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BobsCNC KL744 Manual

Mechanical system
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K L 7 4 4
Mechanical System
MANUAL 5 of 8
Version 2.6
Page 1

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Summary of Contents for BobsCNC KL744

  • Page 1 K L 7 4 4 Mechanical System MANUAL 5 of 8 Version 2.6 Page 1...

  • Page 2: Table Of Contents

    Table of Contents Mechanical Systems Hardware ······································································ 3-4 Safety Information and Hints ········································································· 5 Installing the Static Bell Everman Belts ·························································· 6-9 Installing the X1 & X2 Servo Motors………………………………………………………….10-11 Installing the Y Servo Motor to the Y Carriage ··············································· 12-15 Installing the Z Servo Motor to the Ball Screw Assembly ···························...

  • Page 3: Mechanical Systems Hardware

    Mechanical System Hardware Components Part # Description Photo Tape (roll) T5 Timing Belt Roll (10M) 10-24 x 3/4 Hex Head Screws M5 Washer M5x30 Socket Head Bolt 5/16 x 1 1/4 Machine Screw 5/16 Lock Nuts Large Zip Ties 20’ Extension Cord DeWalt 611 Router Drag Chain 5/16 x 1 Hex Head Bolt...
  • Page 4 Part # Description Photo Adjustment Tool Vacuum Shoe Vacuum Shoe Retainer Page 4...

  • Page 5: Safety Information And Hints

    Safety Information and Hints. 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. Indicates a possible risk of injury that CAUTION can result from failure to follow this warning.

  • Page 6: Installing The Static Bell Everman Belts

    Installing the Static Bell Everman Belts The Bell Everman Drive system requires two belts on each axis, one Static the other Dynamic. The Static Belt is attached to the Belt Support. The Dynamic Belt is routed through the Bell Everman Drive. The teeth of the Dynamic Belt are meshed into the teeth of the Static Belt beneath the Idler Pulleys and driven by the Dynamic Belt as its teeth are...
  • Page 7 Expose 3 to 4 inches of 3M double sided tape. Beginning at Step 2 one end of the Belt Support, carefully position the tape. The edge of the tape must be placed along the outside edge as shown. The tape will be placed from one end to the other and cover the length of the Belt Support.
  • Page 8 Measure a length of belt approx. 1/8” shorter than Step 3 the Belt Support. Using snips, cut the belt to length. Clean any oil, dust and dirt from the back of the Step 4 belt with denatured alcohol and a lint-free rag. Page 8...
  • Page 9 Peel back a few inches of the paper protective layer Step 5 and carefully 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.

  • Page 10: Installing The X1 & X2 Servo Motors

    Installing the X1 and X2 Servo Motors Step 1 Thread the Servo Motor and Encoder Wires through the Left side of the Gantry as shown Step 2 Secure the Bell Everman assembly in place with four 1 1/4 Machine Screws and Lock Nuts as shown. Page 10...
  • 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 11...

  • Page 12: Installing The Y Servo Motor To The Y Carriage

    Installing the Y Servo Motor to the Y Carriage Step 1 Thread 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.
  • Page 13 Route the Servo Motor and Controller cable through Step 2 the back of the Y Carriage Assembly as shown. Page 13...
  • Page 14 After carefully pulling all the cables through the Step 3 Y Carriage, loop the excess wire and secure it with two zip ties. Hang it over the back of the Carriage Mount Top. Page 14...
  • 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. Front view Back view Page 15...

  • Page 16: Installing The Z Servo Motor To The Ball Screw Assembly

    Installing the Z Servo Motor to the Ball Screw Assembly Step 1 Align 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. Page 16...
  • Page 17 Tighten Spider Coupler to the shaft using an 2.5 mm Step 2 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 17...

  • Page 18: Installing The X1 & X2 Dynamic Bell Everman Belts

    Installing the X1 and X2 Dynamic Bell Everman Belts At the back left of the X1 axis, align and mesh the Step 1 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.
  • Page 19 Pull the Bell Everman Assembly up so that there is a gap Step 2 between the Idler Pulleys and the Static belt. Slip the Dynamic Belt beneath the two back Idler Step 3 Pulleys. Page 19...
  • Page 20 Step 4 Loop the Dynamic Belt over the Timing Pulley and 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.
  • Page 21 Trim the belt to length and secure with a X9 Belt Step 5 Holder and one 5/16 x 1 1/4 Machine Screw and Nut. Tighten the four screws holding the Bell Everman Assembly Step 6 in place, making certain the belts are meshed. Repeat above steps to install the X2 Dynamic Belt.

  • Page 22: Installing The Y Carriage On The Gantry

    Installing the Y Carriage on the Gantry Hang the two upper bearings on the upper Y rail on Step 1 the Gantry as shown. Upper Bearing hanging securely on upper rail. Page 22...
  • Page 23 Step 2 Raise the lower Bearings against 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: Installing The Y Bell Everman Dynamic Belt

    Installing the Y Bell Everman Dynamic Belt At the back left side of the Gantry, align and mesh Step 1 the ends of the Belts together. Secure with a G15 Belt Holder and one 5/16 x 1 1/4 Machine Screw and Lock Nut as shown.
  • Page 25 Loop the Belt over the Timing Pulley and under the two Step 3 front Idler Pulleys as shown. Remove excess slack from the Belt Pully and push Step 4 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.
  • Page 26 Trim the Belt to length. Step 5 Secure with a G15 Belt Holder and one 5/16 x 1 1/4 Step 6 Machine Screw and Nut. Page 26...

  • Page 27: Preparing The Drag Chain

    Preparing the Drag Chain. Lay out the Drag Chain on its side. Notice the end Step 1 cap of the end links. One end cap fits within the adjoining link. The other end cap fits around the outside of the adjoining link. This end cap snaps around the adjoining link This end cap snaps within...
  • 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 28...
  • Page 29 NOTE: Proper orientation of the Drag Chain ends. Page 29...

  • Page 30: Attaching The Cable Drag Chains

    Attaching the Cable Drag Chains Attach the Left Side Drag Chain to the G8 Drag Step 1 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 30...
  • Page 31 Attach the other end of the Drag Chain to the Step 2 X4 Drag Chain Support using two 10-24 x 3/4 Socket Head Bolts and M5 Washers as shown. Page 31...
  • Page 32 Attach the Y Axis Drag Chain to the Y1 Carriage Top Step 2 Mount and the G10 Gantry Top Support using four 10-24 x 3/4 Socket Head Bolts and M5 Washers as shown. Finished View Top Left Finished View from Front Page 32...

  • Page 33: Cable Routing Of The Servo Motor Wires/Cables

    Cable Routing of the Servo Motor Cables Preparing the Drag Chain for Wire Routing Slide the Gantry half way along the X axis as shown. Step 1 Step 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.
  • Page 34 Remove the upper tabs until you reach the bend Step 3 Page 34...
  • Page 35 Leave one tab on the front of the bend. Leave three tabs on the back of the bend. Page 35...
  • Page 36 Carefully label the Servo Motor and Encoder Cables Step 4 for each of the axes (X1, X2, Y, and Z). The Encoder Connector has five pins, the Servo Motor Connector has six. Tape the Cables of each axis pair together and label as shown.
  • Page 37 Route the left side X1 Servo Motor and Encoder Cables Step 5 through 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.
  • 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 38...
  • 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 39...
  • Page 40 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. Route the X2 Servo Motor and Encoder Cables up and through Step 6 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.
  • 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 41...
  • Page 42 Step 7 Gather all 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.
  • Page 43 Carefully 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 43...

  • Page 44: Preparing For The Home Switch Installation

    Preparing for the Home Switch Installation Keep the Home Switch cables separate WARNING from the Servo Motor and Encoder Cables as much as possible to minimize electronic interference (noise) which can adversely affect machine performance. 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: Installing The Z Home Switch

    Installing the Z Home Switch Slip the Z Home Switch threaded body through Home Switch Step 1 mount as shown. The hardware should be arranged: Upper Nut, Lock Washer, Plywood, Lock Washer, Lower Nut. Snug in Place the home switch so that the end of the barrel measures at least 1/2 inch from the Home Switch Mount surface.
  • 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 46...

  • Page 47: Installing The Y Home Switch

    Installing the Y Home Switch Step 1 Place the threaded body through the Y Home Switch Mounting 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.
  • Page 48 Finish by routing the Y Home Switch wire down Step 2 and through the Drag Chain. Page 48...

  • Page 49: Installing The X Home Switches

    Installing the X Home Switches Step 1 Install the threaded body of the X2 Home Switch into X2 Home Switch 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.
  • Page 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 50...
  • Page 51 Route the X2 Home Switch Wire up through the Left Step 4 Gantry Side into and through the Drag Chain as shown. Step 5 Follow the same process to install the X1 Home Switch Page 51...

  • Page 52: Securing, Trimming, And Managing The Excess Wire

    Securing, Trimming, and Managing the Excess Wires Step 1 Trim Home Switch Wires to the same length as the Servo Motor and Encoder Cables. Once trimmed, bundle the X1, X2, Y and Z Home Switch Wires together with Zip Ties placed 6 inches apart. Be careful to protect the connectors from damage.

  • Page 53: Tightening The Bell Everman Dynamic Belts

    Tightening the Bell Everman Dynamic Belts Do not overtighten the Dynamic belt. WARNING 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. Step 1 To tighten the Y belt, use a 1/2”...
  • Page 54 Step 2 Once the Belt has been tightened, then tighten the four Y Servo Motor mounting Screws as shown. Step 3 Loosen the 5/16” Hex Bolt so that it no longer touches the Y Servo Motor. Page 54...
  • 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 55...
  • Page 56 Step 5 Insert the Belt Tensioning Tool beneath the X1 Stepper Motor 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.
  • Page 57 Properly tightened belt with teeth fully engaged beneath the Idler Pulleys. Page 57...

  • Page 58: Attaching The Z Assembly

    Attaching the Z Assembly Step 1 Attach the Z Assembly by holding one side of the Bearings against the Rod and rotating the Assembly into position as shown. Step 2 Screw the 8-32 Inserts inward to push the Bearings snug up against the Rails as shown.
  • Page 59 Step 3 Slide the Z Assembly and align the four mounting holes with the Ball Screw Nut Housing. Step 4 Tighten the Z Assembly to the Ball Screw Nut Housing using four M5 X 30 Socket Head Screws with the M5 washers as shown. Page 59...

  • Page 60: Routing The Extension Cord And Attaching The Spindle

    Routing the Extension Cord and Attaching the Spindle Step 1 Route the Extension Cord through the Left Side Gantry Frame Assembly and Drag Chain. The female end of the Extension Cord should be positioned at the entrance of the Y Drag Chain as shown.
  • Page 61 Step 2 Insert the Spindle mid way through the mount and rotate as the cord is gently pulled through the access hole in the Z Assembly as shown. Gently turn the Router as you feed the strain relief and power cord through the access hole.
  • Page 62 Step 4 Plug the Router into the Extension Cord as shown. Page 62...

  • Page 63: Wire Management

    Wire Management Step 1 Re-install the Drag Chain Clips for Both Drag Chains. Be careful not to damage any of the Cables. Page 63...
  • 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 64...

  • Page 65: Assembling And Mounting The Vacuum Brush Shoe

    Assembling and Mounting the Vacuum Brush Shoe Install two 1/4-20 Inserts into the Shoe Plate as shown. Step 1 Using a slotted screw driver, insert the 2” Brush material Step 2 securely into the groove of the Shoe Plate until the brush completely surrounds the plate and trim to length.
  • Page 66 Thread a 1/4-20 Nut onto both Bolts until the bottom of Step 2 Nut is approximately 9/16” from the bottom of each Bolt. Then thread the Bolts Assembly into the Threaded Inserts as shown. 9/16” Insert the Brush Assembly around the Router body with Step 3 the Bolts fitting up and through the access holes in the Router Base Plate as shown.
  • Page 67 Lock the Brush Shoe Assembly in place by inserting the Step 4 Shoe Retainer as shown. Page 67...

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