to the Gantry Front Vertical Support GR19L and secure with a M4 x 16 Screw and Nut ...

Page 92: ...Chuck Support and secure with two M6 x 20 Socket head Screws and Lock Nuts Note that the hub side of the Bearing is set so that it extends through the opening The Screws are placed so that the Nuts are exposed on the side with the laser engraved outline ...

Page 93: ...r with two M4 x 16 Screws and Nuts 5e Connect the Gantry Mid Support Assembly to the Gantry Front Support Assembly and secure with two M4 x 16 Screws with Nuts 5f Connect the GR14 Gantry Top Brace to the GR21 Gantry Back Vertical Support and secure with one M4 x 16 Screw with Nut ...

Page 94: ...d and Back components as shown and secure with one M4 x 16 Screw and Nut 5h Align the tabs on the Side Support Assembly with the slots on the Left Side of the Revolution Assembly and secure with nineteen M4 x 16 Screws and Nuts ...

Page 95: ...ottom Brace into the corresponding slots in the Assembly and secure with six M4 x 16 Screws and Nuts 5j Insert the tabs of the GR15 Gantry Mid Brace into the corresponding slots in the Assembly and secure with six M4 x 16 Screws and Nuts ...

Page 96: ...95 Completed Left Side ...

Page 97: ...rt the tab of the GR14 Gantry Top Brace into the GR20R Gantry Mid Vertical Support and secure with one M4 x 16 Screw and Nut 6b Insert the tab of the Gantry Top Brace GR14 into the slot of the Gantry Mid Vertical Support GR21 and secure with one M4 x 16 Screw and Nut ...

Page 98: ...cal Assembly to the slots of the Right Side Assembly and secure with fourteen M4 x 16 Screws and Nuts 6d Align the tabs of the Gantry Front Vertical Support GR19R to the slots of the Gantry Right Side and secure with three M4 x 16 Screws and Nuts ...

Page 99: ...Brace GR16 into the slots of the attached vertical supports and secure with six M4 x 16 Screws and Nuts 6f Insert the Gantry Mid Brace GR15 into the slots of the attached vertical supports and secure with six M4 x 16 Screws and Nuts ...

Page 100: ...99 Completed Right Side ...

Page 101: ... 7 Attach A Axis Stepper Motor Support 7a Insert the tabs of the A Axis Stepper Motor Support GR3 into the Left Frame Assembly slots and secure with two M4 x 16 Screws and Nuts Left Side Rear View of Revolution ...

Page 102: ...101 7b Repeat for the remaining A Axis Stepper Motor Mount GR3 and secure with two M4 x 16 Screws and Nuts as shown Top and Bottom A Axis Stepper Motor Supports Installed ...

Page 103: ... remaining previously built Idler Bearing Assembly see pages 76 77 insert the Idler Bearing Assembly with an Idler Fender Washer into the A Axis Stepper Motor Mount GR2 install a Idler Fender Washer and secure with a M5 Lock Nut Washers on both sides of Motor Mount ...

Page 104: ...ead Screw through the hole below the Bearing as shown The idler should be able to slide within the slotted hole Hold the Socket head Screw in place and turn the Motor Mount over as shown to place a Bearing Fender Washer over the Screw ...

Page 105: ...t Tensioner GR10 as shown Secure the Belt Tensioner GR10 with a M6 Lock Nut The idler should be able to slide within the slotted hole Note The hex shaped hole in the Tensioner is designed to fit over the Idler Assembly Lock Nut ...

Page 106: ...105 8d Insert the 20 X 2 inch Screw as shown 8e Place the Spacer on the Screw and snug in place with a 20 Nut ...

Page 107: ...is Stepper Motor Mount Assembly with the tabs of the Stepper Motor Support and secure with four M4 x 16 Screws and Nuts Step 10 Insert the Dial Indicator L8 on the Front Left of the Frame Assembly and secure with one M4 x 16 Screw as shown ...

Page 108: ...ng After sliding the 12mm Shaft through the first Bearing the second Bearing can be rotated within its Block as needed to pass a shaft through two Bearings Step 11 Slide the 12mm Stainless Steel Shaft of the Chuck Assembly through the two mounted Pillow Block Bearings Inside View Outside View TIP T Inside View ...

Page 109: ...Chuck Assembly so there is a 1 16 gap between the Inner Chuck Plate and the Dial Indicator L8 and tighten the two Set Screws on each Pillow Block Bearing and the Set Screws on the Chuck Flange 1 16 gap Edge of Dial Indicator ...

Page 110: ...n the Plate so that it can move from end to end beneath the Base Frame NOTE The Nut Assembly is oriented toward the right end of the Base Position the Nut so that it rests on a Base Brace Step 14 Align the tabs of the Tail Stock Guide and the threaded shaft of the Screw into the Bottom Plate ...

Page 111: ...ositioned over the hex head of the 3 Screw The shim was lifted to hold the hex head down At the same time the Tail Stock Top Plate and Bottom Plate are gently squeezed together to enable the end of the bolt to engage the Nut while the Tail Stock Tensioner was turned in a clockwise direction to tighten the Nut ...

Page 112: ...ents GR6 X Rail Stop 2 GA1 21mm Pulley Gauge 1 L1 Belt Guard 1 Required Hardware Part Description Qty Photo H26 Small Zip Ties 30 H56 GT2 Open Loop Belt 1 H68 GT2 Closed Loop Belt 1 H52 Stress Proof Steel X Rail 2 H37 M3 x 10 Machine Screw 8 ...

Page 113: ...30 Machine Screw 5 H45 1 4 x 20 Wing Nut 1 H15 M4 Nut 4 H27 M2 5 x 16 Machine Screw 2 H43 M2 5 Lock Nut 2 CB13 Home Switch 1 CB12 Power Supply with cord 1 CB16 UNO Controller 1 H55 GT2 Pulley 2 CB11 Stepper Motor 2 ...

Page 114: ...ounce routine that ignores these spikes and only validates a signal if it is held for a few milliseconds The best way to minimize electrical interference is careful wire routing Please follow the wire routing instructions in the manual Step 1 Install the UNO Controller to the Controller Mount on the Gantry Assembly using four Zip Ties as shown NOTE when threading the Zip Ties through the attachmen...

Page 115: ...upper left corner of the Gantry Assembly as shown below Thread the Home Switch Wire through the access hole in the top of the Side Assembly across the interior of the Gantry and through the access hole in the top of the Gantry Back Brace Finish by routing the female end through the back of the Controller Mount and through the hole marked HS as shown ...

Page 116: ...connector to the X pin on the Arduino Controller as shown circled below Step 3 Attach the X Axis Home Switch to the underside in upper left corner of the Gantry Assembly as shown and secure with M2 5x10 Machine Screws and Lock Nuts ...

Page 117: ... Stepper Motors Make sure the legs of the Gauge are set flat on the Motor Housing as shown 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 the two Set Screws using Locktite 242 ...

Page 118: ...tepper Motor through the rectangular opening in the left end of the Gantry Assembly Make sure to the wires are oriented to the left side of the Motor toward the controller mount Secure the Motor in place with four M3x10 Machine Screws ...

Page 119: ... hole in the bottom of the Gantry Back Brace and through the X Slot in the Controller Support as shown Step 3 Connect the 4 pin Dupont connector to the X Driver on the Controller as shown Note All Stepper Motor connections to the Controller are made with the Blue Wire on top ...

Page 120: ...pening of the Left Side Assembly With the Belt Pulley protruding through the hole secure the Stepper Motor with four M3 x 10 Machine Screws Note The Stepper Motor is oriented so that the wires are at the top to make it easy to route the wires up through the Side Assembly ...

Page 121: ...s Stepper Motor wires up and through the Side Assembly and across the Gantry as shown Secure the A and X Axes Stepper Motor wires together with Zip Ties routing the A Axis wires through the hole in the bottom of the Gantry brace ...

Page 122: ... A opening in the Controller mount and connect the 4 pin Dupont Connector onto the pins of the A Axis Driver as shown Step 7 Secure the bundled wires together with Zip Ties every four inches and secure the bundled wires to the Gantry Assembly as shown ...

Page 123: ...h the top hole in the Left Side panel Carefully guide the X Rail through the Rail supports across the Gantry and into the top hole in the Right Side Panel Rotate each Rail as you guide them through each of the components This will help them to slide smoothly into place TIP T ...

Page 124: ...23 Step 2 Cut the GT2 Open Loop Belt to 56 1 2 inches Lay the Y Carriage Assembly on the Base Assembly and insert the ends of the X Axis Belt into the Belt Retainer making certain the Belt is not twisted ...

Page 125: ...d the X Carriage Assembly making sure the ends remain secure in the X Belt Retainer Then hang the upper Bearings of the X Carriage Assembly onto the upper X Rail as shown being careful to keep the Belt between the upper and lower Bearings ...

Page 126: ...125 With the Belt out of the way insert the lower X Rail through the Gantry Side through the lower Rail Supports over the top of the lower SG20U Bearings and across into the opposite Gantry Side ...

Page 127: ...f the Gantry Side using two M4 x 30 Machine Screws and Nuts for each side as shown 2c Loop the G2 Belt over the Idler Pulley at the right end of the Gantry as shown Make sure the Belt is not twisted and that the Belt teeth are oriented as shown ...

Page 128: ... Pulley as shown Make sure the teeth in the Belt engage the teeth of the Belt Pulley Step 3 Adjust the X Carriage Eccentric Spacers equally on both sides using the alignment marks to tighten Bearings against the Rail as shown Clockwise Counterclockwise ...

Page 129: ...mm socket and a Phillips Screwdriver tighten the Lock Nuts to secure the 4 Bearing positions Step 1 Installing the Makita RT0701C Router 1a Insert the Router into the Holder and with downward pressure gently twist the Router body until it is fully seated in place in the Holder ...

Page 130: ...irst align each Screw with one of the elongated access holes in the back of the Gantry Note To align the access hole with the Phillips head Screws it may be necessary to raise or lower the Z Carriage This can be done by manually rotating the Aluminum Coupler at the top of the Z Axis as shown ...

Page 131: ...130 1c With the Gantry and X Carriage aligned correctly tighten the four Screws in the Router Z Mount 1d Tighten the 2 M4 X 30 Machine Screws and Lock Nuts to clamp the lower Router Mount ...

Page 132: ...rriage and Gantry Use Zip Ties to secure the Router Power Cord as shown Be careful to route the Cord without putting stress on the stress relief as shown 1f Route the plug down and through the access hole on the right side of the Gantry Back Side as shown then through the side access hole ...

Page 133: ...X Carriage all the way to the right Allow enough slack in the cord so the X Carriage can travel from the right side of the Gantry to the left without binding as shown Cord length estimated from the right side Cord length estimated from the left side ...

Page 134: ...133 1h Connect the Z Axis Home Switch wire to the Z terminal 11 Connect the Z Axis Stepper Motor wire to the Z terminal ...

Page 135: ... Tighten the X Belt 2a Insert the M4 x 30 Machine Screw through the large hole in the X Rail Stop as shown Thread the Screw into the Nut of the Y Adjuster Assembly Verify that both ends of the belt are still completely inserted in the holder then tighten the Belt by turning the Screw clockwise ...

Page 136: ...Pulley to secure Belt Tensioner as shown Step 3 Installing and tightening the GT2 Closed Loop A Belt 3a Loop the belt around the Idler Pulley as shown 3b Loop the belt beneath the Idler bearing and over the top of the Chuck Pulley as shown ...

Page 137: ...136 3c Rotate the Chuck Assembly so that the Belt is surrounds the Pulley 3d Tighten the Belt by pushing the A Axis Belt Tensioner down which lowers the Idler Pulley down against the Belt as shown ...

Page 138: ...137 3e Use a Phillips screwdriver to tighten the Idler Pulley in place Step 4 Install the Belt Guard L1 and secure with x 20 Wingnut ...

Page 139: ...138 Step 5 Install the Power Supply on the end in the back right side of the Gantry and then lay it horizontally behind the Gantry Back Support as shown ...

Page 140: ...139 Step 5a Route the Power Cord through the lower hole in the Back Brace then behind the Controller Mount and through the PWR access hole ...

Page 141: ...terminal on the UNO Controller Insert the exposed end of the Red Wire into the side of the terminal and securely tighten in place Repeat to install the Black wire in the side of the terminal Finish by securing the power wire in place with Zip Ties ...

Page 142: ...141 Step 6 Route the USB Cord up and through the left Gantry side through the Gantry Assembly and connect it to the Uno Controller as shown ...

Page 143: ...142 Completed Views Front View Back View ...

Page 144: ...143 Left Side Right Side ...

Page 145: ...144 Properly Wired Controller ...

Page 146: ... a rotating axis is to ensure that the Router bit is perpendicular to the horizontal line that extends from the center of the Live Center though the center of the Chuck as illustrated below If the Spindle is not perpendicular the Revolution can be trammed on the X Axis by adjusting the four Eccentric Adjustment Spacers on the Z Carriage 90o ...

Page 147: ...spacers on the left side should be rotated clockwise so that the SG20U is snug up against the Rail Eccentric spacers on the right side should be rotated counterclockwise so that the SG20U is snug up against the Rail ...

Page 148: ... on the top will tilt the axis clockwise Placing the shim on the bottom will tilt the axis counterclockwise The shim placement is always on the top or bottom sets of the X Carriage and placed in between the SG20U and Bearing Fender Washer The center of the router bit must be aligned vertically to the point on the Live Center ...

Page 149: ...ave Completed the Assembly of Your Revolution Please review our Software Setup Guide for Software installation and setup and our Getting Started guide to help with your first project Revolution Manuals and Documentation BobsCNC ...

Page 150: ...evolution Firmware Values Key Value Description 0 10 step pulse usec 1 25 step idle delay msec 2 0 step port invert mask 00000000 3 0 dir port invert mask 00000000 4 0 step enable invert bool 5 1 limit pins invert bool 6 0 probe pin invert bool 10 1 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 boo...

Page 151: ... y step mm 102 400 z step mm 110 10000 x max rate mm min 111 10000 y max rate mm min 112 2000 z max rate mm min 120 500 X axis acceleration mm sec 2 121 500 Y axis acceleration mm sec 2 122 500 Z axis acceleration mm sec 2 130 610 X axis maximum travel millimeters 131 3600 A axis maximum travel millimeters 132 85 Z axis maximum travel millimeters ...

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