torchmate 2 bolt together assembly instructions
TRANSCRIPT
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Torchmate 2
Bolt-together Kit
Assembly InstructionsRevised July 23, 2013
© Torchmate Inc. 2012-2013
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TECHNICAL SUPPORT
Toll Free: 1-866-571-1066 x3International: 775-673-2200 x3
Fax: 775-673-2206
Email: [email protected]
Torchmate 2 Bolt-together Kit Assembly Instructions
Published by:Lincoln Electric Cutting Systems
Torchmate Distribution Center
1170 Trademark Drive, #101
Reno, NV 89521
www.torchmate.com
Copyright © 2011-2013 by Torchmate Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission
of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in this
manual, whether such error results from negligence, accident, or any other
cause.
Publication Date: July 23, 2013
mailto:support%40torchmate.com?subject=Technical%20Support%20%28general%29http://www.torchmate.com/http://www.torchmate.com/mailto:support%40torchmate.com?subject=Technical%20Support%20%28general%29
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ContentsWelcome Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Quick Link Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Torchmate 2 Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Gantry Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Table Frame Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Gear Rack Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Slat Support Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
Cable Carrier Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Other Included Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Safety First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Step 1: Assemble 8-hole corner gusset. . . . . . . . . . . . . . . . . . . . . . . 11
Step 2: Assemble slat support mounting brackets. . . . . . . . . . . . . . . . 12Step 3: Add leveling feet to legs . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 4: Add gussets to central legs . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step 5: Add gussets to corner legs. . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 6: Add legs to side extrusions . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 7: Add slat-support holder-brackets . . . . . . . . . . . . . . . . . . . . . 17
Step 8: Attach slat-support brackets to sides . . . . . . . . . . . . . . . . . . . 18
Step 9: Assemble gear racks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 10: Assemble guide rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 11: Install gear racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Step 12: Install guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Step 13: Join sides with cross-members . . . . . . . . . . . . . . . . . . . . . . 23
Step 14: Install the (customer-provided) slats. . . . . . . . . . . . . . . . . . . 24
Step 15: Assemble the joining plate. . . . . . . . . . . . . . . . . . . . . . . . . 25
Step 16: Assemble the inside-corner brackets . . . . . . . . . . . . . . . . . . 26
Step 17: Add joining plate and brackets to gantry support . . . . . . . . . . 27
Step 18: Assemble the top rail cam-follower brackets . . . . . . . . . . . . . 28
Step 19: Assemble the side rail cam-follower brackets . . . . . . . . . . . . . 29
Step 20: Add cam-follower assemblies to gantry support . . . . . . . . . . . 30
Step 21: Add gantry arm to gantry support . . . . . . . . . . . . . . . . . . . . 31
Step 22: Attach motor to mount plate . . . . . . . . . . . . . . . . . . . . . . . 32
Step 23: Add gear, pulleys, and belt to motor assembly . . . . . . . . . . . . 33
Step 24: Assemble inside corner brackets . . . . . . . . . . . . . . . . . . . . . 34
Step 25: Install motor assembly on gantry. . . . . . . . . . . . . . . . . . . . . 35
Step 26: Add drive-shaft support bracket to gantry. . . . . . . . . . . . . . . 36
Step 27: Instal l drive-shaft on gantry . . . . . . . . . . . . . . . . . . . . . . . . 37
Step 28: Assemble slide and cassette . . . . . . . . . . . . . . . . . . . . . . . . 38Step 29: Add slide and cassette to gantry . . . . . . . . . . . . . . . . . . . . . 39
Step 30: Add cam-follower support-bracket to gantry . . . . . . . . . . . . . 40
Step 31: Install cam-follower on gantry end. . . . . . . . . . . . . . . . . . . . 41
Step 32: Install motor on mount plate . . . . . . . . . . . . . . . . . . . . . . . 42
Step 33: Add gear, pulleys, and belt to motor assembly . . . . . . . . . . . . 43
Step 34: Attach L-bracket and mounting plate to gantry cassette. . . . . . 44
Step 35: Attach motor assembly to gantry L-bracket . . . . . . . . . . . . . . 45
Step 36: Attach cable-carrier brackets to gantry . . . . . . . . . . . . . . . . . 46
Step 37: Install cable-carrier end caps and links on gantry . . . . . . . . . . 47
Step 38: Attach cable-carrier brackets to side and gantry support . . . . . 48
Step 39: Install cable-carrier end caps and links on side . . . . . . . . . . . . 49
Building a water table (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Basic water table dimensions: . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Water table design considerations . . . . . . . . . . . . . . . . . . . . . . . . 52
Water table suppor t struc ture . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Water pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Water table slat support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Incorporation of the water table: . . . . . . . . . . . . . . . . . . . . . . . . . 56
Tool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Attaching an Arc Voltage Height Control (AVHC) . . . . . . . . . . . . . . . . 58Adjust the AVHC height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Attaching a plate marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjusting a plate marker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Attaching an oxy-fuel torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Attaching a Z-axis for routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Router backlash-compensation adjustment . . . . . . . . . . . . . . . . . . . 64
Attaching a Laser Crosshair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Adjusting a laser crosshair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Plasma with Manual Height Control . . . . . . . . . . . . . . . . . . . . . . . . 68
Plasma with Automatic Voltage Height Control . . . . . . . . . . . . . . . . . 69
Plasma with Automatic Voltage Height Control & Plate Marker . . . . . . . 70
Plasma with Automatic Voltage Height Control & Oxy / Fuel Torch . . . . . 71
Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Raw Arc Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 74Raw Arc Voltage Points for AVHC. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Thermal Dynamics: Cutmaster 51, Cutmaster 81, Cutmaster 101,
Cutmaster 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Thermal Dynamics: Cutmaster 52, Cutmaster 82, Cutmaster 102,
Cutmaster 152, Cutmaster A40, Cutmaster A60, Cutmaster A80,
Cutmaster A120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Hypertherm: Powermax 1000, Powermax 1100, Powermax 1250,
Powermax 1650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hypertherm: Powermax 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hypertherm: Powermax 65 & 85 . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hyper therm: Powermax 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Lincoln Electr ic: Tomahawk 1000 . . . . . . . . . . . . . . . . . . . . . . . . . 82
Driver Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Installing the Driver Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Manually Installing the Device Drivers (if necessary) . . . . . . . . . . . . . . 86
Driver Software Setup & Basic Overview. . . . . . . . . . . . . . . . . . . . . . 88
Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Coordinates or DRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connection Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
G-code Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Viewports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Output Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Basic Driver Software Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Motion Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Testing Output Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Test Cutting - Manual Height Control Plasma . . . . . . . . . . . . . . . . 100
Test Cutting - Manual Height Control Plasma . . . . . . . . . . . . . . . . 101
Test Cutting - Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Setup & Test Cutting - Plasma with Automatic Height Control. . . . . . 104
Setup & Test Cutting - Line Speed Test. . . . . . . . . . . . . . . . . . . . . 108Setup & Test Cutting - Voltage Test . . . . . . . . . . . . . . . . . . . . . . . 109
Test Cutting Checklist for Plasma with AVHC. . . . . . . . . . . . . . . . . 111
Importing Files & Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Pierce Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Maintenance and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 115General Maintenance Procedures & Suggested Replacement Parts List . 116
Basic Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Gear Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Loose Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bevel Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
How Torch Position Affects Bevel . . . . . . . . . . . . . . . . . . . . . . . . 123
What Causes Bad Cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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To the newest member of our Torchmate Family:
Thank You! Thank you for putting your faith and trust in Torchmate. When you purchased
your Torchmate CNC Cutting System, you purchased more than just a machine. You
purchased a team. The Torchmate team was built with the goal in mind of helping you get
the most value out of your automation investment.
For some, this Torchmate CNC Cutting System purchase is their first endeavor into the world
of automation. Others may consider themselves seasoned automation experts. No matter
which category you fall into it is important that you realize that investing in a Torchmate is
unlike any other machinery purchase you have made. We consider your success our success
as well as your challenges our challenges.
The Torchmate product line is designed to be simple, reliable and accurate. While there is no
“Easy” button on your new system, I can promise that you will get out of it what you put in.
Operating any machinery is a skill and does have a learning curve.
The first and perhaps most important item I want to give you today is the Torchmate
Technical Support Hotline: (866) 571-1066, ext 3. This number is toll free for those within
the United States. For those outside the United States, use the following number (775)
673-2200, ext 3. There is a dedicated professional support staff available Monday –
Friday from 7:30am to 4pm to assist you in any way that they can. We pride ourselves on
offering free unlimited telephone support for your machine and all we expect in return is
communication, understanding and patience. We are here for you as long as you need us.
Please don’t be a stranger. If you have questions or problems, call us. No matter how trivial
your issue may seem it is not trivial if it cuts into your productivity. Call, Call, Call! We are
here for you! Thank you again for putting your trust in us. We will do our best to not let you
down.
Sincerely,
Bill Kunz, CEO
Torchmate CNC Cutting Systems
This manual is written to make assembly of
the Torchmate 2 CNC machine as easy as
possible. Each step in the assembly process
outlines the components needed for the
step and describes in text and pictures how
the step should be completed. On each step
there will be a small button that will link to avideo online of the step animated to further
clarify the process.
To view this video internet access is required.
If any questions arise while building or
operating the Torchmate CNC cutting systemplease contact Torchmate technical support.
Click here to seethis step animated.
TECHNICAL SUPPORT
Toll Free: 1-866-571-1066 x3
International: 775-673-2200 x3
Fax: 775-673-2206
Email: [email protected]
Welcome Letter
mailto:support%40torchmate.com?subject=Welcome%20to%20Supportmailto:support%40torchmate.com?subject=Welcome%20to%20Support
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Click on a section link below
Quick Link Contents
Section 5:Maintenance and
Replacement Parts
Section 4:Software Setup and Operation
Section 3:Raw Arc Voltage Connection
Points
I
Section 2:Wiring Diagrams
for Different ConfigurationsPlasma Relay
INPUTOUTPUT
MOTORLINES
USB
ToMotors
V O L T S
T O R C H
P I E R C E
F A U L T
C O R N E R
O K T O M O V E
S T A R T
MotorConnection
1 210’InputCable lines1 &2 are
used, 3, 4, &5 are unused.
W i r e s 1 2 & 1 4
o n t h e C N C
I n t e r f a c e C a b l e
W i r e s 3 & 4
o n t h e C N C
I n t e r f a c e C a b l e
R a w a r c v o l t a g e
c o n n e c t i o n o n
p l a s m a c u t t e r
To Plate Marker
To Oxy Solenoid
Plasma Relay
INPUTOUTPUT
MOTORLINES
USB
ToMotors
V O L T S
T O R C H
P I E R C E
F A U L T
C O R N E R
O K T O M O V E
S T A R T
MotorConnection
1 210’InputCable lines1 &2 are
used, 3, 4, &5 are unused.
W i r e s 1 2 & 1 4
o n t h e C N C
I n t e r f a c e C a b l e
W i r e s 3 & 4
o n t h e C N C
I n t e r f a c e C a b l e
R a w a r c v o l t a g e
c o n n e c t i o n o n
p l a s m a c u t t e r
To Plate Marker
To Oxy Solenoid
Section 6:Basic Troubleshooting
Section 1: Table and Gantry Assembly
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The following parts list outlines the basic parts usedfor a 4’x8’ cutting area table.
The Torchmate 2 CNC cutting table is available in various sizes. The provided aluminum extrusions and other parts will vary de-pending on the table size.
The parts list is organized in groups based on where the parts areused in the table. You will find it helpful to organize the parts intothese groups before starting assembly. This will not only ensurethat you have all the required parts, but will make assemblyeasier and faster.
When a different size of part would be used for a different sizetable the specifications are listed in red based on the cuttinglength or width. Torchmate part numbers are shown in green.
Torchmate 2 Supplied Parts List
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Gantry Supplied Parts List
X 3
Top Cam-follower
Support Bracket
AR05
X 2
Side Cam-follower
Support BracketAR06
X 71” Cam Follower08-0001-002 X 1
Y-Axis L-Bracket08-0010-003
The gantry of a Torchmate 2 spans the table frame and supportsthe tools being used. The gantry structure consists of an extrud-ed aluminum cross member and t-section. The gantry supportsboth drive motors, the drive shaft, and linear slide on which the
tool mounts.
X 1
61½”x 3”x 3”
Aluminum Extrusion Table cutting width +131 /2”
X 1
12”x 3”x 3” Aluminum
ExtrusionSame size for all table sizes.
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X 1½” Mounting Plate08-0003-001
X 1X-Axis Motor Mount
PlateAR19
X 1
Y-Axis Motor Mount
PlateAR03
X 1Drive Shaft Support
PlateAR20
Gantry Supplied Parts List
X 3
⁄” Shaft Collar
09-0001-87986204
X 3
Spur Gear Pressed on
⁄” Shaft08-0011-002
X 2 Timing Belt08-0006-001
X 2
48 Tooth Large Pulley Timing Pulley (Large)
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Gantry Supplied Parts List
X 214 Tooth Small Pulley
Timing Pulley (Small)
X 2
380 oz in. Stepper
Motor08-0004-380
X 4M10x40
Hex Head Bolt09-0001-67444802
X 28
7 /16” SAE Flat Washer09-0001-67746644
7 /16 (0.4375)”(11.11 mm)
X 7
7 /16”-20 Hex Nut09-0001-67473041
7 /16 (0.4375)”(11.11mm)
X 8#8-32x3 /4” SHCS09-0001-05507074
3 /4 (0.75)”(19.05 mm)
0.164”(4.1656 mm)
X 8
#8 SAE Flat Washer09-0001-67746446
0.164”(4.1656 mm)
1.575”(40 mm)
0.3937”(10 mm)
X 4
M10 Flat Washer09-0001-67493080
0.3937”(10 mm)
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X 2
4 Hole Inside Corner
Gusset4303
X 2
6 Hole Inside Corner
Bracket4375
X 112 Hole Tee Joining
Plate
4325
Gantry Supplied Parts List
X 1
49½” Drive ShaftUsed to drive the gantry.
Table cutting width +11 /2”
X 8
#8-32 Hex Nut09-0001-87921292
0.164”(4.1656 mm)
X 6
⁄”-18 Hex Nut09-0001-87920914
5 /16 (0.3125)”(7.9375 mm)
X 12⁄” SAE Flat Washer09-0001-67746560
5 /16 (0.3125)”(7.9375 mm)
X 6⁄”-18x⁄”
Hex Head Bolt09-0001-87914933
7 /8 (0.875)”(22.225 mm)
5 /16 (0.3125)”(7.9375 mm)
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X 48⁄” T-nut T-nut
X 48
⁄”-18x5 /8” T-bolt09-0001-65366833
Gantry Supplied Parts List
X 157½” Slide with
Cassette Table cutting width +91 /2”
X 18Special Fabricated
Washer 0.1” Thick Special Fabricated Washer
The total number of ⁄”-18x1½” Socket Head Cap Screws and SpecialWashers corresponds to the number of holes on the slide listed below.Note the 5 /16”-18x1½” Socket Head Cap Screws will be used in other parts of assembly
and this quantity is just for use with the slide.
The total number of T-nuts and T-bolts provided will be much
more than the quantity listed here. The amount listed here
corresponds to the number used with the gantry. The number
of T-nuts will vary based on the width of the table; the number
of T-bolts used on the gantry is the same for all widths.
X 16
⁄”-18x1½” Socket
Head Cap Screw09-0001-60667169
11 /2”(38.1 mm)
5 /16 (0.3125)”
(7.9375 mm)
5 /16 (0.3125)”(7.9375 mm)
Table Cutting Width ⁄” T-nuts Needed4’ 48
5’ 52
6’ 56
7' 60Table Cutting Width Screws and Washers Needed
4’ 18
5’ 22
6’ 26
7’ 30
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Table Frame Supplied Parts List
The frame of a Torchmate 2 supports the gantry, provides struc-ture and stability for the motion control components, and mayhold the material being cut. The frame is made from extrudedaluminum, upon which the precision ground guide rails rest.
X 6
32”x3”x3”
Aluminum ExtrusionUsed for legs.
The 4’ and 5’ cutting length tableshave four legs. Tables with 6’ to
12’ cutting lengths have six legs. Tables with cutting length greater
than 14’ will use eight legs.
X 2
56”x3”x3”
Aluminum ExtrusionUsed for the width of the table. Table cutting width +8”
X 2114”x3”x3”
Aluminum ExtrusionUsed for the length of the table.
Table cutting length +18”
X 6Leveling Foot09-0001-40610172
One used per leg.
X 6
Base Plate2140One used per leg.
X 245 /16”-18x1” Socket
Head Cap Screw3122Four used on each leg.
1”(25.4 mm)
5 /16 (0.3125)”(7.9375 mm)
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X 128 Hole Inside Corner
Bracket4338
Two used on each leg.
X 2
120” Cold Rolled
Precision Ground RailsUsed along the length of the table.
Table cutting length + 24” Tables with a cutting area longer
than 12’ have multiple sections ofrail per side.
Table Frame Supplied Parts List
X 108
⁄”-18x5 /8” T-bolt09-0001-65366833
X 108⁄” T-nut T-nut
5 /16 (0.3125)”(7.9375 mm)
The total number of T-nuts and T-bolts provided will be manymore than the quantity listed here, which are just for the tableframe. The number of T-nuts and T-bolts will also vary based onthe cutting length of the table.
Table Cutting Length 5/16” T-bolts & T- Nuts Needed
4’ 76
5’ 76
6’ 108
8’ 108
10’ 108
12’ 116
14’ 148
16’ 148
18’ 180
20’ 180
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xv Torchmate 2 Bolt-together Kit Assembly Instructions
X 549” Gear Rack 03-0013-005
Gear Rack Parts List
Provided Gear Rack and Hardware for 4’ x 8’ Table
X 20⁄”-18x⁄”
Hex Head Bolt09-0001-87914933
7 /8 (0.875)”(22.225 mm)
5 /16 (0.3125)”(7.9375 mm)
X 20⁄” SAE Flat Washer09-0001-67746560
5 /16 (0.3125)”(7.9375 mm)
X 20⁄” T-nut T-nut
5 /16 (0.3125)”(7.9375 mm)
The gear rack is used to convert the rotational motion of themotors to the linear motion of the machine. The quantityand length of gear rack will vary based on the cutting lengthand width of the table. Torchmate uses three lengths of gearrack 24”, 49”, and 61”. A combination of these lengths will be
used for each machine.
Mounting hardware is included for each rack. A 24” sectionof gear rack has three mounting holes, and the 49” and 61”sections of gear rack have five mounting holes. For eachgear rack mounting hole, one ⁄”-18x⁄” hex head bolt, one⁄” flat washer, and one ⁄” T-nut are provided.
Use the tables below to determine the length of gear rackprovided for the size of table ordered.
Table Cutting Width Gear Rack Provided 4’ 1x49”
5’ 1x61”
6’ 1x49”, 1x24”
7’ 1x61”, 1x24”
Table Cutting Length Gear Rack Provided
4’ 2x49”
5’ 2x61”
6’ 2x49”, 2x24”
8’ 4x49”
10’ 4x61”
12’ 6x49”
14’ 4x61”, 2x49”
16’ 8x49”
18’ 4x61”, 4x49”
20’ 8x61”
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Slat Support Parts List
Torchmate’s slat support system is designed to mount to thetable frame and support the material being cut. The system usesa long slat support bracket to hold individual slats that hold thematerial. This bracket is held to the table using a holder.
X 16
⁄” ID Spacer09-0000-0000
X 16
⁄”-18x1½” Socket
Head Cap Screw09-0001-60667169
X 8
Slat Support Bracket
Holder
08-0012-001
X 4
Slat Support Bracket03-0011-048
X 32⁄” SAE Flat Washer09-0001-67746560
5 /16 (0.3125)”(7.9375 mm)
X 16
⁄”-18 Hex Nut09-0001-87920914
5 /16 (0.3125)”(7.9375 mm)
11 /2”(38.1 mm)
5 /16 (0.3125)”(7.9375 mm)
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xvii Torchmate 2 Bolt-together Kit Assembly Instructions
X 16
⁄”-18x5 /8” T-bolt09-0001-65366833
Slat Support Parts List
X 16⁄” T-nut T-nut
5 /16 (0.3125)”(7.9375 mm)
The number and length of slat support brackets provided willvary based on the length of table purchased. Torchmate ma-chines use two lengths of slat support brackets: 2’ and 4’. Eachlength uses two slat support bracket holders and four sets of
hardware.
The total number of T-nuts and T-bolts provided will be many more
than the quantity listed here. The number listed here corresponds to
the number used only with the slat support brackets. The number of
T-nuts and T-bolts will vary based on the cutting length of the table.
Table Cutting Length Slat Support Brackets Provided
4’ 2x4’
5’ 2x4’, 2x2’
6’ 2x4’, 2x2’
8’ 4x4’
10’ 4x4’, 2x2’
12’ 6x4’
14’ 6x4’, 2x2’
16’ 8x4’
18’ 8x4’, 2x2’
20’ 10x4’
Table Cutting Length 5/16” T-bolts & T- Nuts Needed
4’ 8
5’ 166’ 16
8’ 16
10’ 24
12’ 24
14’ 32
16’ 32
18’ 40
20’ 40
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xviii Torchmate 2 Bolt-together Kit Assembly Instructions
X 1
Bracket ACC Bracket A
X 2
Bracket BCC Bracket B
X 1Bracket CCC Bracket C
X 2
Bracket DCC Bracket D
X 1Bracket ECC Bracket E
X 1Bracket FCC Bracket F
Cable Carrier Parts List
The Torchmate cable carrier system is designed to keep controlcables and tool cables clear of the CNC machine’s moving parts. Thisextends the life of the cables and helps prevent damage.
The cable carrier system is optional but is generally purchased with a Torchmate 2 table.
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xix Torchmate 2 Bolt-together Kit Assembly Instructions
X 8
#10-32 Hex Nut09-0001-87921326
X 2 X 2
X 8#10 Flat Washer090001-67746487
Cable Carrier Parts List
X 14
⁄”-18x5 /8” T-bolt09-0001-65366833
X 14⁄” T-nut T-nut
5 /16 (0.3125)”(7.9375 mm)
X 8
#10-32 x 3 /4”
Socket Head Counter
Sunk Cap Screw09-0001-60504198
3 /4”(19.05 mm)
5 /16 (0.3125)”(7.9375 mm)
(X 58)
X 72 Cable Carrier Link 03-0016-200(Optional Heavy-duty
Cable Carrier Link)03-0016-301
(sold per foot [5-links])
Male Cable Carrier
End Cap03-0016-201(Male & Female Set)
(Optional Heavy-duty
Male Cable Carrier
End Cap)03-0016-300
(Male & Female Set)
Female Cable Carrier
End Cap03-0016-201
(Male & Female Set)
(Optional Heavy-duty
Female Cable Carrier
End Cap)03-0016-300
(Male & Female Set)
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X 225’ Motor Cable08-0005-025
X 1USB CableUSB CableX 1
3 Axis Micro Stepping
Drive Box3 Axis Drive Box
Other Included Parts
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Safety
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1 Torchmate 2 Bolt-together Kit Safety
Torchmate and Lincoln Electric Cutting Systems equipment is designed and built with safety in mind. However, your overall
safety can be increased by proper installation ... and thoughtful operation on your part.
Safety First
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. ALLOW NOBODY YOUNGER THAN 14 NEAR THIS EQUIPMENT.
IF YOU WEAR A PACEMAKER, YOU SHOULD CONSULT WITH YOUR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase acopy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 orCSA Standard W117.2.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR IS DONE ONLY BY QUALIFIED PEOPLE.
WARNINGDO NOT INSTALL,OPERATE, OR REPAIRTHIS EQUIPMENT WITH-OUT READING THESAFETY WARNINGS CON-TAINED THROUGHOUTTHIS MANUAL.
Think before you act—and be careful.
Electric Shock 1. ELECTRIC SHOCK can kill.1.1 The electrode and work (or ground) circuits are electrically “hot” when the power source is on. Do not touch these “hot”
parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
1.2 Disconnect the power source before performing any service or repairs. When the power source is operating, voltages in
excess of 250 volts are produced. This creates the potential for serious electrical shock - possibly even fatal.
1.3 Insulate yourself from work and ground using dry insulation. Wear dry gloves and clothing. Take extra care when the work
place is moist or damp.
1.4 Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The connection
should be as close as possible to the area being cut or gouged.
1.5 Ground the work or metal to be cut or gouged to a good electrical (earth) ground.
1.6 Maintain the plasma torch, cable and work clamp in good, safe operating condition. Repair or replace all worn or damaged
parts. Replace damaged insulation.
1.7 Never dip the torch in water for cooling or plasma cut or gouge in or under water.
1.8 When working above floor level, protect yourself from a fall should you get a shock.
1.9 Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.
1.10 Also see Items 4.3 and 6.
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2 Torchmate 2 Bolt-together Kit Safety
2. ARC RAYS can burn.
2.1 Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultraviolet and
infrared rays. These will damage your eyes and burn your skin if you are not properly protected.
2.2 Use safety glasses and a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of thearc when performing or observing plasma arc cutting or gouging. Glasses, head-shield, and filter lens should conform to
ANSI Z87. I standards.
Arc Current MinimumShade No.
SuggestedShade No.
Less than 20A 4 4
20A-40A 5 5
40A-60A 6 6
60A-300A 8 9300A-400A 9 12
400A-800A 10 14
2.3 Use suitable clothing including gloves made from durable flame-resistant material to protect your skin and that of your
helpers from the arc rays.
2.4 Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
Safety First (continued)
Arc Rays
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Safety First (continued)
Fumes, Gases
and Dust
3. FUMES AND GASES can be dangerous.
3.1 Plasma cutting or gouging may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.
When cutting or gouging, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone.
3.2 Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
3.3 When plasma cutting or gouging on lead or cadmium plated steel and other metals or coatings which produce highly
toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or
mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
3.4 Additional precautions are also required when cutting (zinc) galvanized steel or materials containing or coated with any of
the following:
Antimony Beryllium Cobalt Manganese Selenium
Arsenic Cadmium Copper Mercury Silver
Barium Chromium Lead Nickel Vanadium
3.5 The operation of plasma cutting or gouging fume control equipment is affected by various factors including proper use
and positioning of the equipment, maintenance of the equipment, and the specific procedure and application involved.
Worker exposure levels should be checked upon installation and periodically thereafter to be certain levels are within
applicable OSHA PEL and ACGIH TLV limits. For information on how to test for fumes and gases in your work place, refer to
publications section of this manual.
3.6 Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene,
a highly toxic gas, and other irritating products. Remove all sources of these vapors.
3.7 Gases used for plasma cutting and gouging can displace air and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.8 Read and understand the manufacturer ’s instructions for this equipment and follow your employer’s safety practices.
3.9 This product, when used for cutting, produces fumes or gases which contain chemicals known to the State of California to
cause birth defects.
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4 Torchmate 2 Bolt-together Kit Safety
Safety First (continued)
Fire or Explosion
3.10 Some dust created by routing, sawing, grinding, drilling, and other construction activities contains chemicals known to
cause cancer, birth defects or other reproductive harm. Avoid prolonged contact with this dust. Wear protective clothing
and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote
absorption of harmful chemicals.
Some examples of these chemicals are:• Lead from lead-based paint.
• Crystalline silica from bricks and cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber (CCA).
3.11 Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these
chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
4. Cutting flame and sparks can cause FIRE OR EXPLOSION.
4.1 Fire and explosion can be caused by hot slag, sparks, oxygen fueled cutting flame, or the plasma arc.
4.2 Have a fire extinguisher readily available. Provide a fire watch when working in an area where fire hazards may exist.
4.3 When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental
contact can cause overheating and create a fire hazard.
4.4 Be sure there are no combustible or flammable materials in the workplace. Any material that cannot be removed must be
protected.
4.4.1 Sparks and hot materials from cutting or gouging can easily go through small cracks and openings to adjacent areas.
4.4.2 Avoid cutting or gouging near hydraulic lines.
4.4.3 Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that suchprocedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even
though they have been “cleaned.” For information purchase “Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American
Welding Society (see address above).
4.4.4 Vent hollow castings or containers before heating, cutting or gouging. They may explode.
4.5 Do not add fuel to engine driven equipment near an area where plasma cutting or gouging is being done.
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Safety First (continued)
4.6 Connect the work cable to the work as close to the cutting or gouging area as practical. Work cables connected to the
building framework or other locations away from the cutting or gouging area increase the possibility of the current
passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
4.7 Hydrogen gas may be formed and trapped under aluminum work pieces when they are cut underwater or while using a
water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
4.8 Read and follow NFPA 51B “ Standard for Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.
5. CYLINDER may EXPLODE if damaged.
5.1 Use only compressed gas cylinders containing the correct gas for the process used and properly operating regulators
designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in
good condition.
5.2 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.5.3 Cylinders should be located: • Away from areas where they may be struck or subjected to physical damage. • A safe
distance from plasma cutting or gouging, arc welding operations and any other source of heat, sparks, or flame.
5.4 Never allow any part of the electrode, torch or any other electrically “hot” parts to touch a cylinder.
5.5 Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
5.6 Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
5.7 Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in Cylinders,”available from the Compressed Gas Association 1235
Jefferson Davis Highway, Arlington, VA 22202.
6. FOR ELECTRICALLY powered equipment.
6.1 Turn off input power using the disconnect switch at the fuse box before working on the equipment.
6.2 Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s
recommendations.
6.3 Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Cylinder
Explosion
Electrical
Power
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6 Torchmate 2 Bolt-together Kit Safety
Safety First (continued)
Electric and
Magnetic Fields
Plasma Arc 7. PLASMA ARC can injure.
7.1 Keep your body away from nozzle and plasma arc.
7.2 Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.
8. ELECTRIC AND MAGNETIC FIELDS may be dangerous
8.1 Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Cutting or gouging
current creates EMF fields around torch cables and cutting machines.
8.2 EMF fields may interfere with some pacemakers, so operators having a pacemaker should consult their physician before
cutting or gouging.8.3 Exposure to EMF fields during cutting or gouging may have other health effects which are now not known.
8.4 All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging
circuit:
8.4.1 Route the torch and work cables together - Secure them with tape when possible.
8.4.2 Never coil the torch cable around your body.
8.4.3 Do not place your body between the torch and work cables. If the torch cable is on your right side, the work cable
should also be on your right side.
8.4.4 Connect the work cable to the workpiece as close as possible to the area being cut or gouged.
8.4.5 Do not work next to cutting power source.
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7 Torchmate 2 Bolt-together Kit Safety
Safety First (continued)
Noise
Heavy Parts
Automatic
Operation
9. AUTOMATIC OPERATION
9.1 Any CNC machine may begin to operate automatically without warning. Only a trained individual familiar with the
software, machine, and computer system should operate this equipment.
9.2 Keep the immediate area around the CNC machine clear of materials that may cause interference. Keep area clear of
bystanders.9.3 All untrained persons should not work on or near a CNC machine. Do not leave the CNC machine unattended while power
is on to any electronics.
10. NOISE
10.1 Noise can cause permanent hearing loss. CNC operation, plasma arc cutting, plate marking, routing, and drilling can cause
noise levels that exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
10.1.1 To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.
10.1.2 Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
10.2 For information on how to test for noise refer to the publications section of this manual.
11. HEAVY PARTS
11.1 Parts of CNC machines are heavy. Also, material you are cutting may be heavy. Use caution when lifting or moving
them. To avoid injury, get someone to help you, or use a mechanical lifter. When using a mechanical lifter, follow all the
manufacturer’s safety guidelines.
11.2 Review the Occupational Safety & Health Administration (OSHA) technical manual Sect. 7, Ch 1.5. See the publications
section for additional information.
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8 Torchmate 2 Bolt-together Kit Safety
Pinch and Crush
Points
Flying Debris
Rotary Tools
Safety First (continued)
12. FLYING DEBRIS
12.1 Metal cutting and marking operations create waste that can fragment and fly. Make sure you have proper eye
protection and that everyone close to the CNC operations has proper eye protection, too.
12.2 Review the ANSI Z87.1 requirements. See the publications section for additional information.
13. PINCH AND CRUSH POINTS
13.1 Pinch and crush points are those normally moving parts of machinery, like CNC machines, that can pinch, capture,
crush, or sever parts of your body. Be aware of hazardous pinch and crush points.
13.2 Do not repair or adjust the machine with the controls on.
13.3 When the end of a CNC machine’s travel creates a “hard stop,” it creates a crush point. Keep fingers and hands awayfrom this.
13.4 Do not stack or store any additional items in contact with the machine. These could create additional pinch or crush
points, or could create a falling hazard.
13.5 Smaller limbs, hands, and fingers can fit into places that create additional pinch or crush points. Do not allow anyone
younger than 14 years old to operate this equipment or reach into it when its power is connected.
14. SHARP ROTARY TOOLS
14.1 Routing and drilling use high-speed rotating bits and cutters with sharp edges. Keep clear of bits when in use.
14.2 Turn the router, spindle, or drill off when changing bits. Be careful of the sharp edges.
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9 Torchmate 2 Bolt-together Kit Safety
Safety First (continued)
15. HOT MATERIALS
15.1 Plasma cutting uses an electric arc that can reach temperatures of 45,000°F (25,000°C). Oxygen-fuel cutting flames can be
up to 6,330°F (3,500°C). Any parts and scrap will be very hot after cutting. Use extreme care.
15.2 Use tongs and wear protective gloves when handling recently cut material. Also, consider other devices for safe hot
material handling.
15.3 It is safest to let material cool completely before handling.
16. MECHANICAL DRIVES
16.1 High-speed mechanical drives made of gears, belts, and or drive screws are used by CNC machines. Keep clear of them
during operation.
16.2 Do not attempt to service, adjust, or otherwise touch these components while the machine is on.
16.3 Secure loose clothing and cables to prevent entanglement.
17. AIR LINES UNDER PRESSURE
17.1 Some tools use compressed air or gases. Often flexible tubing (lines) bring the high-pressure air or gas to the machine.
Inspect these lines periodically. Repair or replace damaged lines.
17.2 Hot sparks, flying debris, other objects, or vehicles can melt, burn, or puncture these lines. Check them for punctures,
burns, or other damage or defects that could cause failure.
17.3 Check the routing of the lines to keep them away from traffic and from underfoot.
Hot Materials
Mechanical
Drives
Pressurized
Air Lines
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Table Assembly
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Step 1: Assemble 8-hole corner gusset
x128 Hole Inside
Corner Gusset
x96⁄” T-nut
• On each of the 12 eight hole corner
gussets, pass a ⁄” T-bolt through
each hole.
• Fasten a ⁄” T-nut to each T-bolt.
• Leave the nut loose on the bolt.
• The T-nuts should be positioned so
that the flanges face away from thegusset.
x96 ⁄” T-bolt
Click here to seethis step animated.
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Step 2: Assemble slat support mounting brackets
• On each of the eight slat support
mounting brackets, pass a ⁄” T-bolt
through the set of holes, spaced 1¼”
from the center holes..
• Fasten a ⁄” T-nut to each T-bolt.
• Leave the nut loose on the bolt.
• The T-nuts should be positioned sothat the flanges face away from the
bracket .
x8Slat Support Mounting
Bracket (6-Hole)
x16⁄” T-nut
x16⁄” T-bolt
1¼ ”
O. C.
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13 Torchmate 2 Bolt-together Kit Table Assembly
Step 3: Add leveling feet to legs
x632”x3”x3”
Aluminum Extrusion
x6Base
Plate
x6Leveling
Foot
x24⁄”x18 x1”
SHCS
• For each of the 32” aluminum
extrusions, place a base plate on the
end of the extrusion that has been
tapped.
• Attach the base plate with four
⁄”x18x1” cap screws.• Attach a leveling foot through each
base plate.
Click here to seethis step animated.
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14 Torchmate 2 Bolt-together Kit Table Assembly
Step 4: Add gussets to central legs
x4Completed Component
from Step 1
x2Completed Component
from Step 3
• Using two legs completed from step
3, slide two eight-hole corner gussets
onto each leg.
• Adjust the gussets so that the top of
the gusset is flush with the end of the
extrusion.
• Position the gussets like this for onlytwo of the competed legs.
• Tighten the T-bolts down so that the
gussets cannot move.
Click here to seethis step animated.
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15 Torchmate 2 Bolt-together Kit Table Assembly
Step 5: Add gussets to corner legs
x8Completed Component
from Step 1
x4Completed Component
from Step 3
• Using the remaining four legs
completed from step 3, slide two
eight-hole corner gussets onto each
leg.
• Adjust the gussets so that the top of
one gusset is flush with the end of
the extrusion.• The second gusset should be 3” from
the top of the extrusion.
• Tighten the T-bolts down so that the
gussets cannot move.
3”
Click here to see
this step animated.
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16 Torchmate 2 Bolt-together Kit Table Assembly
Step 6: Add legs to side extrusions
x2114”x3”x3”
Aluminum
Extrusion
x4Completed
Component
from Step 5
x2Completed
Component
from Step 4
• Using the 114” aluminum extrusions,
slide the leg completed in step 4
onto the extrusion.
• Position this leg in the center of the
long extrusion.
• Position a leg completed in step 5 on
each end of the 114” extrusion.
• Ensure that the lower gusset faces
the same direction on both end legs.
• Once positioned fully, tighten the
legs.
Click here to seethis step animated.
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17 Torchmate 2 Bolt-together Kit Table Assembly
Step 7: Add slat-support holder-brackets
• For each side completed in
step 6, slide four slat-support
holder-brackets from step 2
onto the extrusion.
• Place the holders-brackets
on the same side as the
protruding gussets.
• Slide the T-nuts into thelower slot of the extrusion.
• Do not fully tighten the slat-
support bracket-holders yet.
They will be adjusted later.
• Repeat for both sides.
x8Completed Component
from Step 2
Click here to see
this step animated.
x2Completed Component
from Step 6
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18 Torchmate 2 Bolt-together Kit Table Assembly
Step 8: Attach slat-support brackets to sides
x16⁄”x18x1½”
Socket Head
Cap Screw
x16⁄” ID
Spacer
x32⁄” SAE
Washer
x16⁄”x18 Nut
x4Slat-Support
Bracket
x2Completed Component
from Step 7
• On each of the side components,
attach two slat-support brackets.
Use the four slat-support bracket
holders on each side, two holders
per bracket.
• Insert a ⁄”x18x11 /2” cap screw
through the lower holes of the slat-
support-bracket holder, followed
by the ⁄” spacer, then the slat-
support bracket, two ⁄ ” washers,
and finally a ⁄”x18 nut.
• Position the slat-support brackets
so that they are centered on each
side.
Click here to seethis step animated.
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19 Torchmate 2 Bolt-together Kit Table Assembly
Step 9: Assemble gear racksx549’ Gear
Rack
x20⁄”x18x⁄” Hex
Bolt
x20⁄” SAE Washer
x16⁄” T-nut
• For each piece of gear rack, for each
hole, insert one ⁄” hex bolt with one
⁄” washer, and retain with one ⁄”
T-nut. Leave the T-nuts loose.
• Repeat this for every supplied piece
of gear rack.
Click here to seethis step animated.
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20 Torchmate 2 Bolt-together Kit Table Assembly
Step 10: Assemble guide rails
x2120” Precision-
Ground Rail
x12⁄” T-nut
x12⁄” T-bolt
• On each of the 120” precision-ground
rails, insert a ⁄” T-bolt through each
hole.
• Fasten a ⁄” T-nut to each T-bolt,
leaving the nut loose.
• Ensure all T-nuts flanges face away
from the rail.
Click here to seethis step animated.
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21 Torchmate 2 Bolt-together Kit Table Assembly
Step 11: Install gear racksx4Completed
Component
from Step 9
x2Completed
Component
from Step 8
• On each side completed in step 8, slide two pieces of gear rack assembled in
step 9 onto the top slot of the extrusion. The teeth of the gear rack should face
up.
• Position one gear rack 15" from the end of the extrusion. Choose the end that
will be on the torch side of the gantry to set this spacing.
• Align the remaining rack(s) with the first rack, using the illustrated spacing
method (with the supplied small section of gear rack as an alignment tool).
• Once the gear racks are correctly positioned, fully tighten their hex bolts.
15”
Engage the teeth of the providedsmall section of gear rack in both
installed sections of gear rack to getthe proper spacing.
Click here to seethis step animated.
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22 Torchmate 2 Bolt-together Kit Table Assembly
Step 12: Install guide rails
x2Completed Component
from Step 11
x2Completed Component
from Step 10
• Slide the precision ground rails from
step 10 onto the long extrusions of
the Torchmate 2 frame.
• Overhang the rail on the outside on
each side of the frame.
• Center the rails so that they extend
by 3” on each end of the extrusion.
• Fully tighten the precision groundrails.
Click here to seethis step animated.
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23 Torchmate 2 Bolt-together Kit Table Assembly
Step 13: Join sides with cross-members
x256”x3”x3”
Aluminum Extrusion
cross-members
x2Completed Component
from Step 12
• Join the two completed sides from step 12. Slide
the two 56” extrusion cross members onto the
protruding gussets.
• Level all horizontal members.
• Ensure table is square.
• Measure the outside edges of the guide rails along
the table length. This measurement must be equalwithin ⁄" overall.
• Once squarely assembled, tighten the T-bolts.
Click here to seethis step animated.
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24 Torchmate 2 Bolt-together Kit Table Assembly
• Place each of the (customer-provided)
slats into the slat-support brackets.
Step 14: Install the (customer-provided) slats
x2Completed
Component
from Step
12
x32551 /4”x3”x3 /16”
Support Slat
Customer Provided
Table Width4’
5’
6’
7’
Slat Length551 /4”
671 /4”
791 /4”
911 /4”
Table Length
4’
5’
8’10’
12’
14’
16’
18’
20’
Number of Slats
16
20
3240
48
56
64
72
80
Slat Specifications
Click here to seethis step animated.
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25 Torchmate 2 Bolt-together Kit Table Assembly
x112-Hole
Joiinng Plate
Step 15: Assemble the joining platex12⁄” T-nut
x12⁄” T-bolt
• On the 12-hole joining plate, insert a
⁄” T-bolt through each hole.
• Loosely fasten a ⁄” T-nut to each
T-bolt, with the flanges facing away
from the plate.
Click here to seethis step animated.
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Step 16: Assemble the inside-corner bracketsx26-Hole Inside-
Corner Bracket
x12⁄” T-nut
x12⁄” T-bolt
• On the two 6-hole corner brackets,
insert a ⁄” T-bolt through each hole.
• Loosely fasten a ⁄” T-nut to each
T-bolt, with the flanges facing away
from the bracket.
Click here to seethis step animated.
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27 Torchmate 2 Bolt-together Kit Table Assembly
Step 17: Add joining plate and brackets to gantry supportx112”x3”x3”
Aluminum Extrusion
x2Completed Component
from Step 16
x1Completed Component
from Step 15
• Slide the 12-hole joining plate onto the bottom of the
extrusion, engaging the 8 T-nuts in both extrusion slots.
• On the same side of the extrusion that has the protruding
part of the 12-hole joining plate, slide each of two-hole sides
of the 6-hole inside-corner brackets onto the extrusion.
• Have the four-hole sides of the brackets face each other.• Do not fully tighten the T-bolts.
Click here to seethis step animated.
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28 Torchmate 2 Bolt-together Kit Table Assembly
Step 18: Assemble the top rail cam-follower brackets
x2 Top Rail
Cam-follower
Support
Bracket
x8⁄” T-nut
x8⁄” T-bolt
x21” Cam
Follower
x87 /16” SAE
Washer
x27 /16”x18 Nut
• For each bracket, insert a 1”
cam-follower through two7 /16” washers, then through
the bracket. Add two more
washers, and finally add a 7 /16”
hex nut.
• As with all cam-followers,
add or subtract washers from
either side of the bracketto best position the cam-
follower on the rail.
• Orient the two top rail cam-follower support brackets as right and left-handed, to
mirror each other.
• On each bracket, insert a ⁄” T-bolt through each of the the four
small holes. Loosely fasten a ⁄” T-nut to each T-bolt, with the
T-nuts flanges facing away from the brackets.
Click here to seethis step animated.
Note: If you are installing a Router kit,
an additional 3/4" cam follower (withwashers and nut) will be installed in each
bracket in the slot below the 1" cam
follower. This step will be done after the
gantry is positioned on the table.
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Step 19: Assemble the side rail cam-follower brackets
• Orient the two side rail cam-follower
support brackets as right and left-
handed, to mirror each other.
• On each bracket, insert a ⁄” T-bolt
through each of the four small holes.
Loosely fasten a ⁄” T-nut to each
T-bolt, with the T-nuts flanges facingaway from the brackets.
• For each bracket, insert a 1” cam-
follower through two ⁄” washers,
then through bracket. Add two more
washers, and finally add a ⁄” hex
nut.
• As with all cam-followers, add or
subtract washers from either side of
the bracket to best position the cam-
follower on the rail.
x2Side Rail Cam-Follower
Support Bracket
x8⁄” T-nut
x8⁄” T-bolt
x41” Cam
Follower
x16⁄” SAE
Washer
x4⁄”x18 Nut
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dd f ll bl
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Step 20: Add cam-follower assemblies to gantry support
x1Completed
Component
from Step 17
x1Completed
Components
from Step 18
x1Completed
Components
from Step 19
• On each side of the T-section
assembled in step 17, slide one side-
rail cam-follower support bracket and
one top-rail cam-follower support
bracket onto the extrusion.
• Slide the two plates on
simultaneously.
• Position the side-rail cam-follower
support bracket to be in contact
with the 12-hole joining plate.
• Repeat at the other end of the
T-section.
• Tighten the T-bolts.
Click here to seethis step animated.
S Add
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Step 21: Add gantry arm to gantry support
Tapped
End
x1Completed Component
from Step 20
x161½”x3”x3”
Aluminum Extrusion
• Slide the gantry T-section assembled
in step 20 onto the 61½” aluminum
extrusion.
• One end of the extrusion is tapped.
Ensure that this end is not covered
by the T-section.• Once positioned, fully tighten all
T-bolts.
Click here to seethis step animated.
S 22 A h l
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32 Torchmate 2 Bolt-together Kit Table Assembly
Step 22: Attach motor to mount plate
x4#8-32x3 /4”
Socket Head
Cap Screw
x4#8x32 Nut
x4#8 SAE Flat
Washer
x1380 oz.-in. Motor
x1X-Axis Motor-
Mount Plate
• Attach a 380 oz.-in. motor to the
x-axis motor-mount plate so that
the motor presses onto the plate.
• Insert four #8 cap screws through
the motor and then through the
plate.
• Add a #8 washers and a #8 hex
nuts to each cap screw.
• Do not fully tighten the nuts at
this time.
Click here to seethis step animated.
St 23 Add ll d b lt t t bl
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33 Torchmate 2 Bolt-together Kit Table Assembly
Step 23: Add gear, pulleys, and belt to motor assemblyx1Completed
Component
from Step 22
x1 Timing
Belt
x1Spur Gear
Pressed on
⁄” Shaft
x114 Tooth
Small
Timing-Pulley
x148 Tooth
Large
Timing-Pulley
x1Shaft
Collar
• Attach the small timing-pulley to the spindle on the 380 oz.-in. motor. The set
screws should be towards the motor.
• Insert the spur gear through the center of the large timing-pulley. The large timing-
pulley’s set screws should be towards the spur gear.
• Insert the end of the spur gear through the motor mount plate and then through a
shaft collar.
• Tighten all the set screws.
• Once assembled, route a timing belt around the large and small timing-pulleys.
• Slide the motor on the x-axis
motor-mount plate, to tighten the
belt.
• Fully tighten the motor cap screws
and nuts.
Click here to seethis step animated.
St 24 A bl i id b k t
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34 Torchmate 2 Bolt-together Kit Table Assembly
Step 24: Assemble inside corner brackets
x24-Hole Inside-
Corner Bracket
x4⁄” T-nut
x4⁄” T-bolt
• On the two 4-hole inside-corner
brackets, insert two ⁄” T-bolt
through one pair of holes.
• Loosely fasten a ⁄” T-nut to each
T-bolt, with the T-nut flanges facing
away from the bracket.
Click here to seethis step animated.
St 25 I t ll t bl t
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35 Torchmate 2 Bolt-together Kit Table Assembly
x2⁄”x18x⁄” Hex Bolt
x2⁄” Nut
Step 25: Install motor assembly on gantry
x4⁄” SAE Washer
x1Completed Component
from Step 21
x1Completed Component
from Step 23
x1Completed Component
from Step 24
• Attach the assembled motor
plate to the 4-hole inside-
corner bracket with two ⁄"
hex bolts and ⁄" nuts. Use a
⁄" washer on both sides.
• Fully tighten the hex bolts.
• From the far end, slide the
motor assembly onto the
left side of the T-section
and gantry extrusion, as
illustrated.
• Leave a ½” space between
the end of the T-section’s6-hole inside-corner bracket
and the x-axis motor-mount
plate.
• Fully tighten the T-bolts.
½”
Click here to seethis step animated.
St 26 Add d i h ft t b k t t t
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36 Torchmate 2 Bolt-together Kit Table Assembly
Step 26: Add drive-shaft support bracket to gantry
x2⁄”x18x⁄”
Hex Bolt
x2⁄” Nut
x4⁄”
SAE Washer
x1Completed Component
from Step 24
x1Completed Component
from Step 25
• Attach the two brackets. Insert a ⁄" Hex Bolt with a ⁄" washer through
the driveshaft supportbracket and then through the 4-hole inside-corner
bracket. Add a ⁄" washer and hex nut, and securely tighten.
• Slide the assembly onto the gantry extrusion, leaving the T-bolts loose.
• Place the support about 6⁄” from the end of the extrusion. The distance will
be adjusted when the gantry is placed on the table.
x1Drive-Shaft
Support-Bracket
6⁄”
Click here to seethis step animated.
Step 27 Install drive shaft on gantry
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37 Torchmate 2 Bolt-together Kit Table Assembly
Step 27: Install drive-shaft on gantryx1Completed Component
from Step 26
x1Spur Gear Pressed
on ⁄” Shaft
x1Shaft
Collar
x13 /4” Diameter
Drive Shaft
• The drive shaft is drilled on both ends and each
end has a set screw.
• Slide one end of the drive shaft over the motor
plate’s spur gear shaft.
• Place a shaft collar over the additional spur
gear's shaft, and then insert the spur gear's shaft
through the drive shaft support and into the driveshaft.
• Tighten all the set screws and T-bolts.
Click here to seethis step animated.
Step 28: Assemble slide and cassette
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38 Torchmate 2 Bolt-together Kit Table Assembly
Step 28: Assemble slide and cassette
x18⁄”x18x1½” Socket
Head Cap Screw
x1Slide and Cassette
x18⁄” Special
Washer
• For all holes in the slide, insert one
special washer with one ⁄”x18x1½”
cap screw.
• On the side opposite the cassette,
loosely attach one T-nut onto each
screw.
• Do not fully tighten the T-nuts.
x18⁄” T-nut
Click here to seethis step animated.
Step 29: Add slide and cassette to gantry
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Step 29: Add slide and cassette to gantry
x1Completed Component
from Step 9
x1Completed Component
from Step 28
x1Completed Component
from Step 27
• On the assembled gantry, insert the slide and
cassette in the top slot on the side opposite
the drive shaft.
• Position the slide to just make contact with
the 6-hole inside-corner bracket on the
T-section.
• Insert the gear rack on the top of the gantry,
into the slot closest to the slide and cassette,with the teeth facing toward the drive shaft.
• Align the center of the gear rack with the
center of the slide.
• Tighten the hex T-bolts.
Click here to seethis step animated.
Step 30: Add cam follower support bracket to gantry
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40 Torchmate 2 Bolt-together Kit Table Assembly
Step 30: Add cam-follower support-bracket to gantryx6⁄” T-nut
x4⁄” T-bolt
x1 Top-Rail
Cam-follower
Support
Bracket
x1Completed Component
from Step 29
• Slide three T-nuts into both slots on the
bottom assembled gantry. These will be used
to attach the cable carrier brackets at a later
step.
• At the base of the gantry T-section, orient the
cam-follower support bracket's protrusion in
the same direction as the cassette—and away
from the gear rack.• Insert four T-bolts into the small holes of the
top-rail cam-follower support bracket, and on
into the end of the gantry.
• Tighten the T-bolts into the tapped holes in
the extrusion.
Click here to seethis step animated.
Step 31: Install cam follower on gantry end
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41 Torchmate 2 Bolt-together Kit Table Assembly
Step 31: Install cam-follower on gantry endx1Completed Component
from Step 30
x11” Cam
Follower
x4⁄” SAE
Washer
x1⁄”x18 Nut
• On the top hole of the cam-follower
support plate, install a 1” cam-follower,
with four washers (install two washers on
each side of the support plate to begin
with), and secure with a ⁄” nut.
• As with all cam-followers, add or subtract
washers from either side of the bracket
to best position the cam-follower on the
rail.
Click here to seethis step animated.
Note: If you are installing a Router kit, anadditional 3/4" cam follower (with wash-
ers and nut) will be installed in the slot
below the 1" cam follower. This step will
be done after the gantry is positioned on
the table.
Step 32: Install motor on mount plate
http://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step31.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step31.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step31.avi
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42 Torchmate 2 Bolt-together Kit Table Assembly
Step 32: Install motor on mount plate
x4#8-32x¾” Socket
Head Cap Screw
x4#8x32 Nut
x4#8 SAE Flat
Washer
x1380 oz.-in. Motor
x1Y-Axis Motor
Mount Plate
• Attach a 380 oz.-in. motor to the
y-axis motor plate. Insert four #8 cap
screws through the motor, and then
through the mount plate.
• Secure each screw with a #8 washer
and a #8 hex nut.
• Do not yet fully tighten the nuts.
Click here to seethis step animated.
Step 33: Add gear pulleys and belt to motor assembly
http://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step32.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step32.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step32.avi
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43 Torchmate 2 Bolt-together Kit Table Assembly
• Slide the small timing-pulley onto the
shaft of the 380 oz.-in. motor, with
the set screws toward the motor.
• Tighten the set screws.
• Insert the shaft of the spur gear
through a shaft collar, then through
the motor-mount plate bushing, andthrough the large timing-pulley, with
the set screws on the large pulley
facing away from the motor-mount
plate.
• Once assembled, attach a timing belt
around the large and small pulley.
Align timing-pulleys so that the belt
runs straight.
• Slide the motor to tighen the belt,
and then fully tighten the motor to
the mounting plate.
• Check the tighness of all set screws.
Step 33: Add gear, pulleys, and belt to motor assemblyx1Completed Component
from Step 32
x1 Timing
Belt
x1Spur Gear
Pressed on
5/16” Shaft
x114 Tooth
Small
Timing-Pulley
x148 Tooth
Large
Timing-Pulley
x1Shaft
Collar
Click here to seethis step animated.
Step 34: Attach L-bracket and mounting plate to gantry cassette
http://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step33.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step33.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step33.avi
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44 Torchmate 2 Bolt-together Kit Table Assembly
Step 34: Attach L-bracket and mounting plate to gantry cassettex1Completed Component
from Step 31
x1Y-Axis
L-Bracket
x4M10
Hex Bolt
x4M10
Washer
• Attach the Y-axis L-bracket
and the half inch mounting
plate to the cassette on the
slide. Use four M10 washers
and bolts.
• If installing a plate marker,
place the mounting platefor the plate marker
between the ½" mounting
plate and the Y-axis L
bracket.
x1½” Mounting
Plate
Click here to seethis step animated.
For Plate Marker
Step 35: Attach motor assembly to gantry L-bracket
http://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step34.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step34.avihttp://fab-solutions.com/download_sites/2baby/TM2BoltTogether-Step34.avi
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45 Torchmate 2 Bolt-together Kit Table Assembly
Step 35: Attach motor assembly to gantry L bracket
x2⁄”x18x⁄”
Hex Bolt
x25 /16” Nut
x45 /16” SAE
Washer
x1Completed Component
from Step 34
x1Completed Component
from Step 33
• Attach the assembled motor plate to the Y-axis
L-bracket with two ⁄” hex bolts using a ⁄” washer