BobsCNC Evolution 4 User manual

Evolution 4
Assembly Instructions
Rev. 1.9
Upgrade Kit
Converts the Evolution 4 CNC Router
into an Evolution 5 CNC Router

1
Contents
EVOLUTION 4 Upgrade Specifications....................................................................................................................2
Information/Warning Boxes........................................................................................................................................3
Safety Precautions and Warnings............................................................................................................................4
Getting Started.................................................................................................................................................................5
Required Tools:............................................................................................................................................................5
Assembly Recommendations: ....................................................................................................................................5
Removing Components:...............................................................................................................................................7
Illustrated Step by Step Instructions...................................................................................................................7
X Frame Extension Assembly................................................................................................................................... 12
Wood Components ................................................................................................................................................ 12
Hardware .................................................................................................................................................................... 13
Illustrated Step by Step Instructions................................................................................................................ 14
Final Assembly............................................................................................................................................................... 21
Illustrated Step by Step Instructions................................................................................................................ 21
T-Slot Spoilboard ......................................................................................................................................................... 39
Wood Components ................................................................................................................................................ 39
Required Hardware................................................................................................................................................. 39
Illustrated Step by Step Instructions................................................................................................................ 40
Updating Firmware...................................................................................................................................................... 49
Evolution 4 Extension Firmware Value Change............................................................................................ 49
Appendix ($130=1283) .............................................................................................................................................. 50
Evolution 4 Firmware Values............................................................................................................................... 50

2
EVOLUTION 4 Upgrade Specifications
The Assembled Footprint:
Length: 58.7" (1490 mm)
Width: 39" (994 mm)
Height: 20.9" (530 mm)
Assembled Weight:
48 lbs.
Cutting Area:
X: 50.5" (1283 mm)
Y: 24" (610 mm)
Z: 3.3" (85 mm)

3
Safety is the First Priority. Always wear proper protective
equipment and use "safety sense" when assembling and
operating your Evolution CNC Router.
Information/Warning Boxes
CAUTION Indicates a possible risk of injury
that can result from failure to follow this
instruction
WARNING Indicates the possible damage
to the machine, its components, the work
piece, or injury that can result from failure to
follow this warning.
DANGER Indicates a serious risk of bodily
harm, injury and death. This is a serious
warning and should not be ignored. Any work
must be carried out with extreme caution.
TIPs Contains helpful information, shortcuts,
and hints to simplify assembly and make
machine operation easier and safer.
TIP
T

4
Safety Precautions and Warnings
Evolution Series CNC Routers have a 110 v. power supply and use bits that spin at
28,000 rpm with cutting edges that are sharp and hazardous. The operator must
understand the potential hazards and is responsible to take appropriate safety
precautions before operating the Router.
•Only use extension cords rated for 20 amps plugged into a dedicated outlet.
•Inspect the machine before every use for maintenance issues: loose fasteners,
belts, etc.
•Do not operate the machine with dull or damaged router bits.
•Always unplug machine after each use and when cleaning the router or changing
router bits.
•Remove rings, bracelets, watches, necklaces before using the machine.
•Wear snug fitting clothing and/or roll up long sleeves to prevent snagging.
•Use appropriate personal protective equipment (PPE) when operating machine
including safety glasses and hearing protection.
•Keep hands, hair and clothing away from the moving parts of the machine.
•Do not operate the machine when under the influence of alcohol or prescription
medications.
•Make certain the workpiece is clamped securely in place before starting the
machine.
•Never leave the machine running unattended.
•Children must be supervised by adults when operating the machine.
•Do not operate the machine in the presence of flammable materials.
•Keep floors clean, dry, and free of debris to eliminate slip and/or trip hazards.
•Have a suitably rated fire extinguisher on hand when the machine is in operation.

5
Getting Started
Required Tools:
A pair of long nose pliers.
Diagonal Cutters or sharp knife to trim nylon ties.
Calipers or measuring tape to measure part placement.
#3 Phillips screwdriver to build the main components.
220 grit sandpaper to remove laser marks on wood pieces (if desired).
LOCTITE 242™thread lock (fingernail polish can be used as a substitute).
Set of Metric Sockets and SAE Wrenches.
Set of Metric and SAE Allen Wrenches.
Assembly Recommendations:
Use a large, flat, clean work surface for assembling your EVOLUTION.
All Screws (unless noted) should be installed snug, then rotated 1-2 ½
turns.
Apply LOCTITE to all M4 X 16 mm Machine Screw that are used to secure
plywood pieces except for the 4 screws that clamp the router in step 10 of
the final assembly.
Light sanding may be required to remove any marks made by the laser.
Painting, or applying stain with a clear coat will provide extra protection to
the wood components.

6
Try using strips of 1inch blue painters’ tape behind the T-Slots to help hold
the Nuts in place during assembly.
Lock Nuts are never used to secure components that have T-Slots. They
are only used to mount components where the Nut is not held in a T-
Slot.
CAUTION This kit contains numerous small
components that pose a choking risk for small
children and pets. Keep kit pieces in a secure
location out of the reach or small children and pets.

7
Removing Components:
Illustrated Step by Step Instructions
Before you can upgrade your Evolution 4 you will need to remove several
components.
Step 1 Remove and discard Spoilboard.

8
Step 2 Remove and discard Belts by first loosening the Belt Tensioner.
Be sure to keep the Belt Retainers.
.

9
Step 3 Remove front Frame End Support
and discard.
Step 4 Remove both sides of the front Frame Corner Supports and set
aside. They will be reinstalled with the new Evolution 5 End
Support.

10
Step 5 Remove both sides of the Frame Corner Braces and set aside to
be used in the Front Assembly.
Step 6 Clip and remove the Zip Ties that secure the USB Cable and
Power Cords to the Wire Harness Supports.
Save these parts

11
Step 7 Slide Gantry Assembly off the Rails and carefully set it aside.
Step 8 Remove the four X Rails and discard. The X frame will form the
Rear Assembly.

12
X Frame Extension Assembly
Wood Components
Part #
Description
Qty
Photo
X1
Rail Support
6
X4
Frame Mid
Support
4
EX4
Extension
Frame Mid
Support
1
EX5
Extension
Frame Side
Support
2
X6
Frame
End Support
2
X7
Wire
Harness
Support
2
EX12
Coupling
Plate
2

13
Hardware
Part #
Description
Qty
Photo
H14
M4 x 16 Machine Screw
74
H15
M4 Nut
58
H47
M4 Locknut
16
H56
GT2 Belts
2
H82
Stress Proof Steel X Rail
4

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Illustrated Step by Step Instructions
Step 1 The X Frame consists of a front and rear Assembly. To build the
Front Assembly:
Align the tabs of the Rail Supports (X1) into the slots in the
Extension Frame Side Support (EX5). Secure with three M4 x 16
Machine Screws and Nuts for each Rail Support as shown.
Repeat for both Frame Side Supports Front.
Right Side
Left Side

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Step 2 Align the tabs of two Frame Corner Supports (previously
removed) into the lower slots of the Frame Side Assembly and
secure with two M4 x 16 Machine Screws and Nuts as shown.
Repeat to complete the second Frame Side Assembly.
Step 3 Align the tabs of the four Frame Corner Braces (previously
removed) into upper slots of the Frame Side Assembly on the
outside and secure with two M4 x 16 Machine Screws and Nuts
as shown. Repeat on the remaining Frame Side Assembly.
Right Side
Left Side

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Completed Front Side Assemblies

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Step 4 Align the slots in one of the Frame Side Assemblies with the
tabs in the Frame Mid Support(X4) as shown and secure with
two M4 x 16 Screws and Nuts.
Inside View
Outside View

18
Step 5 Repeat the process until three Frame Mid Supports have been
installed and secured.
Step 6 Repeat this procedure to install the remaining Side Support
Assembly.

19
Step 7 Align the slots in the X6 Frame End Support with the tabs in the
Front X Frame Assembly and secure each side with six M4 x 16
Screws and Nuts.
Completed Front X Frame
Assembly