Zen Toolworks CNC Carving Machine DIY Kit User Installation
Contents
1. 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual 13 Y Axis Lower Frame 14 Y Alex Top Frame 15 Y Alex Side Frame 16 Tool Base 17 Gantry Left Outer 18 Gantry Left Inner Frame Frame 19 Gantry Right Outer 20 Gantry Right Inner 21 Z Axis Base Frame Frame Frame 22 Gantry Back Enforce 23 Working Table Frame 5 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual Assemble Instruction STEP Y 01 Here is the layout of the main components for assembling Y Axis STEP Y 02 First we need to put the bearing into 3 If you have a bench vise it will make this job much easier If not you can find any equivalent tool that you have the access Just make sure that when you apply the pressure it should be even and slow The bearing should be pushed straight into the block When it is done the bearing edge should be flush with the bearing block Parts P 03 Frame 3 STEP Y 03 Before push the bearings make sure the hole is clean from manufacture debris If not use a needle file and small tool to clean it STEP Y 04 Push the bearing slowly into the bearing block hole 6 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 05 Here is how it looks like when it is done STEP Y 06 We need to push the2. WD 40 clean the rod thoroughly STEP Y 30 Using a paper towel is fine STEP Y 31 The rods and 11 are installed STEP Y 32 On the other side we need to first install the motor support blocks on before moving forward This will make it much easier to access the screws Parts Frame 14 12 2 P 12 4 P 13 4 13 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 33 Using M3 screws to attach the motor support blocks STEP Y 34 Using an electrical screwdriver is a good idea STEP Y 35 Now the motor support blocks are installed onto the frame 14 STEP Y 36 We are ready to put the rest of the frames of Y Axis together Parts Frame 14 13 15 2 14 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 37 Push the lead screw shaft through the end ball bearings STEP Y 38 The other side same STEP Y 39 It should look like this STEP Y 40 Using M6x15 for attaching the guide rods to end frames Parts P 19 2 P 20 2 15 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 41 Using a hex key to fasten the screws STEP Y 42 It is done on one side STEP Y 43 Same to the other side of the Y Axis Parts P 19 2 P 20 2 STEP Y 44 It is done 16
3. Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 43 Using M3 machine screws provided STEP X 44 For gantry motor you probably want to face the motor leads backward STEP X 45 Use screwdriver to fasten the screws STEP X 46 Now we need to put the Z Axis base onto the gantry support frames Parts Frame 21 P 12 8 P 13 8 33 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 47 Using M3 screws and washers STEP X 48 It is done STEP X 49 Make sure you can turn the lead screw by hand easily Check it often and it will save you later STEP X 50 Now let s put the gantry back support on Parts Frame 22 P 12 16 P 13 16 34 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 51 Use M3 screws with washers STEP X 52 No hurry do it slowly There are a lot of screws STEP X 53 Yes it is done STEP X 54 Here is the finished gantry assembly 35 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 55 Now let t try to put the gantry and Y Axis base together STEP X 56 Using M6 x 25 machines screws Parts P 22 2 P 20 4 P 23 2 STEP X 57 Finished one side STEP X 58 Tight them up 36 Copyright 2010 Zen Toolworks LLC All Rig
4. linear ball bearings into the support frames Be aware of the orientation during the install Parts Frame 10 11 P 24 4 STEP Y 07 Again we are using bench vise for the job STEP Y 08 Push it slowly and make sure it is straight 7 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 09 Push it till the end STEP Y 10 Then do the other side Please take a look at the orientation of two bearings in the picture STEP Y 11 Here is how they will look like when it is done STEP Y 12 Other side The bearing s ends flush with the board surface 8 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 13 Now we need to attach the bearing block with bearing already installed onto part 13 Parts Frame 13 3 P 15 2 P 16 4 P 18 2 STEP Y 14 Using M4 machine screw and put flat washers on both sides STEP Y 15 Now it is done STEP Y 16 On the other side we need to put another bearing block onto part 14 The stepper motor will be attached to this frame Parts Frame 14 3 P 15 2 P 16 4 P 18 2 9 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 17 Using M4 washers and nuts STEP Y 18 It is done now STEP Y 19 Here is the Y Axis lead screw and
5. Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 45 Now we are ready to put the side frame on STEP Y 46 Using M3 screws provided M3 flat washers should also be used Parts P 12 6 P 13 6 STEP Y 47 Screw them on Check the squareness often STEP Y 48 On the other side same Parts P 12 6 P 13 6 17 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 49 Now we finished the M3 screws for the side frames STEP Y 50 Finally we need to fasten the M6 screws on guide rods STEP Y 51 It is done STEP Y 52 Check whether you can turn the lead screw easily It should other wise you should check where can be the problem It is always a good idea to identify the issue earlier in the install Otherwise you will have to back out many steps to get it fixed 18 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 53 We use a lead screw end holding nut to hold the lead screw to the ball bearing and frame Parts P 07 1 STEP Y 54 To install the nut you should hold the lead screw and the nut as shown in the picture Make sure the nut lead screw and ball bearing there is no gap in between Then fasten the setscrews on the nut STEP Y 55 Using a hex key to fasten the setscrew
6. The M3 screws are much easier to access then after put everything together Parts Frame 19 20 P 12 4 P 13 4 STEP X 29 2 Motor support blocks for Gantry will be inserted into those square holes STEP X 30 As shown 29 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 31 Use M3 screws and washers STEP X 32 It is done STEP X 33 Now we put all Gantry parts together STEP X 34 Using M6x20 to connect the gantry side frames and guide rods Parts P 21 2 P 20 2 30 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 35 Done on one side STEP X 56 Similar to the other side Parts P 19 2 P 20 2 STEP X 37 Using a hex key to fasten the screws STEP X 38 Same install lead screw holding nut Parts P 07 31 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 39 Squeeze them together make sure there is no gap between lead screw and ball bearing and holding nut STEP X 40 Then fasten the setscrews on the holding nut STEP X 41 Put the flex coupling on before the stepper motor Parts P 02 1 STEP X 42 Put the motor onto motor base 2 Parts P 01 P 14 4 P 13 4 Frame 2 32 Copyright 2010 Zen Toolworks LLC All Rights Reserved
7. Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 31 Fasten them up with a screwdriver STEP Z 32 Don t forget the screws at the bottom STEP Z 33 Use a screwdriver to fasten all screws STEP Z 34 The Z Axis assembly is installed on the machine now 46 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 35 Now let s put the tool base 16 to the Z Axis support frames You can do this step later if you haven t decided what kind of tool will be used It is easier to install tool when the base is off Parts P 12 8 P 13 8 STEP Z 36 The tool base has been installed on Z Axis There are 4 pre drilled holes on the tool base which is for your tool holders Zen Toolworks carries optional spindle motors with tool holders which can be easily screwed onto this tool base STEP Z 37 We have completed the machine assembly Hope it didn t take you too long and you have enjoyed the process so far Now it is time to learn stepper motor controller software and design software for the project want to do 47 Copyright 2010 Zen Toolworks LLC All Rights Reserved
8. Zen Toolworks CNC Carving Machine DIY Kit User Manual Zen Toolworks CNC Carving Machine DIY Kit User Installation Manual Visit Us At http www zentoolworks com or http www zentoolworks com zenwiki mediawiki Contact Us At zentoolworks gmail com l Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual P 01 Nema 17 Stepper Motor 3 P 02 Motor Shaft Flex Coupling 3 P 03 End Support Ball Bearing 6 P 04 Anti Backlash Big Falan 3 P 05 Anti Backlash Small Falan 3 P 06 Anti Backlash Spring 3 P 07 Lead screw End Holding Nut 3 P 08 X Y Axis Guide Rod 4 P 09 X Y Axis Lead Screw 2 P 10 Z Axis Guide Rod 2 P 11 Z Axis Lead Screw 1 P 12 M3 x 20 Screw 2 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual P 13 M3 Washer P 14 M3 Machine Screw 12 P 15 M4 Machine Screw 18 P 16 M4 Washer P 17 M4 Lock Washer P 18 M4 Nut gd P 19 M6 x 15 Machine Screw 8 P 20 M6 Washer P 21 M6 x 20 Machine Screw 4 oe P 22 M6 x 25 Machine Screw 4 P 23 M6 Nut 4 P 24 Linear Ball Bearing 12 3 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual 03 End Bearing Block 06 Gantry Right Support 09 Z Top Frame 10 Y Axis Higher Support 11 Y Axis Lower Support 12 Motor Support Block 4 Copyright
9. anti backlash nuts assembly We will need to put them on following the steps as illustrated in the next few picture Parts P 09 1 P 04 1 P 05 1 P 06 1 STEP Y 20 First put the small falan on Just make a few turns onto the lead screw 10 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 21 Now put the spring onto it STEP Y 22 Finally put the falan on Apply some pressure to squeeze both falans together and then turn the screw into the big falan You may need to give it a couple of tries Make sure the anti backlash nuts and lead screw are aligned properly STEP Y 23 Turn the anti backlash into the lead screw STEP Y 24 Here is the anti backlash nuts installed on the lead screw 11 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 25 The 10 will be attached to the anti backlash nuts using M4 machine screw with flat washer lock washer and nuts Parts Frame 10 P 15 2 P 16 4 P 17 2 P 18 2 STEP Y 26 Put the screws on STEP Y 27 And then tight them up STEP Y 28 Now we need to put another support frame and guide rods on Parts Frame 11 P 08 2 12 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 29 Before we put the guide rod on please use
10. asher flat washer and nut Parts P 15 2 P 16 4 P 17 2 P 18 2 39 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 07 Close up detail STEP Z 08 Use a hex key to and a small wrench to fasten M4 screws and nuts STEP Z 09 Put the bearing support onto 8 using M4 screws and washers Parts Frame 3 8 P 15 2 P 16 4 P 18 2 STEP Z 10 On the motor side we need to put bearing block onto 9 using M4 screws and washers Parts Frame 3 9 P 15 2 P 16 4 P 18 2 40 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 11 Before we put the motor support blocks on we need to pre insert the M6 x 15 machine screws onto 9 Otherwise you will not be able to put those screws in Parts Frame 9 Frame 12 2 P 19 2 P 20 2 STEP Z 12 Push M6 screws into the 9 frame STEP Z 13 The M6 screws are pre inserted STEP Z 14 Then put the motor support blocks on Parts P 13 4 P 12 4 41 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 15 Using M3 screw between 9 and motor support blocks STEP Z 16 Now we can put the motor side frame onto the guide rods STEP Z 17 Here you can use a hex key to fasten the M6 machine screw STEP Z 18 Install a
11. ave used so far STEP X 01 Now let s start Gantry install STEP X 02 First thing we need to prepare the ball bearings and linear bearings Clean the holes if necessary Parts Frame 19 17 22 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 03 Again we are going to use bench vise Parts Frame 19 17 P 03 2 STEP X 04 Push it slowly and make sure it is straight If it is not aligned properly and force the bearing in it can break the board so be very careful here STEP X 05 Now ball bearings have been pushed into the side frames STEP X 06 Now let s install linear bearings to the support frames Parts P 24 4 Frame 7 Frame 8 23 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 07 Make sure it is straight it 1s important STEP X 08 Linear bearings have been installed to Gantry support frames STEP X 09 The end of the bearings is flush with the frame surface STEP X 10 Again install the anti backlash nuts to the Gantry lead screw refer to the install procedure for Y Axis Parts P 09 P 04 P 05 P 06 24 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP vU The anti backlash nuts are on the lead screw STEP X 12 Here is the layout of the mai
12. hts Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 59 Here is the other side Parts P 22 2 P 20 4 P 23 2 STEP X 60 Before you tighten the screws on the other side use a ruler check that it is even on both side You can fine tune it later but now let s just make sure that there is no big error just because ignorance STEP X 61 Tight them up STEP X 62 Now we have gantry and Y axis installed We are ready for putting Z Axis together 3 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 01 Here is a layout of main components of assembling the Z Axis STEP Z 02 For Z Axis we also need to push the ball bearings into bearing blocks 3 Parts P 03 2 Frame 3 2 38 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 03 Also linear bearings will be pushed into support frames Parts Frame 3 2 Frame 4 2 P 24 4 STEP Z 04 Linear bearings have been installed onto Z Axis support frames STEP Z 05 Screw the Anti back lash nuts onto the Z Axis lead screw as demonstrated earlier Parts P 11 1 P 4 1 P 5 1 P 6 1 STEP Z 06 Screw the Anti back lash nuts onto the Z Axis lead screw as demonstrated earlier Connect the support frame and anti backlash nuts using M4 machine screw with lock w
13. n parts for Gantry Parts P 08 2 STEP X 13 Again clean the rod using WD 40 STEP X 14 Attach the anti backlash to the support frame using M4 with lock washers Parts P 15 2 P 16 4 P 17 2 P 18 2 25 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 15 Fasten them using a hex key STEP X 16 Ready for guide rods STEP X 17 Slide the rods on STEP X 18 Now let s prepare the side frames This two are on the motor side right Parts Frame 19 20 P 15 2 P 16 4 P 18 2 26 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 19 Close them up as shown STEP X 20 Using 2 M4 machine screws STEP X 21 Ready to fasten the screws STEP X 22 Put the washers and nuts on 27 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 23 It is done on one side STEP X 24 Ready for the other side Parts Frame 17 18 P 15 2 P 16 4 P 18 2 STEP X 25 Be aware of the orientation STEP X 26 Close them up 28 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP X 27 Fasten using M4 screws with washers and nuts STEP X 28 Now we need to put the motor support blocks on
14. nother side with M6 x 15 machine screw Parts P 19 2 P 20 2 42 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 19 Looks good STEP Z 20 Check whether you can easily turn the lead screw by hand If not there is an alignment problem and it is better fix it right now STEP Z 21 Put the lead screw holding nut on squeeze lead screw and holding nut towards the ball bearing Parts P 07 1 STEP Z 22 The lead screw holding nut is installed 43 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 23 Put the flex coupling on before install the motor Parts P 02 1 STEP Z 24 The motor and motor base 2 Parts Frame 2 P 01 1 P 14 4 P 13 4 STEP Z 25 Using M3 machine screws with washers to connect motor and motor base 2 STEP Z 26 Put the motor onto the motor support blocks Parts P 12 4 P 13 4 44 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Z 27 Motor is installed for the Z Axis STEP Z 28 Fasten the setscrews on the flex coupling STEP Z 29 Z Axis assembly is ready to be put on the machine STEP Z 30 Use M3 screws and washers to connect the Z Axis to the Z Axis baseboard on the gantry Parts P 12 8 P 13 8 45 Copyright 2010 Zen
15. s on the lead screw end holding nut After this check that there should no play between lead screw bearing and frame STEP Y 56 Now we are ready to put the motor on Parts P 01 1 Frame 2 1 P 14 4 P 13 4 19 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 57 Use M3 Machine screws provided to attach the stepper motor to the part 2 STEP Y 58 Now put the flex coupling onto the lead screw shaft Parts P 02 1 STEP Y 59 Then put the motor onto the motor support blocks Parts P 12 4 P 13 4 STEP Y 60 Here you go 20 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 61 Move the coupling to the middle position STEP Y 62 Fasten the setscrews on the flex coupling Now the motor and lead screw is connected STEP Y 63 Be aware of the motor lead orientation make sure it is easy for your wiring later For Y Axis you can either let the wire outlet face up or on the side STEP Y 64 Now we are putting the working table onto the support frames for Y Axis Parts Frame 23 P 12 10 21 Copyright 2010 Zen Toolworks LLC All Rights Reserved Zen Toolworks CNC Carving Machine DIY Kit User Manual STEP Y 65 Now the Y Axis assembly is done The picture shows tools we have used except the bench vise STEP Y 66 Tools we h
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