1. Manuals
  2. Brands
  3. BobsCNC Manuals
  4. Wood Router
  5. REVOLUTION 642
  6. Assembly manual

BobsCNC REVOLUTION 642 Assembly Manual

Rotating axis cnc router
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
REVOLUTION
642
Rotating Axis CNC Router
Assembly Manual
Rev. 1.23

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the REVOLUTION 642 and is the answer not in the manual?

Questions and answers

Related Manuals for BobsCNC REVOLUTION 642

Summary of Contents for BobsCNC REVOLUTION 642

  • Page 1 REVOLUTION Rotating Axis CNC Router Assembly Manual Rev. 1.23...
  • Page 2 Welcome to the Family! We’re excited that you purchased the new Revolution 642 CNC Router Kit from BobsCNC. This manual was written to give you step-by-step instructions to ensure your success in assembling the Revolution CNC Router and provides all the information you need to get your machine up and running.

  • Page 3: Table Of Contents

    Contents REVOLUTION Specifications ........................5 Information/Warning Boxes ........................6 Safety Precautions and Warnings ......................7 Getting Started ............................8 Required Tools: ....................................8 To Operate the REVOLUTION Rotating Axis Router, you will need: ................8 Assembly Recommendations: ........................9 Z Spindle Mount Assembly: ........................10 Required Wood Components ..............................
  • Page 4 Illustrated Step by Step Instructions ............................. 60 Base Assembly: ............................69 Required Wood Components ..............................69 Required Hardware .................................. 70 Illustrated Step by Step Instructions ............................. 71 Gantry Assembly ............................. 77 Required Wood Components ..............................77 Required Hardware .................................. 77 Illustrated Step by Step Instructions .............................
  • Page 5 Machine Set-Up ............................. 156 Wood Components (Included with Kit) ..........................156 Congratulations! ............................ 163 Appendix ..............................164 Revolution 642 Washer Dimensions ............................. 164 Revolution 642 Firmware Values ............................164...

  • Page 6: Revolution Specifications

    REVOLUTION Specifications Laser cut 6mm Baltic Birch Frame components. Fully Engineered Frame with rigid Box and Beam Gantry. Fully supported 5/16-inch stress proof steel Rails with SG20U Bearings. GT2 Belt Drive on X and A axes. Chuck Mounting Plate 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.

  • Page 7: Information/Warning Boxes

    Safety must be your First Priority. Always wear proper protective equipment and use "safety sense" when assembling and operating your Revolution CNC Router. Information/Warning Boxes CAUTION Indicates a possible risk of injury that can result from failure to follow this instruction WARNING Indicates the possible damage to...

  • Page 8: Safety Precautions And Warnings

    Safety Precautions and Warnings The Revolution Rotating Axis CNC Router has a 110vac Power Supply and uses bits that spin up to 30,000 rpm with cutting edges that are sharp and hazardous. The operator must understand the potential hazards and is responsible for taking appropriate safety precautions before operating the Router.

  • Page 9: Getting Started

    Getting Started Required Tools: A pair of long nose pliers and/or forceps. Diagonal Cutters or sharp knife to trim nylon ties. Calipers or measuring tape to measure part placement. Small standard screwdriver to connect electronics. Phillips screwdrivers to mount Home Switches and Stepper Motors. 220 grit sandpaper to remove laser marks on wood pieces (if desired).

  • Page 10: Assembly Recommendations

    Assembly Recommendations: Use a large, flat, clean work surface for assembling your REVOLUTION 642. All Screws (unless noted) should be installed snug, then rotated 1-2 ½ turns. Apply LOCTITE 242 to all M4 Machine Screws that are used to secure ™...

  • Page 11: Z Spindle Mount Assembly

    Z Spindle Mount Assembly: Required Wood Components Part # Description Qty Photo Back Frame Side Support Top Brace Top Spindle Mount Inner Spindle Mount Mid Spindle Mount...

  • Page 12: Required Hardware

    Outer Spindle Mount Required Hardware Part # Description Qty Photo M6 x 35 Machine Screws M6 Locknuts Eccentric Spacer Eccentric Washer Bearing Fender Washer SG20U Bearing ZD12 ACME Nut Assembly M5 X18 Machine Screw M5 Lock Nut...
  • Page 13 M4 x 16 Machine Screw M4 Nut M5 x 30 Machine Screw M5 Square Nut Idler Fender Washer M4 x 35 Machine Screw M4 lock Nut...
  • Page 14 Step Instructions Illustrated Step by Step 1 Building SG20U Bearing Assemblies. NOTE: the Bearing Assembly Order: M6 x 35 Machine Screw (H95), SG20U Bearing(H44) with hub facing toward the Bearing Fender Washer, Bearing Fender Washer (H42), Eccentric Washer (H41), Eccentric Spacer (H40), M6 Locknut (H18).
  • Page 15 Step 1a Insert the Bearing Assemblies through the mounting holes in the Back Frame (QZ1) with the Bearing Fender Washer (H42) against the wood and the Hub against the Bearing Fender Washer as shown below. Step 1b Slide the Eccentric Washer (H41) over the Eccentric Spacer (H40), inserting the shaft of the M6 x 35 Machine Screw (H95) through the Eccentric Spacer as shown.
  • Page 16 Step 1c Secure the Bearing Assembly in place with an M6 Lock Nut (H18) on each of the four Assemblies.
  • Page 17 Step 2 Building the Router Mount. Step 2a Slide the two Idler Fender Washers (H50) onto the M5 x 30 Machine Screw (H48) and secure with the M5 Square Nut (H93). Step 2b Place the Screw, Nut and Washer Assembly into the Inner Spindle Mount (QZ5).
  • Page 18 Step 2c Position the Mid Spindle Mount (QZ6) over the Inner Spindle Mount (QZ5), the Screw, Nut and Washer Assembly as shown. Step 2d Making sure the Screw, Nut and Washer Assembly stay in place, carefully turn the Spindle Mount Assembly over and cover with the second Mid Spindle Mount (QZ6) as shown.
  • Page 19 Step 2e Position the two Outer Spindle Mounts (QZ7) on the top and bottom of the Router Mount Assembly. Step 2f While holding the Assembly stack together, insert two M4 x 35 Machine Screws (H85) through the bottom of the Assembly and secure with two M4 Lock Nuts (H47) as shown.
  • Page 20 Adjustment Slot The Assembly stack can be oriented so that the slot for securing the Router is located on either the left or right side with the curved front corners facing you. Step 2g Align the tabs of the stack with the slots in the Back Plate Assembly and secure with four M4 x16 Machine Screws and Nuts.
  • Page 21 Step 2h Align the tabs of the Top Spindle Mount (QZ4) with the slots in the Back Plate Assembly and secure with two M4 x 16 Machine Screws and Nuts as shown.
  • Page 22 Step 2i Align the tabs of the Top Brace (QZ3) with the slots in the Back Plate Assembly and secure with two M4 x 16 Machine Screws and Nuts as shown. Step 2j Align the tabs of the Router Mount Assembly with the slots in the Side Support (QZ2) and secure with six M4 x 16 Machine Screws and Nuts.
  • Page 23 Step 2k Prepare the ACME Nut Assembly (ZD12) by inserting two M5 Lock Nuts (H49) in the ACME Block. Note: Make sure the nylon washer at the top of the Lock Nut is visible after inserting as shown. Step 2l Insert two M5 x 18 Machine Screws (H97) through the Router Mount Assembly as shown and secure the ACME Nut Assembly in place as shown.
  • Page 24 NOTE: The slot in the ACME Nut must be oriented on the bottom as shown. Left Side Right Side...

  • Page 25: Belt Drive

    Belt Drive Wood Components (Included with Kit) Part # Description Qty Photo X Stepper Motor Mount Required Hardware Part # Description Qty Photo Flanged Bearing F635Z M5 x 30 Machine Screw M5 Lock Nut Idler Fender Washer Small Black Washer GT2 Pulley Long M3 x 10...
  • Page 26 CB11 Stepper Motor NOTE: There are two different size GT2 Pullies, Long and Short. The long Pulley is used for the X-Axis Drive.

  • Page 27: Illustrated Step By Step Instructions

    Illustrated Step by Step Instructions Step 1 Preparing the X Stepper Motor for Mounting Step 1a Align one of the Set Screws of the GT2 Long Pulley (H84) to the flat surface of the Stepper Motor Shaft. Snug the Set Screw so that it engages the shaft but still allows the Drive Pulley to slide down the shaft.
  • Page 28 Step 1b Use an Idler Fender Washer (H50) as a shim and gently slide the Long Drive Pully down to the surface of the Washer. Fully tighten the Set Screw against the flat. Tighten the second Set Screw. Remove the Idler Fender Washer. The gap between the bottom of the Long Drive Pulley and the Stepper Motor housing will be...
  • Page 29 Step 2 Building and Mounting the Idlers Step 2a Build two Idler Bearing Assemblies using one M5 x 30 Machine Screw (H48), two Flanged Bearings (H86), two Small Black Washers (H89) and two Idler Fender Washers (H50) in the sequence shown below. Be sure the head of the Machine Screw fits against the Bearing flange and the other is mounted so that both flanges are oriented as...
  • Page 30 NOTE: There must be two Fender Idler Washers on the Bearing side.
  • Page 31 Step 2c Align the mounting holes of the Stepper Motor with holes in the Stepper Motor Assemblies. Secure the Stepper Motor to the Stepper Motor Mount with four M3 x 10 Machine Screws (H37) with M3 Washer(H88). Verify the Alignment of the Drive Pulley and the Bearing as shown.

  • Page 32: Carriage Assembly And Z Assembly

    X Carriage Assembly and Z Assembly Required Wood Components Part # Description Photo Z Stepper Motor Mount Carriage Top Support Bearing Retainer Plate Carriage Frame Carriage Side Support...

  • Page 33: Required Hardware

    Z Rail Stop Carriage Bottom Support Outer Rail Support Required Hardware Part # Description Qty Photo M6 x 35 Machine Screws M6 Locknuts Eccentric Spacer Eccentric Washer Bearing Fender Washer SG20U Bearing Bearing Retainer Washer M4 x 20...
  • Page 34 M4 Lock Nut CB11 Stepper Motor M3 x 10 Machine Screw M3 washer Aluminum Helical Coupler 626-2RS Bearing 6mm Split Locking Collar ACME Screw 1/4 Shim Washer M4 Nut M4 x 16 Machine Screw...

  • Page 35: Illustrated Step By Step Instructions

    Stress Proof Steel Z-Rail Home Switch CB19 M2.5 x 16 Machine Screw M2.5 Lock Illustrated Step by Step Instructions...
  • Page 36 Step 1 Installing the Upper and Lower Bearings Mounting Holes for Upper Bearings Step 1a Mounting Holes for Lower Bearings Step 1a Install the two Upper SG20U Bearing Assemblies for the Carriage Frame (XR4). The assembly order for the Upper Bearing: M6 x 35 Machine Screw (H95), SG20U Bearing(H44) with hub facing toward the Bearing Washer, Bearing Fender Washer (H42), Plywood, Bearing Fender...
  • Page 37 Step 1b Install the two lower SG20U Bearings for the X Carriage Assembly as shown. The assembly order for the Lower Bearings: M6 x 35 Machine Screw (H95), SG20U Bearing (H44) hub facing toward the Bearing Fender Washer, Bearing Fender Washer (H42), Plywood, Eccentric Washer (H41), Eccentric Spacer (H40) secured with a M6 Lock Nut (H18).
  • Page 38 Step 2 Building the X Carriage Assembly Step 2a With the Bearings facing down, align the tabs of the Carriage Bottom Support (XR7) with the slots at the bottom of the Carriage Assembly and secure with two M4 x 16 Machine Screws and Nuts. Step 2b Align the tabs of the Outer Rail Support (XR8) with the slots located below the opening in the X...
  • Page 39 Step 2c Align the tabs of the remaining Outer Rail Support (XR8) with the next set of slots above in the X Carriage Assembly and secure with three M4 x 16 Machine Screws and Nuts. Step 2d Slide the narrow tongue of the Carriage Top Support (XR2) through the long narrow slot at the top of the X Carriage Assembly as shown.
  • Page 40 Step 2e Carefully thread the Dupont Connector of the X Stepper Motor wires through the upper Outer Rail Support, as shown.
  • Page 41 Step 2f Align the tabs of the X Stepper Motor Assembly with the corresponding slots in the Carriage Frame Assembly and set in place. Thread the wire through the X Carriage Top Support.
  • Page 42 Step 2G Align the tabs and slots of the Carriage Side Support (XR5) with the X Carriage Frame Assembly and secure with eight M4 x 16 Machine Screws and Nuts. Repeat, attaching the other Carriage Side Support. Step 2H Attach the Z Rail Stop (XR6) to the bottom of the X Carriage Frame Assembly and secure with two M4 x 20 Machine Screws (H98) and Lock Nuts (H47).
  • Page 43 Step 3 Attach the Z Frame Assembly to the X Carriage Frame Assembly This closeup view shows the Locknut tightened against the Eccentic Spacer. Note the space between the faces of the locknut and those of the Eccentric Spacer. This will indicate the position of the SG20U Bearing and the Rail.
  • Page 44 Step 3a With the Locknut firmly snugged against the face of the Eccentric Spacer, use a 13mm socket to turn just the Eccentric Spacer as shown. IMPORTANT Make sure the points on the wide edge of the Eccentric Spacers of the upper bearings pointing down and the...
  • Page 45 Step 3b Carefully set the Z Carriage Frame onto the X Carriage Assembly as shown.
  • Page 46 Step 3c Carefully slide the Z Rail (H54) through the hole in Carriage Top Support (XR2), through both Outer Rail Supports (XR8) until it is seated at the bottom of the X Carriage Assembly. Top View Bottom View...
  • Page 47 Step 4 Installing the Acme Screw. Step 4a Thread the Acme Rod Assembly through the hole located at the front of the Carriage Top Support (XR2) and into the Acme Nut. Rotate the Acme Screw through the Acme Nut until the bearing touches the Carriage Top Support.
  • Page 48 Step 4b Place the Bearing Retainer Plate (XR3) over the ACME Screw Assembly and secure with three M4 x 20 (H98) Machine Screws and Bearing Retainer Washers (H57), and M4 Locknuts (H47). The Bearing Retainer Plate (XR3) is designed so that the Bearing Retainer Washers cover the Bearing race to hold it in place.
  • Page 49 Step 5 Fasten the Z Axis Stepper Motor to the Carriage Top Support (XR2) using four M3 X 10 Machine Screws (H37) and Washers(H88). Step 6 Installing the Z Home Switch. Step 6a Align the Home Switch Arm pointing down as shown.
  • Page 50 Step 7 Attaching the Carriage Top Support (XR2). Step 7a While aligning the tabs of the Carriage Frame Assembly with the slots in the Z Stepper Motor Mount, make sure that the flat of the Stepper Motor shaft lines up with a Set Screw in the Helical Coupler.

  • Page 51: Chuck Assembly

    Chuck Assembly: Required Wood Components Inner Chuck Plate Outer Chuck Plate Chuck Pulley Plate...

  • Page 52: Required Hardware

    Required Hardware M4 Lock Nut M4x16 Machine Screw 12mm Chuck Shaft 12mm Chuck Flange M6 x 35 Machine Screws M6 Nut 1/4 Shim Washer...

  • Page 53: Illustrated Step By Step Instructions

    Illustrated Step by Step Instructions Step 1 Attach the 12mm Chuck Flange(H70) to the Inner Chuck Plate (L4) using four M4 x 16 Screws with Locking Nuts. NOTE: Before attaching the Flange, insert the two Set Screws in the Flange body.
  • Page 54 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. Back View Front View Step 2 Insert the 12mm Chuck Shaft(H71) through the Chuck Plate Flange as shown below.
  • Page 55 Step 3 Insert four M6 x 35 Machine Screws(H95) through the Chuck Plate as shown. Cover the Screw heads with Painter’s Tape to temporarily hold them in place. Step 4 Slide a Shim Washer(H66) over each of the four threaded bolts.
  • Page 56 Step 5 Align the Chuck Pully Plate(L3) over each of the four threaded bolts and center shaft and slide in place. Step 6 Install a Shim Washer over each of the four threaded Screws.
  • Page 57 Step 7 Align the Outer Chuck Plate(L2) slide over the Screws and 12mm Chuck Shaft. Secure assembly with four M6 Nuts(H60) and tighten.
  • Page 58 Step 8 Temporarily slide a Chuck Face Plate (L4) over the completed Assembly. With the plate resting on the ends of the exposed Screws, slide the shaft back through the Chuck Flange until the end of the shaft is flush with the surface of the Workpiece Attachment.

  • Page 59: Tail Stock Assembly

    Tail Stock Assembly: Required Wood Components Tail Stock Side Plate Tail Stock Top Plate Tail Stock Bottom Plate Tail Stock Top Brace Tail Stock Bottom Brace Tail Stock Guide Tail Stock Tensioner Tail Stock Retainer...

  • Page 60: Required Hardware

    Required Hardware Part # Description Photo 5/16 x 3 Hex Cap Screw 5/16 Nut M4 x 16 Machine Screw M4 Nut 12mm Pillow Block Bearing 12mm Live Center M6x20 Socket-head Screw M6 Locknut M4 Lock Nut...

  • Page 61: Illustrated Step By Step Instructions

    Illustrated Step by Step Instructions Step 1 Securely set a 5/16 Nut in the hex shaped hole in the Tail Stock Nut Retainer (TS8). It will be necessary to use a hammer, 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...
  • Page 62 Step 3 Attach a Pillow Block Bearing to the Tail Stock Side Plate (TS1). A Pillow Block Bearing is designed to allow the bearing to swivel within 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.
  • Page 63 Holding the 12 mm Pillow Block Bearing in place turn the Tail Stock Side Plate over and insert the Socket-head Screws so that the Screw head rests against the wood. Do not tighten completely until the live center is in place.
  • Page 64 Step 5 Build the Tail Stock Tensioning Assembly 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 65 Insert the tab of Tail Stock Bottom Brace (TS5) into the slot in the Tail Stock Assembly. 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 66 Insert the 5/16 x 3” Hex Cap Screw into the hex shaped hole. 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.
  • Page 67 Align the tabs with the slots in the second Tail Stock Side Plate Assembly and secure them together with four M4 x 16 Screws and Nuts. Rotate the Tail Stock Assembly to align the tabs of the Tail Stock guides with the slots of the Tail Stock Top Plate (TS2).
  • Page 68 Place the Tail Stock Guides through the Tail Stock Bottom Plate Assembly and insert 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.
  • Page 69 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 70: Base Assembly

    Base Assembly: Required Wood Components Part Descripti Photo Base Frame Base Tail Stock Guide Front Base Support Rear Base Support Base Brace Base Corner Bracket...

  • Page 71: Required Hardware

    Back Brace Side Brace Required Hardware Part # Description Photo M4 x 30 Machine Screws M4 x 16 Screws M4 Nuts...

  • Page 72: Illustrated Step By Step Instructions

    Illustrated Step by Step Instructions Step 1 Lay the Base Tail Stock Guide (BA2) on the Base Frame (BA1) as shown.
  • Page 73 Step 2 Holding the two pieces together with the Base Tail Stock Guide on the bottom, 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 (twenty-four total). Repeat with the remaining eleven Base Braces (BA5).
  • Page 74 Top View Bottom View Step 3 Attach the Rear Base Support (BA4) to the Base Assembly using twenty-four of the M4 x 16 Machine Screws. Align the slots of the Rear Base Support Assembly to the tabs of the Base Assembly as shown.
  • Page 75 Repeat the process to attach the Front Base Support (BA3) to the Base Assembly using Twenty-four M4 x 16 Screws and Nuts. Note: The Rear Base Support is unmarked. The BobsCNC and the Revolution logos are clearly visible on the Front Base Support.
  • Page 76 Step 5 Assemble the Back Brace Assembly. Secure the two Side Braces (BA8) to the bottom of the Back Brace (BA7) and secure with four M4 x16 Machine Screws and Nuts. Step 6 Attach the Back Brace Assembly to the Base Assembly by aligning the inserting the tabs of the Back Brace into the slots in the back side of the Base Assembly as shown.
  • Page 77 Step 7 Attach the Base Corner Brackets (BA6) to both ends of the Base Assembly and secure with two M4 X 16 Machine Screws and Nuts each as shown.

  • Page 78: Gantry Assembly

    Gantry Assembly Required Wood Components GR1 Gantry Frame GR4 X Rail Support GR5 Controller Mount GR7 Gantry Back Brace GR8 Gantry Back Support GR9 Gantry Top/Bottom Brace Required Hardware Part # Description Photo M4 x 16 Machine Screws M4 Nuts...

  • Page 79: Illustrated Step By Step Instructions

    Illustrated Step by Step Instructions Step 1 Align and insert the tabs of the eleven X Rail Supports (GR4) into the slots in the Gantry Frame(GR1) and secure with two M4 x 16 Machine Screws and Nuts each. Finished Assembly will look like this.
  • Page 80 Step 2 Align and insert the tabs of the Gantry Frame Assembly into the slots in the Gantry Bottom Brace (GR9) and secure with twenty- three M4 x 16 Machine Screws and Nuts as shown. Note the laser markings designate the top and bottom pieces for GR9 pieces.
  • Page 81 Step 4 Align and insert the tabs of the Controller Mount (GR5) into the slots at the right end of the Gantry Frame Assembly facing you and secure with two M4 x 16 Machine Screws and Nuts. Step 6 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Gantry Top Brace (GR9).
  • Page 82 Step 7 Turn the Assembly face down. Align and insert the tabs of the four Gantry Back Braces (GR7) into the slots of the Gantry Frame Assembly. There are four notches in each of the Top and Bottom Braces to receive each Back Brace. Secure with three M4 x 16 Machine Screws and Nuts in each.
  • Page 83 Finished assembly shown below. Front View. Rear View.

  • Page 84: Attaching The Base And Gantry Assembly

    Attaching the Base and Gantry Assembly Required Wood Components Part # Description Photo A-Axis Stepper Motor Mount A-Axis Stepper Motor Spacer GR17 Left Gantry Side Dial Indicator...
  • Page 85 GR18 Right Gantry Side GR20L Gantry Mid Vertical Support GR20R...
  • Page 86 GR21 Gantry Back Vertical Support GR14 Gantry Top Brace GR15 Gantry Mid Brace GR16 Gantry Bottom Brace GR19L Gantry Front Vertical Support GR19R...

  • Page 87: Required Hardware

    Chuck Support Front Chuck Brace Rear Chuck Brace Required Hardware Part # Description Photo M4 x 16 Machine Screws M4 Nut M4 x 35 Machine Screw M4 lock Nut 12mm Pillow Block Bearing M6x20 Socket-head Screw M6 Lock Nut...

  • Page 88: Illustrated Step By Step Instructions

    Illustrated Step by Step Instructions Step 1 Attach a 12mm Pillow Block Bearing(H69) to the Left Gantry Side (GR17) and secure with two M6 x 20 Socket Head Screws(H73) and Lock Nuts(M18). Align the Pillow Block Bearing with the laser markings on the Gantry Side (below left). Turn the Gantry Side over and insert the two Socket Head Screws and secure with M6 Lock Nuts (below right).
  • Page 89 Step 2 Align and insert the tabs of the Gantry Frame Assembly into the slots of the left Gantry Side Assembly and secure with eleven M4 x 16 Machine Screws and Nuts.
  • Page 90 Step 3 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Right Gantry Side (GR18) and secure with eleven M4 x 16 Machine Screws and Nuts.
  • Page 91 Step 4 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Gantry Sides and middle Brace then secure with eighteen M4 x 16 Machine Screws and Nuts. Photos below show both Gantry Sides attached to the Gantry and Base Assemblies.
  • Page 92 Step 5 Attaching the Left Side Assembly Components. Attach the Rear Chuck Brace (L7) to the Gantry Mid Vertical Support (GR20L) and secure with one M4 x 16 Screw and Nut.
  • Page 93 Attach the Front Chuck Brace (L6) to the Gantry Front Vertical Support (GR19L) and secure with one M4 x 16 Screw and Nut.
  • Page 94 Insert a 12mm Pillow Block Bearing(H69) to the Chuck Support(L5) 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, as shown.
  • Page 95 Attach the Gantry Mid Support Assembly and Chuck Support Assembly together with two M4 x 16 Screws and Nuts. Connect the Gantry Mid Support Assembly to the Gantry Front Support Assembly and secure with two M4 x 16 Screws with Nuts. Connect the Gantry Top Brace (GR14) to the Gantry Back `Vertical Support (GR21) and secure with one M4 x 16 Screw and Nut.
  • Page 96 Connect the Gantry Top Brace (GR14) and the Gantry Back Vertical Support (GR21) as shown and secure with one M4 x 16 Screw and Nut. Insert the tabs of the Gantry Top Brace (GR14) into the corresponding slots in the Assembly and secure with one M4 x 16 Screws and Nuts.
  • Page 97 Insert the tabs of the Gantry Mid Brace (GR16) into the corresponding slots in the Assembly and secure with six M4 x 16 Screws and Nuts. Insert the tabs of the Gantry Mid Brace (GR15) into the corresponding slots in the Assembly and secure with six M4 x 16 Screws and Nuts.
  • Page 98 Insert Dial Indicator (L8) into the corresponding slot in the Assembly and secure with one M4 x 16 Screw and Nut. Step 6 Attach the Gantry Right Side Assembly Components. Insert the tab of the Gantry Top Brace (GR14) into the Gantry Mid Vertical Support (GR20R) and secure with one M4 x 16 Screw and Nut.
  • Page 99 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. Align the tabs of the Right-Side Vertical Assembly to the slots of the Right-Side Assembly and secure with fourteen M4 x 16 Screws and Nuts.
  • Page 100 Align the tabs of the Gantry Front Vertical Support (GR19R) to the slots of the Gantry Right Side Assembly and secure with three M4 x 16 Screws and Nuts. Insert the Gantry Bottom Brace (GR16) into the slots of the attached vertical supports and secure with six M4 x 16 Screws and Nuts.
  • Page 101 Insert the Gantry Mid Brace (GR15) into the slots of the attached vertical supports and secure with six M4 x 16 Screws and Nuts. Step 7 Attach the A-Axis Stepper Motor Mount Assembly to the right side of the Base and Gantry Assembly. Insert four M4 x 30 Machine Screws(H38) through the A- Axis Stepper Motor Mount...
  • Page 102 Lay the two A-Axis Stepper Motor Spacers (GR3) over the Mount with the Screws through the two holes in each spacer as shown. Insert four M4 x 30 Machine Screws in the Stepper Mount Assembly through the holes in the left side of the Gantry and secure with four M4 Lock Nuts.
  • Page 103 Finished Front Finished Back...

  • Page 104: Final Assembly

    Final Assembly Required Wood Components Part # Description Photo X Rail Stop Belt Retainer Belt Guard Pass Through Frame Pass Through Left Guide...

  • Page 105: Required Hardware

    Pass Through Right Guide Pass Through Bottom Guide Short Bearing Medium Bearing ARM Long Bearing Required Hardware Part # Description Photo Small Zip Ties GT2 Open Loop Belt GT2 Closed Loop Belt H102 Stress Proof Steel X Rail...
  • Page 106 M4 x 30 Machine Screw M4 lock Nut M4 x 20 Machine Screw M4 x 16 Machine Screws M4 Nuts M5 x 30 Machine Screw M5 Square Idler Fender Washer M2.5 x 16 Machine Screw M2.5 Lock CB19 Home Switch CB23 Wire Extension Kit...
  • Page 107 CB12 Power Supply with cord CB16 Controller Drag Chain 18x25 mm CB 14 USB Cable GT2 Pulley Short M3 x 10 Machine Screw M3 Washer M6 x 35 Machine Screws...
  • Page 108 626-2RS Bearing Hardened Washer Locknuts M6 Nut Makita Router...

  • Page 109: Installing The Chuck Assembly

    Installing the Chuck Assembly Step 1 Attach the A-Axis Stepper Motor by sliding the shaft through the Stepper Motor Mount Assembly on the left side of the Assembly. Be sure that the Stepper Motor wires are oriented at the top of the motor as shown. Align the holes in the Stepper Motor Plate with the slotted holes of the...
  • Page 110 A Pillow Block Bearing is designed to allow the Bearing to swivel within 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 though both Bearings.
  • Page 111 Step 3 Insert the 12 mm shaft of the Chuck Assembly through both Pillow Blocks. Inboard View Outboard View Step 4 Align the Chuck Pulley Plate and the Short Drive Pulley on the A-Axis Stepper motor. Loop the GT2 Drive Belt(H68) around the Chuck Pulley Plate and the A-Axis Drive Pulley.
  • Page 112 Gently pull the A-Axis Short Drive Pulley back to remove any slack in the Belt, then tighten the A-Axis Stepper Motor in place. Gently push the A-Axis Stepper Motor Drive Pulley toward the Mount until the Belt is parallel to the Gantry Side and tighten in place.
  • Page 113 Tighten the M3 x 10 Stepper Motor Screws. Tighten the two Set Screws on the inboard and outboard Pillow Block against the 12mm Shaft. Inboard Outboard...
  • Page 114 Step 5 Install the Belt Guard (L9) by aligning the tabs on the Plate with the slot in the bottom of the Gantry. Slide the tab up into the slot and allow the two tabs at the bottom of the plate to drop into the two slots in the Back Corner Brace.

  • Page 115: Installing The Tail Stock

    Installing the Tail Stock Step 1 Insert the Tail Stock Bottom Plate Assembly into the Base Assembly and position the Plate so 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.
  • Page 116 In the photo above a ¼” thick piece of shim stock was inserted into the Live Center Assembly with one end positioned 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 117: Installing The Pass-Through Rest

    Installing the Pass-Through Rest. Step 1 Stack the two Pass Through Frames (RP1) on top of each other Place the Pass Through Guides (RP2, 3, and 4) on the Pass Through Assembly as shown below. Make sure that the laser line is showing on each piece. Insert seven M4 X 30(H38) Machine Screws into the holes as shown.
  • Page 118 Step 2 Orient the Pass-Thru Rest to the right Gantry Side and align the Machine Screws to the mounting holes and secure with the seven M4 Locknuts(H47). Step 3 Assemble the three Long Bearing ARM. Each set Long, Medium, and Short contains three equal length Bearing Arms.
  • Page 119 Step 3a Assemble the three Large Bearing Arms in the following sequence. The Bearing assembly consists of a M6 x 35 Machine Screw(H95), Hardened Washer(H61), Pass-Thru Arm(RP5,RP6, RP7), Hardened Washer, 626-2RS Bearing(ZD3), Hardened Washer, and M6 Locknut (H18).
  • Page 120 Step 3b Attach the three Large Pass-Thru Guides to the Pass-Thru Assembly by first inserting the M6 Nut(H60) in the Pocket of the Assembly. Holding the Nut in place insert a M6 x 35 Machine Screw(H95) and Hardened Washer(H61) through the hole in the Arm Assembly.

  • Page 121: Installing The Xz Assembly

    Installing the XZ Assembly Step 1 Attach the X Carriage to the Gantry Assembly. Step 1a Insert the upper Rail(H52) through the Gantry Side Assembly. Rotate the Rail as it passes through the Gantry Rail Supports and is fully seated in the opposite Gantry Side Assembly.
  • Page 122 Step 1c Hang the upper SG20U Bearings of the X Carriage Assembly on the Upper Rail. Step 1d Finish threading the Rail across the top of both of the lower SG20U Bearings on the X Carriage Assembly through the remaining Rail Supports and seat the Rail in the opposite Gantry Side Assembly.
  • Page 123 Step 1e Secure the Upper and Lower Rail by attaching a X Rail Stop (GR6) at each end of the Gantry Assembly with two M4 X 20 Machine Screws(H98) and M4 Locknuts(H47) for each. Step 1f Adjust the Eccentric Spacers until the SG20U Bearings are snug against the Rails.

  • Page 124: Installing The X Belt

    The SG20U Bearing should be snug against the Rail. Use your finger to roll the Bearing. It should not spin in place. When the Bearing is properly adjusted against the Rail, the entire X Carriage Assembly should move as you roll the Bearing. Make sure the X Carriage rides smoothly along the full length of the Rails.
  • Page 125 Step 1b With the teeth of the GT2 Belt facing down, thread one end of the GT2 Belt through the rectangular slot in a Belt Retainer. Step 1c Cover the Belt with the teeth still facing down with the second Belt Retainer.
  • Page 126 Step 1d Sandwich the GT2 Belt between the two Belt Retainers and bolt them together with three M4 x 16 Machine Screws(H14) and Nuts(H15). After installing the first Screw and Nut, it is possible to adjust the amount of GT2 belt installed through the bottom of the clamp by gently pulling the GT2 belt until only two or three of the teeth are visible.
  • Page 127 Step 2e Stretch the Belt Assembly out and measure the distance between the two notched ends in the Belt Retainers. The distance should be 49.25 inches. 49.25 inches Step 3 Installing the X Axis GT2 Belt Assembly. Step 3a Insert a M5 x 30 Machine Screw(H48) with Idler Fender Washer (H50), through the Rail Stop and thread a M5 Square Nut(H93) on the exposed threads.
  • Page 128 Step 3b Slip the Belt Retainer Assembly end over the exposed thread so that the Square Nut is seated in the cutout in the Belt Retainer Assembly. Be sure the smooth side of the GT2 Belt is visible with the teeth oriented toward the Gantry Assembly.
  • Page 129 Step 3d Slide the X Carriage Assembly past the Belt Retainer Assembly. Position the X Carriage Assembly so that it is immediately in front of one of the large openings in the Gantry Frame. Align the rectangular opening in the Z Frame Assembly with the opening in the Gantry Frame by manually turning the Helical Coupler at the top of the Y Carriage Assembly to lower the Z Frame Assembly.
  • Page 130 Step 3e Position the GT2 Belt so that it runs across the two Idler Pulleys. Back View Front View...
  • Page 131 Step 3f Using a long Allen Wrench or a stiff piece of wire (e.g., AWG 12 solid core copper wire), bend a small hook into one end of the wire. Carefully insert the hook through the front of the Z Frame Assembly and hook the wire over the GT2 Belt as shown.
  • Page 132 Step 3g Loop the GT2 Belt over the GT2 Pulley. Hold the X Carriage Assembly in place and pull the GT2 Belt snug. Step 3h Slip the Belt Retainer Assembly end over the exposed thread so that the Square Nut is seated in the cutout in the Belt Retainer Assembly and tighten the GT2 Belt to remove any slack.

  • Page 133: Installing The Router

    Installing the Router Step 1 Slip the Makita Router (R2) into the Router Mount. Step 2 Snug the Makita Router in place by tightening the Router Mount Clamp. Then tighten the two M4 x 35 Screws and Locknuts at the front of the Router Clamp.

  • Page 134: Installing The Drag Chain And Extending Stepper Motor And Home Switch Wires

    Installing the Drag Chain and Extending Stepper Motor and Home Switch Wires. Home Switches are simple contact switches. They can create a transient voltage spike when opened or closed. Stepper Motors also generate electrical interference which can cause the Controller to act as if a Home Switch has been depressed.
  • Page 135 Step 1b Connect the Two-Wire Extension (CB23) to the Z Home Switch Wires, making sure the connections are Red to Red and Black to Black. Step 2 Bundle the extended X and Z Axis Stepper Motor Wires and the Z Home Switch Wire together with Zip Ties every 6 inches.
  • Page 136 Step 3 Facing the back of the Gantry, slide the X carriage to the right. Unroll the Drag Chain across the top of the Gantry. Attach one of the end links to the top of the Gantry using two M4 X 16(H14) Machine Screws and Lock Nuts(H47) as shown.
  • Page 137 The links have hinged connectors that must be opened to install the wires. Step 4 Open all the hinged connectors and route the Router Cord, the X and Z Stepper Motor Wires and Z Home Switch Wire around the loop and along the Drag Chain. Keep the Router Cord on one side of the Drag Chain and the other wires on the other side to minimize electrical interference.
  • Page 138 Step 5 Take the Router Plug and thread it though the large hole next to the end of the Drag Chain.
  • Page 139 Continue threading the Cord through the top holes in the Gantry Supports and out through the lower hold in the Gantry Side as shown. Step 6 Take the bundled X and Z Stepper Motor wires and the Z Home Switch Wires and thread them though the large hole next to the end of the Drag Chain routing them toward the Controller then behind the Gantry Back Support, through small holes in both Back Braces as shown below.
  • Page 140 Step 7 Attach the X Home Switch by threading its connector through the rectangular hole in the Left Gantry Side. Continue threading the wires through the small hole in the Gantry Top Brace and the large upper hole in the Gantry side to the Controller.

  • Page 141: Attaching The Controller

    Attaching the Controller Step 1 Attach the Controller (CB16) to the Controller Support. Step 1a Use four small Zip Ties to attach the Controller (CB16) to the Controller Support, as shown. Step 1b Gently tighten the Small Zip Ties and then carefully trim the ends with scissors.

  • Page 142: Installing The Power Supply

    Installing the Power Supply Step 1 Place the Power Supply (CB12) in the second bay from the left as shown. Thread the plug end behind the Gantry Back Support and through the large hole in the Gantry Back Brace as shown.
  • Page 143 Step 2 Thread the Power Supply cord behind the Gantry Back Support and through the large hole in the Gantry Back Brace and behind the Controller Support. Step 3 Thread the exposed Power cord end through the hole in the upper left corner of the Controller Support.
  • Page 144 IMPORTANT When connecting the Power Supply to the Controller, make sure the red wire is connected to the (+) positive terminal and the black wire is connected to the (-) terminal. Step 4 Secure the Power cord wire to the Controller Support with a small Zip Tie.

  • Page 145: Wiring The Controller

    Wiring the Controller Step 1 Connect the Z Home Switch wire to the “Z+” Pins on the Controller. NOTE: Polarity doesn’t matter. Step 1 Connect the Z Home Switch wire to the “Z+” Pins. On the Controller.
  • Page 146 Step 2 Connect the X Stepper Motor Wires to the X Driver on the Controller. Make sure the red wire is on the top.
  • Page 147 Step 3 Connect the Z Stepper Motor Wires to the X Driver on the Controller. Make sure the red wire is on the top.
  • Page 148 Step 4 Connect the A Stepper Motor Wires to the A Driver on the Controller. Make sure the red wire is on the top.
  • Page 149 Step 5 Connect the X Home Switch Wires to the X- Pins on the Controller.
  • Page 150 Step 5 Connect the USB cord to the controller. Thread the cord through the hole at the top of the Gantry Side.

  • Page 151: Completed Views

    Completed Views Front View Back View...
  • Page 152 Left Side Right Side...
  • Page 153 Controller Wiring...

  • Page 154: Tramming

    Tramming Tramming is the process of adjusting the CNC Spindle (Router) so that it is perpendicular to the material being cut. The goal with 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.
  • Page 155 Eccentric 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 156 The Spindle (Router) can be trammed on the A Axis by placing shims behind the SG20U Bearing Fender Washer on the X carriage. Placing the shim on the top will tilt the axis clockwise. Placing the shim on the bottom will tilt the axis counterclockwise.

  • Page 157: Machine Set-Up

    Machine Set-Up Wood Components (Included with Kit) Part # Description Qty Photo Chuck Face Plate Z Gauge To mount a stock, first find and mark the center point of both ends by marking diagonal lines from corner to corner. Align the center hole of the Chuck Face Plate (L4) over the center marked on the stock.
  • Page 158 Secure the Face Plate to the stock using four wood screws. Align the four holes in the Mounting Plate with the four threaded studs on the Chuck and secure with four M6 nuts and tighten.
  • Page 159 After the workpiece is mounted, align the point of the Live Center to the center point of the stock. Push the point of the Live Center into the end of the stock and tighten the Stock Tensioner to hold the Tail Stock in place.
  • Page 160 Rotate the Stock until the 0-mark on the Chuck Plate lines up with the Dial Indicator as shown. Then set the A Axis to zero. Note: The A-axis does not have a Home Switch and is set for reference only. Setting this axis zero point will allow you to return to a known A-axis position.
  • Page 161 Set the Z-Zero using Z Gauge. After the Tail Stock has been locked in place, slide the Gauge between the Bit and the Live Center so that the radius rests on the outer surface of the Live Center, as shown. Router Bit Gauge Live Center...
  • Page 162 Slowly lower the Router Bit until it touches the top of the Gauge. This is the Z- Zero location, however the zero is offset. Set the DRO in the Sender to 50.8 mm or 2.0 inches by typing the number into the Z DRO textbox and pressing the shift +enter keys.
  • Page 163 Using the Pass-Thru. The Pass-Thru lets us machine round stock that is longer than 42 inches. Depending on the diameter of the stock, use either the small, medium or large arms to support the material. Make sure all three arms are of the same length and are on the same alignment mark.

  • Page 164: Congratulations

    Congratulations! You Have 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 642 Manuals and Documentation – BobsCNC...

  • Page 165: Appendix

    Appendix Revolution 642 Washer Dimensions Thickness Thickness Part number Description (min) (max) Eccentric Washer 0.453 0.750 0.059 0.063 Bearing Fender Washer 0.250 0.750 0.060 0.090 Idler Fender Washer 0.203 0.750 0.043 0.051 Bearing Retainer Washer 0.172 0.050 0.050 0.080 Hardened Washer 0.260...
  • Page 166 250 (homing feed, mm/min) 2000 (homing seek, mm/min) 250 (homing debounce, msec) 5 (homing pull-off, mm) 1000 Maximum spindle speed, RPM 0 Minimum spindle speed, RPM 0 Laser-mode enable, boolean $100 80 (x, step/mm) $101 144 (a, step/mm) $102 400 (z, step/mm) $110 10000 (x max rate, mm/min) $111...

Table of Contents