Photographic Shapeoko 3/XL/XXL Assembly Instructions (from parts)

This page was begun when the Shapeoko 3/XL/XXL were shipped without a pre-assembled wiring harness. It is out-dated and obsolete and for reference only.

The photos and text below show using packaging to support parts to aid assembly --- having the aid of a suitable assistant will avoid the need for this and speed assembly greatly.

The images may be clicked on to open the source page for them in the wiki.

Please feel free to edit or improve or add to these instructions, or to provide feedback in the forums.

Building your Shapeoko 3/XL/XXL
You are about to Build a CNC Machine with your bare hands.

Please read the official instructions for your machine all the way through --- this will take 5 minutes at most and can save you 30.

You will make a mistake. The Phone will ring. A bolt will roll out of sight. It's OK, things could be a lot worse. Breathe and Stay Hydrated.

First, find a suitable flat, empty space to assemble your machine.



Unpack the Master Shipping Container Box and take inventory of your Boxed S3 Parts.

The Shapeoko XL and XXL ship in a box inside an overbox which will require an initial unboxing.



Packing List


Please see the B.O.M. and Carbide 3D packing list for specifics of the includes parts. For detailed information, see Parts.


 * Hardware
 * Steel
 * Extrusions
 * Gantry Plates
 * Belts
 * Electronics
 * Misc.

Notes: The XL and XXL Mount the controller/enclosure on the left side rail. The standard SO3 mounts the controller on the rear of the X rail. You can identify this rail by the 2 tapped holes used to mount the controller.

The controller is mounted reversed for the XL/XXL and SO3 (USB and power connections on the left side on the XL/XXL, right side on the SO3).

NOTE: X and Z Assembly 1 --- since the instructions were created this has been separated into two components: X-Carriage Assembly and Z-Carriage Assembly.

Things to check
Trust in God, Lock your Doors. We do our Best to ensure everything leaves our Factory perfectly, but we are human and you want to be sure. So here's some things to DOUBLE check:

Check pulley set screws are secured to the flat of the stepper motor shafts. http://docs.carbide3d.com/article/169-shapeoko-3-how-to-check-the-pulley-set-screws

Check that all bearings spin smoothly with no lateral play.

Inspect V-wheels --- when placed on the rails they should roll smoothly with no lateral play. If loose --- loosen the bolt some more --- 3 turns and apply Loctite, and retighten to a snug fit with vigor.

Unpack Parts Box


PRO TIP: Use some plastic cups to sort and store the content of the hardware in baggies for assembly.



Use the included Sharpie to label the wiring connectors.



Note: Inspect all cable connections, this is peace of mind, chrome wiring connectors should be seated and visible in the lock channels. Wire colors are: black red green blue

End Plates and Wasteboard
If possible, sealing the MDF Wasteboard with lacquer or polyurethane or epoxy is highly recommended, especially if the machine will be subject to changes in humidity, or exposed to lubricants or coolant.

Note: that the SO3 will not have any cross straps, just place the single piece wasteboard, the XL will have shorter cross straps and a single wasteboard, while the XXL will have cross straps and a two piece wasteboard as depicted in the photographs.



Assemble the Bed. Locate the Steel front and rear END Plates.



Insert the 4 adjustable feet in the outside corners of the Endplates.



Locate the Straps (XL and XXL only) and place across and on top of the end plates.



Place the wasteboard (wasteboards for an XXL) on the metal frame (on top of the straps for an XL or XXL, sandwiching the straps between the endplate).



PRO TIP: use a flash light and a 3mm driver to align the wasteboard and strap holes to the threads in the end plates.

Only tighten the M5 bolts 50% until final calibration, this will allow the larger extrusions and End plates to pull the base and MDF Wasteboards into postion.

NOTE: The XL and XXL instructions have one lay out the extrusions at this point. The extrusion with tapped holes for the controller will go on the left of the machine for XL and XXL, and will be used for the gantry for the SO3.

Preparing the Plates
NOTE: The SO3 and XXL instructions have a nice image and text describing turning the eccentric nuts to their widest point, if assembling an XL, please refer to that.

X Z Carriage
Assemble the X Z Carriage



The Z plate is short and bent at the edges (shown on the left in the above photo). Note that it may be necessary to install any hardware which was loose in the box (typically the M4 which is used for vertical adjustment, and the M5 and the two flanged bearings and spacer which it holds in place.

Install Spindle Mount


It is also easier to install the spindle mount before installing the Z-axis spindle carriage plate.



The router will be secured in the spindle mount using the two long M5 SHCS.





Assembly of Z-axis


Rotate the Eccentric nuts outward. More information on eccentric nuts at: MakerSlide_Tips_and_Tricks



The X carriage has the 2 aluminum extrusion rails. (Shown in its packaging in the above photo)



Loosen lower Z belt Roller Bearing Nut.

Slide Z plate v-wheels onto the Rails of the X plate.



Loop belt over Z Stepper pulley



Loop belt over lower belt roller bearings.



Tighten the belt tension bolt with 4mm driver. This can be done from the top of the plate and below. Both methods were necessary for the Universrity of Florida's Nuclear research department. Adjust the eccentric nuts gradually outward and as they engage the rails, make sure they are equally and evenly adjusted.

NOTE: Properly adjusted V wheels will turn when the carriage is moved, and are only engaged enough to ensure that you can not hold a wheel still while moving a gantry.

NOTE: Excessive V-wheel engagement will flatten the wheels and could damage the bearings.

NEED IMAGE OF SPRINGS

The Final X Z assembly step is to attach 1 spring ONLY. The Second spring will be attached after the Router has been Installed.

Y-axis


Locate the Extrusion with 2 threaded holes --- the control board will be mounted to it, on the left of the machine for XL and XXLs, at the rear of the gantry for standard-size SO3s. (A set of rails for an XXL is used in the above photo, and the rail with holes is shown on the left in the above photo)



Locate the Cardboard sleeves from the Y rails packing. Locate the Y assemblies.



Rotate the Eccentric nuts outward.



Install the Left Y gantries onto the Left Y rail. The Stepper motors will be rearward, allowing the X Rail to mount toward the front of the machine.

The Left extrusion will have 2 threaded Holes (on an XL or XXL), slide the Left Y AXIS plate onto this extrusion with the stepper motor located towards the rear.

The Right extrusion does not have 2 threaded Holes, slide the RIGHT Y AXIS plate onto this extrusion with the stepper motor located towards the rear.



Use the Cardboard wraps to capture the Y gantries and support the rails for attachment to the endplates.

X-axis






Homing Switches
Assemble Homing Switches



















Attach switches to plates as shown. M3x14 Label the white connectors of the Switches Large Rectangular plate is Z Smallest plate is Y and medium is X.

Belts




Belt tensioning with The ping pong technique. Attach 1 side with 2 turns into the threads - Attach other side with belt tight where bracket can just be reached by the bolt at 1 turn of thread. Tighten 2 turns. Now tighten the first side all the way down Finally tighten the second side all the way. With the X gantry moved all the way to the back, the largest expanse of belt will allow a pinky finger tip only.

Wiring
Mount Cable Snake Mounting Brackets.

Note that it will be necessary to remove links from the Y-axis drag chain (12 for an XXL, 20 for an XL).









Diagram of Cable Snake

5 Across cable mounts Alcohol wipe Clamp to hold

Mount Snake Heads







Thread cables Image

Attach Feet





















Open Chains with wrench

Lay lines as shown in snakes

Close snap links

Attach bodies to heads

Attach bodies to feet.











Thread Rubber grommets onto wires as shown.

Thread Cables into the box

Connect Homing wires to board. X Y Z from inside toward the outside of the boards shown. Image



Insert Grommets

Massage the wiring and attach the black cover with M6 bolts