Torchmate 2 Bolt Together Assembly Instructions

8/9/2019 Torchmate 2 Bolt Together Assembly Instructions

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Torchmate 2

Bolt-together Kit

Assembly InstructionsRevised July 23, 2013

© Torchmate Inc. 2012-2013


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ii Torchmate 2 Bolt-together Kit Assembly Instructions

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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iii Torchmate 2 Bolt-together Kit Assembly Instructions

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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iv Torchmate 2 Bolt-together Kit Assembly Instructions

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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v Torchmate 2 Bolt-together Kit Assembly Instructions

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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vi Torchmate 2 Bolt-together Kit Assembly Instructions

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


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


W i r e s 3 & 4

o n t h e C N C


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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vii Torchmate 2 Bolt-together Kit Assembly Instructions

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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viii Torchmate 2 Bolt-together Kit Assembly Instructions

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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ix Torchmate 2 Bolt-together Kit Assembly Instructions

X 1½” Mounting Plate08-0003-001

X 1X-Axis Motor Mount

PlateAR19

X 1

Y-Axis Motor Mount

PlateAR03

X 1Drive Shaft Support

PlateAR20


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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x Torchmate 2 Bolt-together Kit Assembly Instructions


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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xi Torchmate 2 Bolt-together Kit Assembly Instructions

X 2

4 Hole Inside Corner

Gusset4303

X 2

6 Hole Inside Corner

Bracket4375

X 112 Hole Tee Joining

Plate

4325


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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xii Torchmate 2 Bolt-together Kit Assembly Instructions

X 48⁄” T-nut T-nut

X 48

⁄”-18x5 /8” T-bolt09-0001-65366833


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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xiii Torchmate 2 Bolt-together Kit Assembly Instructions

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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xiv Torchmate 2 Bolt-together Kit Assembly Instructions

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


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)


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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xvi Torchmate 2 Bolt-together Kit Assembly Instructions

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


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


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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xx Torchmate 2 Bolt-together Kit Assembly Instructions

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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1 Torchmate 2 Bolt-together Kit Safety

Safety


22/146


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. 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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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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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.


26/146



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


27/146



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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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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Pinch and Crush

Points

Flying Debris

Rotary Tools


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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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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10 Torchmate 2 Bolt-together Kit Table Assembly

Table Assembly


32/146


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


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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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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.




35/146


Step 4: Add gussets to central legs

x4Completed Component

from Step 1


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.




36/146


Step 5: Add gussets to corner legs


from Step 1


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.



37/146


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.




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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.


from Step 2

Click here to see

this step animated.


from Step 6



39/146


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


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.




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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.




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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.




42/146


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.




43/146


Step 12: Install guide rails


from Step 11


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.




44/146


Step 13: Join sides with cross-members

x256”x3”x3”

Aluminum Extrusion

cross-members


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.




45/146


• 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




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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.




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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.


T-bolt, with the flanges facing away

from the bracket.




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Step 17: Add joining plate and brackets to gantry supportx112”x3”x3”

Aluminum Extrusion


from Step 16


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.




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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.


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


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.


S Add



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Step 21: Add gantry arm to gantry support

Tapped

End


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.


S 22 A h l



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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.


St 23 Add ll d b lt t t bl



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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.


St 24 A bl i id b k t



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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.


T-bolt, with the T-nut flanges facing

away from the bracket.


St 25 I t ll t bl t



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x2⁄”x18x⁄” Hex Bolt

x2⁄” Nut

Step 25: Install motor assembly on gantry

x4⁄” SAE Washer


from Step 21


from Step 23


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”


St 26 Add d i h ft t b k t t t



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Step 26: Add drive-shaft support bracket to gantry

x2⁄”x18x⁄”

Hex Bolt

x2⁄” Nut

x4⁄”

SAE Washer


from Step 24


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⁄”


Step 27 Install drive shaft on gantry



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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.


Step 28: Assemble slide and cassette



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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


Step 29: Add slide and cassette to gantry



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Step 29: Add slide and cassette to gantry


from Step 9


from Step 28


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.


Step 30: Add cam follower support bracket to gantry



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Step 30: Add cam-follower support-bracket to gantryx6⁄” T-nut

x4⁄” T-bolt

x1 Top-Rail

Cam-follower

Support

Bracket


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.


Step 31: Install cam follower on gantry end



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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.


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



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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.


Step 33: Add gear pulleys and belt to motor assembly



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• 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


Step 34: Attach L-bracket and mounting plate to gantry cassette



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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


For Plate Marker

Step 35: Attach motor assembly to gantry L-bracket



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Step 35: Attach motor assembly to gantry L bracket

x2⁄”x18x⁄”

Hex Bolt

x25 /16” Nut

x45 /16” SAE

Washer


from Step 34


from Step 33

• Attach the assembled motor plate to the Y-axis

L-bracket with two ⁄” hex bolts using a ⁄” washer

Date post:	01-Jun-2018
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Torchmate 2 Bolt Together Assembly Instructions

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