Carbide 3D Shapeoko XXL Manual Download Page 105

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Remove the Base by pulling the black latch. This
will unlock the base and allow you to slide it off the
Compact Router by pulling it towards the end.

With the base removed, unscrew the plastic collar
with the dewalt logo. This is not required when
using on the Shapeoko XXL.

Summary of Contents for Shapeoko XXL

Page 1: ...ory Welcome and Congratulations You are now the proud owner of the Shapeoko XXL an incredibly powerful and easy to use CNC machine NOTE This is a note information that point out critical steps or refe...

Page 2: ...XL should arrive in a single box If you opted to include a compact router it will be shipped in a second box The primary shipping box has dimensions of 48 x 26 x 12 The box weighs approximately 149lbs...

Page 3: ...xes are held tightly in place by cardboard inserts rocking the boxes side to side can help release them from their insert holes Remove and place all the items in a location where they will not be drop...

Page 4: ...DF in a location where there is no risk of spilled liquids until you need them Once the shipping box is emptied you should have the following 9 items Item Quantity Description Other Info Package Dimen...

Page 5: ...e Right Y Axis Assembly Labeled E 1 X Z Assembly Contains X and Z axis carriages Labeled F 2 MDF Pieces Found Below cardboard divider 42 x 29 75 x 0 75 G 1 Aluminum Rails Packaged 3 to a bundle 40 x 7...

Page 6: ...d to verify you have all the hardware needed to complete your Shapeoko XXL PROTIP Your Shapeoko XXL has been carefully hand packed and checked for all the necessary components you ll need to assemble...

Page 7: ...bags may be inserted into larger plastic bags for shipping purposes You should find all of the following in this box Item Description A Baseplate Wasteboard Hardware 18 pieces M5x25mm BHCS B Spindle M...

Page 8: ...Keys 5 4 3 2 1 5mm Wrenches 13 10 8mm M Power Cord N Thread Locker non permanent O Sharpie Permanent Marker P Belting 3 pieces 1200mm Q 201 1 4 Square Endmill R Adjustable Leveling Feet S Extrusion H...

Page 9: ...ded X Z Assembly Box Open the box labeled X Z Assembly and visually verify that the items inside match the image below After verifying the X Z Assembly place it back in the box The box should contain...

Page 10: ...le differences that you need to pay attention to If you do not identify the correct rails you will have to undo work later The three aluminum rails are packed together each rail is wrapped in a cardbo...

Page 11: ...the cardboard from the three aluminum rails Examine the three rails and identify the following Rail with the Shapeoko logo is the X Axis Rail Rail with two 2x mounting holes is the Y LEFT Rail 1x Rai...

Page 12: ...shell and secured with plastic bands Carefully cut all plastic bands and remove the cardboard from the Cross Straps Examine the container and identify the following End Plates Box Dimensions 45 5 x 8...

Page 13: ...End Plates have inserted PEM nuts which are threaded These allow for the addition of threads in plates which otherwise would not be thick enough to have threads added and to do so without the manual o...

Page 14: ...verifying the MDF Baseplates store them where the risk of high humidity or liquids spilling on them is low MDF is sensitive to moisture so avoid having drinks or other liquids in the vicinity of the...

Page 15: ...peoko 3 have been included but a large table or workbench will be helpful during the assembly The completed dimensions of the Shapeoko 3 are 45 W x 40 1 2 L x 16 H so a table larger than this is recom...

Page 17: ...e Frame Assembly The base frame is the main sub structure of the machine Supporting the rail and the gantry system it is important that you follow each step in this section to ensure your machine base...

Page 18: ...ustable Leveling Feet 4 5 M5 x 25mm BHCS 18 Leveling Feet Carefully screw in the four leveling feet two per End Plate The feet will only fit in the outermost nuts on the bottom of the End Plates Turn...

Page 19: ...Cross Straps will be placed so the flanged edges are facing down Note that there are two threaded holes in the center of each Cross Strap Rear Baseplate Place one MDF Baseplate across the back half of...

Page 20: ...es of the Cross Straps that will be used for the second MDF Baseplate Insert 3x M5x25mm screws into the three countersunk holes as shown in the figure below Turn the screws until they stop but do not...

Page 21: ...he image below Place the MDF Baseplate so that the six countersunk holes on the long side are farthest away from the centers of the Cross Straps and the MDF Baseplate is flush with the edges of the Cr...

Page 22: ...d Plate Carefully lift the rear edge of the Cross Straps MDF Baseplate assembly and insert a single End Plate as shown in Figure X Note that the flange on the End Plate will go beneath the Cross Strap...

Page 23: ...and the End Plates Turn the screws until they stop but do tighten PROTIP Use one of the other hex keys to align the holes insert a spare hex key through the MDF baseplate and cross strap as shown in...

Page 24: ...embly and insert the remaining End Plate as shown in the image below Once again the flange on the End Plate will go beneath the Cross Straps and the six holes drilled into the End Plate will match up...

Page 25: ...stop but do not tighten NOTE As you begin to assemble the machine you should try to gradually bring the machine into square now is a good point to begin this If you have a level use it to ensure that...

Page 27: ...shown in the image below If you do not follow this step you will have to undo work later in the process 1 The extrusion labeled Holes has mounting holes for the Controller in its middle as shown in th...

Page 28: ...late as shown Preparing the Carriages Remove the three Carriages from their boxes Y Axis Right Assembly box Y Axis Left Assembly box X Z Assembly box and place them carefully on the MDF Baseplate The...

Page 29: ...below to keep them in their proper orientation with respect to the front of the Shapeoko However they can easily be distinguished by examining the side with the bearings the Y Axis Left Carriage has...

Page 30: ...rriage is the smaller of the two carriages shown in the image below Carefully remove the Z Carriage from its protective wrapping ensure that the belt is not damaged or removed from its initial install...

Page 31: ...ate shown in the image below Secure in place by finger tightening the nut on the opposite side of the X Carriage Once the idler assembly is through the slot loosely attach the nut on the backside of t...

Page 32: ...left or right is fine The fixed pulley location should be on the left side of the plate as shown in the photo For further reference the eccentric nuts will be on the left side as well NOTE If you wer...

Page 33: ...this point in the assembly Using some thread locker will help keep them secure and reduce the chance of vibration causing the screws to become loose Z Carriage Flip the Z Carriage and orient the Z Car...

Page 34: ...hown in the image below When aligning the carriages make sure the groove in the V wheel is aligned with V rail on the X carriage The wheels will slide up the V seating evenly and securely on both side...

Page 35: ...Carriage is attached to the rails properly a portion of the belt should be exiting the top and bottom of the Z Carriage as shown in the image below Slowly pull the bottom portion of the belt and loop...

Page 36: ...wn in its groove You may have to loosen the nut to move the Idler Carefully wrap the upper portion of the belt around the top pulley as shown NOTE If you had to loosen the Idler nut to move it move th...

Page 37: ...w Carefully place the X Z Carriage on its back resting on the motor as shown in the image below Slide the Z Carriage all the way to the top until it stops at the two posts shown in the image below Ens...

Page 38: ...ough that it doesn t slip off the Idler and does not flex as the carriage moves up and down When the belt is tight use a 4mm hex key and 10mm wrench to tighten the Idler Assembly as shown in the image...

Page 39: ...mage below Turn the X Z Carriage on its other side and attach the second spring in identical manner as shown in the image below Using the 2x M5x55mm screws install into spindle mount Do not tighten at...

Page 40: ...tton head cap screws You will also need the 4mm hex key The X axis Extrusion Rail is the one with the Shapeoko sticker label attached to it Examine this rail and note it has two distinct sides The V R...

Page 41: ...Left Carriage must be bolted to the X Axis Extrusion Rail with the bearings facing outward or to the left and the motor pointing in or to the right as shown in the photo below Before bolting on the Y...

Page 42: ...ge to the X Axis Extrusion Rail with four 4x M6x12mm bolts as shown in the image below Be careful not to cross thread the bolts Note that the motor will be behind the X Axis Rail when the Y Axis Left...

Page 43: ...Extrusion Rail as shown in the image below Use the empty carriage boxes to support the rail and be careful not to let the X Z Carriage slide into the Y Axis Left Carriage Aligning the V wheels on the...

Page 44: ...ans the Y Axis Right Carriage must be bolted to the X Axis Extrusion Rail with the bearings facing outward or to the right and the motor pointing in or to the left as shown in the image below Before b...

Page 45: ...l not to cross thread the bolts Note that the motor will be behind the X Axis Rail when the Y Axis Right Carriage is properly attached There is no need to tighten the bolts completely Later in the ins...

Page 47: ...s helpful to have another set of hands The gantry system is large heavy and awkward for a single person to handle Install Left Y Rail Carefully insert the V shaped edge of the Left Extrusion Rail thro...

Page 48: ...the image below Position Assembly Move the assembly so the left Y Rail is sitting between the front and rear plates as shown in the image below PROTIP If you are having trouble sliding the rails in be...

Page 49: ...the image below Securing the Left Y Rail You will initially use only two 2x M6x12mm screws to attach the Left Extrusion Rail Lifting the rail to align at least one hole from the extrusion to the fron...

Page 50: ...give us a pivot point to help rotate the right rail into place Securing the Right Y Rail Move to the right side of the assembly Using the foam blocks from the Y Left and Y Right carriages support the...

Page 51: ...rews to attach the Right Extrusion Rail Insert 1 screw into the front plate and one screw into the back plate Only finger thread the M6x12mm screws and do not tighten down completely leave a small gap...

Page 52: ...S to completley secure the rails to the baseframe Do this by installing 3 additional screws into each end of the end plates Each extrusion should be secured with 4 screws at each end Do not completely...

Page 54: ...the three belts from their bag Note that the three belts are of identical length For all three belt installations the following process will be followed 1 One end of each belt will be inserted into a...

Page 55: ...nd lower sections of belt are interlocked as shown in Step 3 NOTE The free end of the belt the end not looped through a belt clip will be routed through the carriages and then secured using another be...

Page 56: ...hould be attached to the carriage as shown in the image below Run the belt teeth down along the X Axis Extrusion Rail to the Y Axis Right Carriage You will need to carefully feed the belt underneath t...

Page 57: ...acing down Use your fingers on both sides of the flanged bearings to feed a portion of the belt up through the flanged bearings as shown in the image below Push evenly and at the same rate on the belt...

Page 58: ...th the 1 5mm hex wrench as shown in the image below and pull the loop up and over the X Axis Motor Pulley Ensure that the belt has not twisted and that the teeth are facing down as the belt is placed...

Page 59: ...the bottom portion of the belt pull through enough so that a 6mm gap exists between the Y Axis Right Carriage and the belt clip as shown in the image below Insert a M5x10mm screw through the Y Axis Ri...

Page 60: ...not over tighten as this could bend and damage the X Axis Motor Pulley Left Y Axis Rail Belt Installation Insert one end of a belt through the belt clip as described above Ensure that the bottom 2 por...

Page 61: ...mm hex wrench feed a portion of the belt up through the flanged bearings as shown in the image below Teeth Facing Down Pull enough belt to be fed over the Y Axis Left Carriage Idler as shown in the im...

Page 62: ...between the left rear End Plate and the belt clip as shown in the image below Right Y Axis Rail Belt Installation PROTIP This is the same process used to install the Y Left Belt Insert one end of the...

Page 63: ...in the image below Using your fingers or the 1 5mm hex wrench feed a portion of the belt up through the flanged bearings as shown in the image below Pull enough belt to be fed over the Y Axis Right Ca...

Page 64: ...of the belt pull through enough so that a gap exists between the right rear End Plate and the belt clip Insert a M5x10mm screw through the End Plate and into the belt clip and tighten down Previous S...

Page 66: ...The Drag Chains come with all wiring pre installed Be careful to not pull on the exposed wiring or allow one of the wire end plugs to be pulled or crushed This step of the assembly process involves at...

Page 67: ...el L shaped brackets Remove the protective film from bracket as shown in the photo below The underside of the film is black the top side is a white silver color Pick one corner of the film up and pull...

Page 68: ...side The screws only need to be loosened enough to slip the bracket between the screw heads and the plate Because thread lock is used at the factory to secure the connection using a pair of pliers not...

Page 69: ...er screws holding the motor to accommodate all three sizes of Shapeoko machines The longer M5x16mm screws for the XXL are needed to attach the remaining Drag Chain Bracket The M5x16mm screws can be fo...

Page 70: ...protruding through the back of the plate in the image below Note that nuts have not been added yet With the two 2x M5x16mm screws in place take the remaining Drag Chain Bracket and remove its protecti...

Page 71: ...the Drag Chain Bracket as shown below and secure tightly with two 2x M5 nuts using the 8mm wrench NOTE The Drag Chain Bracket is mounted with the nuts beneath the longer section of the bracket not ab...

Page 72: ...th the 2 tapped holes in the center and facing left Using the M6 hex key remove the cover from the Controller by unscrewing the two 2x M8 head cap screws found on either side of the cover Inside is th...

Page 73: ...ach the Controller Board to the Left Y Axis Rail by inserting the screws into the countersunk holes drilled in the aluminum plate and threading them into the rail Loosely re install the cover of the c...

Page 74: ...ed correctly and the Drag Chains are spaced the correct distance apart You only need to attach the Wiring Harness to the Shapeoko XXL and then connect the various wires to their respective ports on th...

Page 75: ...t locations Do not connect the wires to the Controller Board at this time Attach the Y Axis Drag Chain Use two 2x M3x12mm flathead screws and two 2x M3 nylon nuts to attach the Drag Chain to the Y Axi...

Page 76: ...g two 2x M3x12mm flathead screws and two 2x M3 nylon nuts attach the Drag Chain to the X Axis Drag Chain Bracket as shown below The screws are inserted down through the head of the Drag Chain and thro...

Page 77: ...and the remaining steps of the installation much easier The free ends of the two Drag Chains will be secured to the rails later in the assembly Installing the Limit Switches With all of the wires con...

Page 78: ...nent locations on the machine Z Axis Limit Switch Attach the Z Axis Limit Switch by locating the larger plate from the end of the harness and connecting to the front of the X Z assembly This plate is...

Page 79: ...om the front of the Shapeoko XXL before securing to the standoffs You can identify the location of the switch by looking for the small hex nut on the outside of the plate NOTE Depending on how your ha...

Page 80: ...below the Z Axis Motor Switch Look at the photo below for the proper way to route the cable In the photo below it is the yellow and black cable X Axis Limit Switch Using two 2x M5x35mm socket head ca...

Page 81: ...n the photo above The switch is mounted to the outside of the plate the screws go through the plate then spacers on the opposite side The screws will attach directly to the integrated nuts on the back...

Page 82: ...carriage reaches the rear End Plate Complete the installation by tightening the screws into the integrated threaded holes When tightening the screws insure the plate stays roughly perpendicular to the...

Page 83: ...itches please refer to the Homing Switch Troubleshooting article for help Homing Switch Troubleshooting Motor Extensions Each cable in the Wiring Harness has been labeled with its proper connection Th...

Page 84: ...he X and Z motors on the rear of the gantry will be connected first Leave their wire leads wrapped as you found them in the package we will not need the extra length for this installation The Z Axis i...

Page 85: ...he Y2 motor is mounted on the RIGHT Y Axis Carriage when viewed from front This cable will stretch of the way across the back of the gantry and connect to the Right Y Axis Carriage motor as shown belo...

Page 86: ...assembly section The Y1 motor is mounted to the Left Y Axis Carriage when viewed from front Connect the wires as shown in the image below Route the wires cables through the first port on the bottom t...

Page 87: ...tensions individually through the hole They will fit but need to be routed through carefully at the center of the hole Do not attempt to insert two or more extensions at the same time Connecting the L...

Page 88: ...twisted wires should be plugged in first followed by the Y Axis Limit Switch wires and then the Z Axis Limit Switch wires Four metal posts will remain as shown in the image below Connecting the Steppe...

Page 89: ...f the Controller Board The labels are directly beneath each of the four ports From left to right the motors should be attached in the following order Z Y1 Y2 X Previous Step Back to Index Next Step Be...

Page 91: ...hain Align the free end of the Y Axis Drag Chain approximately 1 behind towards the rear of the machine the Controller Box as shown in the photo below Use one of the provided alcohol wipes to clean th...

Page 92: ...squares to secure the free end of the Drag Chain Peel one side of the tape away and press it firmly on the rail where the Drag Chain will rest as shown in the image below Peel off the upper side of th...

Page 93: ...sing the same method to secure the Y Axis Drag Chain clean the X Axis Rail with the alcohol wipe allowing to dry if alcohol is still present Apply the VHB tape keeping the upper side of the protective...

Page 94: ...es to reduce clutter Start by pressing all of the wires that cross over the left Y Axis Carriage down through the cutout as shown in the photo below Insert the limit switch cables black and yellow fir...

Page 95: ...free from the cutout Secure X Z Wires The bundle of wires on the back of the X Z Assembly can be secured to the back of the X Axis Motor using one of the self adhesive tie downs provided in the kit Y...

Page 96: ...Securing Gantry Wires Moving across the back of the gantry secure four self adhesive zip tie mounts to the rails in the positions shown in the image below...

Page 97: ...r 4 14 26 36 Using the image above as a reference zip tie all of the cables at each of the locations shown above Trim down each of the zip tie ends with a pair of flush cut pliers Be careful not to cu...

Page 98: ...Peel and apply the warning decal to the right side of the X Axis rail as shown PROTIP Make certain that you record your Shapeoko XXL s serial number in a secure location...

Page 100: ...low you will find the installation steps for both these options NOTE For other spindle options and more information about the spindle mount see the support page Makita Trim Router Carefully remove the...

Page 101: ...Trimmer Base by releasing the black latch This will unlock the Trimmer Base and allow you to slide it off the Compact Router Install the removable bushing into the spindle mount as shown in the follo...

Page 102: ...alled into the spindle mount insert the Router into the Spindle Mount by pushing the Z axis carriage DOWN until it has reached the bottom of its travel This will provide enough clearance to install th...

Page 103: ...he top of the body just below where it begins to taper is touching the top of the bushing Slowly raise the Z axis to its full upright position Fully secure the router into the mount by tightening the...

Page 104: ...t Trim Router The spindle mount is designed for the 69mm body of the Dewalt so no bushing is required for a proper fit Carefully remove the Dewalt Compact Router from its packaging You will only need...

Page 105: ...k latch This will unlock the base and allow you to slide it off the Compact Router by pulling it towards the end With the base removed unscrew the plastic collar with the dewalt logo This is not requi...

Page 106: ...ING Be careful not to let go of the Z axis carriage when you are pushing it down to install the spindle The carriage is spring loaded and if released with slam violently against the end posts Although...

Page 107: ...Slowly raise and then release the Z axis carriage With the spindle in the full up position fully tighten the M5x55mm screws into the spindle mount as shown in the image below...

Page 108: ...er cord until it reaches the top left standoff of the Z axis limit switch plate The Compact Router power cable will be routed to the right side of the Shapeoko XXL away from the Controller Box To do t...

Page 109: ...Use the adhesive tie down on the back of the X Axis motor to secure the power cord Route the power cable back to the right side of the Shapeoko XXL and through the slot in the Y Right carriage...

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