Carbide 3D SHAPEOKO XXL User manual

XXL
ASSEMBLY
GUIDE

Table of Contents
Welcome and Congratulations!................................................................................................................1
Important Safety Instructions ..................................................................................................................2
Machine Operating Checklist ...................................................................................................................3
Glossary of Terms....................................................................................................................................4
Step 1: Inventory.....................................................................................................................................5
Step 2: Baseframe .................................................................................................................................12
Step 3: Carriages....................................................................................................................................18
Step 4: Gantry .......................................................................................................................................27
Step 5: Belting .......................................................................................................................................32
Step 6: Drag Chains................................................................................................................................38
Step 7: Proximity Switches.....................................................................................................................46
Step 8: Wiring........................................................................................................................................50
Step 9: Cleanup .....................................................................................................................................55
Step 10: Compact Router .......................................................................................................................58
Step 11: Level and Square......................................................................................................................63
Connect to Power..................................................................................................................................65
Download the Software.........................................................................................................................65
Configure Carbide Motion 5...................................................................................................................66
Run the Test Project ..............................................................................................................................67
Workholding .........................................................................................................................................68
Cutting Tutorials and Projects ................................................................................................................69
User Guides and Video Tutorials ............................................................................................................69
Have Questions? Need Help?
We have a fully-staffed support department waiting to help you if you run into trouble while assembling your
Shapeoko XXL. Just send us an email at [email protected] and we’ll get back to you on the quick!
3/27/2020 Version 5.0

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Welcome and Congratulations!
You are now the proud owner of the Shapeoko XXL, an incredibly powerful and easy-to-use CNC machine. In this guide
we will walk you through the assembly of your Shapeoko XXL, step-by-step. If you run into problems as you go, send us
an email at suppo[email protected] and we’ll help get you back on track!
Important Notes Used in This Guide
Throughout the guide, you will find information that we’ve called out for you to pay particular attention to. We use
three types of call-outs: Warnings, Notes, and Pro Tips:
Do NOT Use Power Tools
Only use the provided tools and hand tools. Do NOT use power tools to assemble your Shapeoko XXL.
Finger Tight Only
Several steps rely on “non-tightened fasteners.”Do not tighten fasteners beyond finger tight until instructed to do so.
Firmware
The Shapeoko XXL controller unit ships with GRBL 1.1 firmware, which must be used with Carbide Motion 5. This
document supersedes any information you may find on the Carbide 3D website.
Stepper Motors
Your Shapeoko XXL is powered by stepper motors. When the power is off, moving the motors by hand will cause them
to generate electricity.
WARNING: This is a warning. Information in these boxes is VERY important. Pay close attention.
WARNING: When moving the stepper motors by hand, go slow. The power generated when moving the
motors by hand will feel like bumps. If the lights on the control board are lighting up, it’s very important to
move the motors slower because you are pushing electricity back through the controller. Too much back flow
could damage the controller unit.
NOTE: This is a note—information that points out critical steps or information for future reference.
PRO TIP: This is a Pro Tip. Anytime you see one of these, you will find helpful additional information.

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Important Safety Instructions
The Shapeoko is a machine tool and requires the same caution that should be exercised with any power tool.
Eye Protection
Always wear safety glasses or goggles which are suitably impact resistant.
Hearing Protection
Always wear ear plugs or ear muffs. For long jobs, it may be desirable to wear both. Hearing damage is cumulative and
irreversible, so one should always err on the side of caution.
Respiratory Protection
Always wear a filter or respiratory mask suitable for the type of dust generated by the material being cut. If necessary,
arrange for dust collection and proper ventilation.
Clothing, Hair, and Jewelry
Always ensure that clothing, hair, and jewelry cannot become caught in the machine. Always wear appropriate
clothing: long-sleeved shirts, pants, and suitable footwear are recommended. When doing metal-working, gloves and
an apron are also recommended.
Machine Safety
Never reach into the machine’s working envelope while it is running. Always shut off and unplug the router to perform
tool changes, adjustments, and maintenance. Never leave the machine running unattended. Always inform someone
before operating the machine and check in with them after successfully completing work. Never allow children to use
the Shapeoko XXL unsupervised.
Fire Prevention
Consider the possibility of a fire caused by friction from the router and take suitable fire prevention precautions (e.g.
having a fire extinguisher handy and other suitable precautions).
Outlet Requirements
Plug the router into an outlet that has a dedicated on/off switch. Be sure this is accessible while the machine is
running, in case you should need to shut the Shapeoko XXL off immediately.
End Mill Safety
Use care when handling end mills—both to avoid being cut and to avoid damaging them. Handling end mills with
suitable gloves, or using a cloth to avoid contaminating them, is recommended. Inspect end mills carefully before each
use and ensure that they are securely held by the collet.
Debris Disposal
Recycle or safely dispose of milling debris and dust, keeping in mind flammability, (potential) spontaneous combustion,
and chemical considerations. Even natural materials can have surprising disposal implications. For example, walnut
wood dust is allelopathic (it inhibits plant growth), an irritant to the skin and respiratory tract, and potentially
poisonous to some animals. All of these possible disposal implications are in addition to the spontaneous combustion
hazard posed by all types of sawdust.

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Machine Operating Checklist
1. Be Safe
Always follow the safety guidelines listed on the previous page. Always wear appropriate safety equipment, especially
safety glasses/goggles, hearing protection, and respiratory protection.
2. Check the Machine
Check that all bolts and set screws are tight, v-rails are in good condition with no nicks or other damage, belts are tight
and in good shape, wiring is in good condition with continuity and securely fastened, and that nothing is frayed or
broken and everything is clear and safe.
3. Secure the Workpiece
Secure the workpiece (the material being milled) right-side up and in the desired orientation to the worksurface using
a technique appropriate to the material. After securing the workpiece, be certain that the machine is still able to move.
4. Mount the Router
Mount an appropriate compact router; ensure that it is vertical, square to the machine, and well-secured.
5. Examine the End Mill
Examine each end mill prior to use to ensure that it is sharp, in good condition, and not chipped (this is best done with
a loupe or magnifying glass). Install the end mill per the compact router manufacturer’s directions so that it projects at
least as much as the deepest intended cutting depth. Check to make certain that the collet is tight and will not work
loose during operation (it needs to be more than finger-tight—the machine will take no notice or care if it works
loose).
6. Clear the Work Area
Ensure the work area is clear and all cables run without interference. Most importantly, check that there is nothing
beneath the rails which might interfere with the movement of the carriages.
7. Connect to a Computer
To connect the Shapeoko XXL to a computer:
a. Power up the computer.
b. Connect the USB cable to your computer.
c. Start Carbide Motion 5 on your computer.
d. Turn the Shapeoko XXL on by flipping the in-line rocker switch on the power supply cord to the ON
position. Once powered on, you will be able to see a steady blue LED light on the controller unit.
e. Open the connection to the machine (it should connect and afford one control).
f. If necessary, home the cutting tool to the proper place in relation to the workpiece.
PRO TIP: The belts can be difficult to inspect because they are assembled “teeth-down” along the extrusion
rails. Use a mirror to examine the underside of the belts while moving the machine along its full range of
movement.
NOTE:It is especially important to check the machine after a crash, a failed cut, or a cut that induces chatter
or excessive vibration.

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8. Disconnect the Touch Probe
If you’re using a Touch Probe, remove the ground clip and secure it safely outside of the machine’s working area.
9. Double Check the Work Area
Ensure that nothing has been left in the work area. Optionally, you may traverse the working boundary of the job as a
final check.
10. Send NC File to Machine
Browse for the NC file (the G-code which gives the machine its instructions) which you have already simulated and
send it to the machine, following all prompts for tool changes and starting the compact router as required and setting
it to the correct speed.
11. Monitor the Machine During Operation
While staying clear of the work area, monitor the machine during operation. Ensure there is no build-up of dust,
debris, or fumes, and that nothing works loose. Do not reach into the machine’s working envelope or insert any object
into it while the machine is operating.
12. Finish and Clean Up
Once the job is complete, turn off the router, return the gantry to the home position or a known offset from home,
and ensure the end mill has stopped spinning before removing the finished piece and any waste.
Store end mills carefully when not in use to protect the cutting edges. Collets and accessories should be cleaned
between uses. Wipe them off with a suitable solvent such as isopropyl alcohol.
Glossary of Terms
Collet: A collet is a cone-shaped sleeve that holds an end mill in place in the router.
Eccentric Nut: Eccentric nuts are off-center nuts which allow you to adjust the tension of your V-wheels. Adjusting the tensioning
of the eccentric nuts allows the V-wheels to slide smoothly along the v-rails, which as you’ll see as we begin to assemble the
Shapeoko XXL, that this allows the carriages to slide easily along the rail system.
End Mill or End Mill Cutter: End mills (or cutters) are the cutting tools used by a CNC machine. End mills are similar to drill bits,
though, typically they can cut in all directions. End mills come in several varieties (including square, ball-nose, and v-carving) and
lots of sizes. Learn more about end mills here: docs.carbide3d.com/tutorials/tutorial-tooling.
G-code: G-code (general, or geometric, code) is a CNC programming language that controls when, where, and how the machine
tools move (for example, when to turn on or off, how fast to travel to a particular location, what paths to take, etc.) across the
workpiece.
Gantry: A gantry is an overhead motion system for use in multi-axis operations. It is the three extrusion rails that make up the
Shapeoko XXL’s rail system.
PEM nut: Penn Engineering & Manufacturing Corp. brand fastener providing self-clinching, permanent threads and mounting
points in thin sheet metal.
Toolpath: A toolpath is the “route” the cutting tool will follow as it shapes the workpiece. We use Carbide Create, Carbide 3D’s
cross-platform CAD/CAM program, to define the toolpaths for a project.
Working envelope: A working envelope is the CNC machine’s range of movement across each of its three axes, X, Y, and Z.
Workpiece: A workpiece is a stock piece, the sheet of material to be milled.
NOTE: It’s a good idea to keep a log of machine usage, making note of when adjustments are made and fasteners
are (re)tightened. Also keep a tally of usage time, including time for specific end mills, to determine when parts
need to be lubricated and when end mills should be relegated to rough work, re-sharpened, or recycled and
replaced. Finally, record machine settings and specifics of each tool chain used with the machine.

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Step 1: Inventory
Unpack Components
Let’s begin by making sure that all components are
accounted for and free from any shipping damage.
Remove all of the boxes and wrapped hardware from the
shipping container.
Once the you have unpacked everything you should have
the items listed below and shown in Figure 1-1.
Item
Description
Qty
Other Info
A
Shapeoko XXL Assembly Guide
1
This Printed Assembly Guide
B
Sweepy (65mm or 69mm)
1
Sweepy Dust Boot
C
Y-Axis Right Assembly Box
1
Contains Y-Axis Right Carriage
D
Pre-Assembled Wiring Harness Box
1
Contains Wiring Harness, Kits, and Hardware
E
Y-Axis Left Assembly Box
1
Contains Y-Axis Left Carriage
F
XXL Final Assembly Box
1
Contains Hardware and Components Needed for Assembly
G
X/Z+ Box
1
Contains the Z-Plus Carriage, Components, and Hardware
H
Cross Strap Package
1
40" x 7" x 1.5" Package Contains 3 Identical Cross Straps
I
Aluminum Extrusion Rail Package
1
40" x 7.5" x 3.5" Package Contains 3 Unique Extrusion Rails
J
Endplate Package
1
45.5" x 8" x 2" Package Contains 2 Identical Endplates
K
MDF Baseplate Board
2
42" x 29.75" x 0.75"; 2 Identical Boards (Under Divider)
Optional Items
L
Carbide Compact Router Box
1
Contains the Compact Router and Accessories/Tools
Now, let’s take a closer look at the contents of each box and the wrapped components. Use the checklists on the
following pages to verify all major components and small parts, including all hardware and tools, are accounted for and
free from damage. Once verified, carefully set aside until needed for assembly.
Figure 1-1
PRO TIP: Your Shapeoko XXL kit has been carefully packaged by hand and double checked for accuracy.
However, sometimes errors are made. If, after completing your inventory, you find that something is missing
or damaged, contact us at [email protected] and we’ll ship it to you ASAP.

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Final Assembly Box
Carefully open the box labeled XXL Final Assembly and inspect its contents. Many parts are packaged in small plastic
bags, and smaller bags may be inserted into larger bags for shipping purposes. This box should contain all of the items
shown in Figure 1-2 and listed in the table on the next page.
Figure 1-2

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Final Assembly Box contents, see Figure 1-2:
Item
Description
Qty
A
Baseframe Hardware: M5 x 25mm Button Head Cap Screws
18
B
Baseframe Adjustable Leveling Feet
4
C
Router Mount
1
D
Router Mount Adapter Ring
1
E
Router Mount Hardware: M5 x 55mm Socket Head Cap Screws (2) and
M5 x 16mm Button Head Cap Screws (2)
4
F
Loctite 242 Threadlocker (non-permanent)
1
G
Extrusion Rail Hardware: M6 x 12mm Button Head Cap Screws
24
H
Belt Clips (6) and Belt Hardware: M5 x 10mm Socket Head Cap Screws (6)
12
I
Toothed Belt (1200mm each)
3
J
Controller Unit and Hardware (inside): M6 x 8mm Button Head Cap Screw (2)
3
K
Shapeoko Decal
1
L
Power Cord
1
M
Power Supply
1
N
USB Cable
1
O
Large Zip Tie
2
P
Permanent Marker
1
Q
#201 ¼-inch Square End Mill Cutter
1
R
Tool Kit: 5, 4, 3, 2.5, 2, and 1.5mm Hex Keys*; 10 and 8mm Wrenches
8
*The 5mm hex key is provided in case you need to adjust the stepper motor idlers; the 1.5mm hex key is provided in
case you need to adjust the motor pulley set screws.
Y-Axis Left Assembly & Y-Axis Right Assembly
Boxes
Open the boxes labeled Y-Axis Right Assembly and Y-Axis Left
Assembly and visually verify they match the carriages as shown in
Figure 1-3.
The Right and Left Assembly components are mirror images.
Figure 1-3
NOTE: We’ll need these two boxes and the two foam blocks
inside them to help with assembling the gantry. Set them
aside for later use.

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Pre-Assembled XXL Wiring Harness Box
This box should contain all the items listed in the table below and
shown in Figure 1-4.
Item
Description
Qty
A
Pre-assembled Wiring Harness (X-Axis and Y-Axis Drag Chains and Cables)
1
B
Drag Chain Support Brackets (7) and Hardware: M4x6mm (10), M5x8mm (2),
M5x16mm (2) Socket Head Cap Screws; M5 Nuts (2); M3x4mm Flat Head
Screws (6)]
29
C
Proximity Switch Plates (2) and Hardware: M3x18 (4), M5x8mm (4) Socket Head
Cap Screws; 30mm Male-to-Female Standoffs (2)
12
D
Cable Tie Mounts (5), Cable Ties (25), and Hardware: M4x6mm Socket Head Cap
Screws (5)
35
E
PCB Riser Board (Adapter Board for Proximity Switches)
1
X/Z+ Box
Open the box labeled X/Z+ and visually verify that the items inside
match those shown in Figure 1-5.
Item
Description
Qty
A
Z-Plus Carriage with Z-Axis Stepper Motor and Z-Axis Proximity Switch Attached
1
B
X-Axis Stepper Motor
1
C
M5 x 10mm Socket Head Cap Screw
4
D
Tramming Plate and Hardware: M5 x 8mm Socket Head Cap Screws (4)
5
Figure 1-4
Figure 1-5

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Sweepy Box
The Sweepy Dust Boot is available for 65mm and 69mm routers.
Open the Sweepy box and verify its contents match those shown in
Figure 1-6.
Aluminum Extrusion Rails
The three aluminum extrusion rails are packed together. Carefully
cut the plastic bands holding the rails together and remove the
cardboard shell.
Examine the three rails, shown in Figure 1-7, and identify the
following:
•X-Axis Rail (X-rail): in addition to the Shapeoko/warning
decals on the front, the rail has sixteen (16) pre-drilled M4
screw holes along the back.
•Y-Axis Left Rail (Y1-rail): has two (2) M6 and four (4) M4
pre-drilled screw holes along one side.
•Y-Axis Right Rail (Y2-rail): has two (2) M6 pre-drilled screw
holes along one side.
Endplates
The two (2) identical endplates are packed together. Remove the
cardboard shell and identify the two endplates shown in Figure 1-8.
Cross Straps
The three (3) cross straps are identical and are packed together in a
cardboard shell. Remove the packaging and identify the three cross
straps pictured in Figure 1-9.
Figure 1-6
Figure 1-7
WARNING: The extrusion rails may look the same, but there
are subtle differences that you need to pay attention to.
Figure 1-8
NOTE:Each endplate has several integrated PEM nuts.
Inspect each one to verify that the threads are properly
formed and that it is firmly and squarely in place.
Figure 1-9

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MDF Baseplates
The two (2) MDF baseplates are identical and packed in the bottom
of the shipping box. Identify the two MDF baseplates pictured in
Figure 1-10.
Carbide Compact Router Box
You will only have this box among your items if you ordered a
separate router with your Shapeoko XXL kit. This box should contain
all of the items shown in Figure 1-11.
Additional Required Tools
The following tools are not included in your Shapeoko kit, but are
required for assembly (see Figure 1-12):
Item
Description
Qty
A
Flush Cut Pliers or Scissors
1
B
Level
1
Recommended Tools
The following tools are recommended for assembly, but not
included (see Figure 1-12):
Item
Description
Qty
C
8 and 10mm Combination Wrench
2
D
Easy-Peel Masking Tape (e.g. blue painter’s
tape; nothing that leaves a residue behind)
1
E
Flashlight
1
F
Tape Measure
1
G
Ruler
1
Figure 1-10
WARNING: Store your MDF baseplates where high humidity
or the risk of liquids spilling on them is low. MDF is sensitive
to moisture. You may want to consider sealing the baseplates
with a suitable finish (e.g. spar urethane or lacquer).
Figure 1-11
Figure 1-12

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Before You Begin Assembly
As you work your way through the assembly
guide you will be instructed to layout, place,
or position components in a specific location
or direction, such as: up, down, left, right,
front, back, rear, inside, outside, under, over,
etc. For example, “drag chain support
brackets are attached to the BACK of the X-
rail,” or “the controller unit is mounted to
the OUTSIDE and to the REAR of the Y1-rail.”
To help avoid confusion, all such references
are given from the perspective of one
standing in front of, and looking at, the
machine as shown in Figure 1-13. As much as
possible the words “left” and “right” are
replaced with “Y1” and “Y2” respectively—in
reference to the Y-Axis LEFT extrusion rail
(Y1) and the Y-Axis RIGHT extrusion rail (Y2).
Take a minute to familiarize yourself with this
view of the machine.
In addition to adopting a front view
perspective, it is very helpful to familiarize
yourself with the machine’s directional axes:
the X-Axis moves left and right, the Y-Axis
moves front and back, and the Z-Axis moves
up and down. See Figure 1-14.
Figure 1-14
Figure 1-13

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Figure 2-2
Step 2:
Baseframe

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Required Components
See Figure 2-2:
Item
Description
Location
Qty
A
Cross Strap
N/A
3
B
MDF Baseplate
N/A
2
C
Endplate
N/A
2
D
M5 x 25mm Button Head Cap Screw
XXL Final Assembly Box
18
E
Adjustable Leveling Foot
XXL Final Assembly Box
4
Required Tools
See Figure 2-3:
Item
Description
Qty
A
3mm Hex Key
1
B
Level (not included)
1
Recommended Tools
See Figure 2-3:
Item
Description
Qty
C
Spare Hex Key (included)
2 or 3
D
Flashlight
1
E
Tape Measure
1
Figure 2-3

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Important Assembly Information
Lay Out the Cross Straps
1. Lay out the three (3) cross straps parallel to each
other, with the flanged edges facing down and
12 inches of space between them. See Figure 2-4.
Attach the Rear MDF Baseplate
1. Select one of the MDF baseplates, ensuring that
the countersunk holes are facing up.
2. Place the MDF baseplate across the back half of
the three cross straps and line up the screw holes,
six across the back and three across the middle as
shown in Figure 2-5.
3. Use the 3mm hex key to insert three (3)
M5x25mm button head cap screws through the
three middle countersunk holes in the MDF
baseplate and into the integrated nuts in the three
cross straps as shown in Figure 2-6.
4. Turn the screws until they stop but do not fully
tighten.
Figure 2-4
Figure 2-5
Figure 2-6
WARNING: Be careful to avoid cross threading
screws.
WARNING: Assembly should not be done on the
floor; a large table or workbench is essential for
assembly. The completed dimensions of the
Shapeoko XXL are 44.8" W x 40.3" L x 16.6" H.
We recommend that you assemble the machine
on a table slightly larger than the machine itself.
PRO TIP: Use one or more of the spare hex keys
to align the screw holes as shown in Figure 2-6.

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Attach the Front MDF Baseplate
1. Place the second MDF baseplate across the front
half of the cross straps and line up the screw
holes, six across the front and three across the
middle as shown in Figure 2-7.
2. Use the 3mm hex key to insert three (3)
M5x25mm button head cap screws through the
baseplate and into the cross straps.
3. Turn the screws until they stop but do not fully
tighten.
Attach the Rear Endplate
1. Select one of the two (2) identical endplates.
2. Place the endplate along the back of the machine
and slide it under the three cross straps. See
Figure 2-8.
3. Adjust the endplate, cross straps, and MDF
baseplates so that all six holes align. Use one or
more of the spare hex keys to help with alignment
as shown in Figure 2-9.
4. Use the 3mm hex key to insert six (6) M5x25mm
button head cap screws into the six countersunk
holes in the MDF baseplate, through the cross
straps, and into the integrated nuts of the rear
endplate. See Figure 2-9.
5. Turn the screws until they stop but do not fully
tighten.
Figure 2-7
NOTE: We’ll come back and tighten all of the
baseframe screws later on when squaring the
machine.
NOTE: If you are having trouble getting any of
these screws started, make sure the machine is
square and apply a little bit more downward
pressure. However, be very careful not to cross
thread any of the screws.
Figure 2-8
Figure 2-9

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Attach the Front Endplate
1. Place the other endplate along the front of the
machine and slide it under the three cross straps as
shown in Figure 2-11.
2. Adjust the endplate, cross straps, and MDF
baseplates so that all six screw holes align. See
Figure 2-12.
3. Use the 3mm hex key to insert six (6) M5x25mm
button head cap screws into the baseplate, through
the cross straps, and into the front endplate.
4. Turn the screws until they stop but do fully tighten.
Figure 2-10
Figure 2-11
Figure 2-12
PRO TIP: To further help with hole alignment,
shine a flashlight under the assembly to
illuminate the holes from the bottom. Adjust as
necessary. See Figure 2-10.
PRO TIP: You can also try loosely inserting
screws from the center and working your way out
(i.e. center, left 1, right 1, left 2, right 2). Then
slowly tighten each screw in the same order. If
you are still having trouble getting the holes to
line up, contact us at [e-mail].

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Screw in the Adjustable Leveling Feet
1. Carefully lift each corner of the baseframe and screw in the four adjustable leveling feet, two per endplate, as
shown in Figure 2-13.
2. Screw in each adjustable leveling foot until it is flush with the endplate as shown in Figure 2-13.
Level the Machine
1. Adjust the leveling feet to bring the fully
assembled baseframe into level. Check front-to-
back, side-to-side, and diagonally. See Figure 2-14.
Optionally, if you wish to check for square now, you can
do so by measuring diagonally across the baseframe from
the outside edges of the endplates. Check both sides. The
machine is square when the two measurements are equal.
See Figure 2-14.
Approximates are acceptable at this stage as the machine
is not fully tightened. A final and more comprehensive
leveling and squaring of the machine will be completed in
Step 11: Level and Square.
Figure 2-13
Figure 2-14
WARNING: The baseframe assembly is heavy. It is recommended you complete this step with the help of
another person. When lifting only one corner of the machine at a time, do not lift any higher than is necessary
to insert the leveling foot. Alternately, lifting from the center of one endplate and inserting a suitable wedge
is acceptable.

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Figure 3-2
Step 3:
Carriages