Maintenance and reference

Students clean accessible surfaces, inspect tooling and report faults. Mechanical adjustments, lubrication and servicing are staff tasks.

• Daily: C5 warm-up and listen for the fan; inspect bit, collet, nut, hose; check alignment without pushing the gantry; tell staff if it is out of square. Jog, C3, C2.[13,4]
• Every 40 h: brush X/Y/Z racks and pinions, then a BB-sized blob of light grease every 6 in, run the axes ~10 times, wipe the excess; Scotchbrite + WD-40 on the V-rails, brass brush on the rollers; push-pull play check at every drive.[13]
• Quarterly / semiannually: spin-test rollers, tighten pinion set screws, check Z eccentrics and spindle square; back up settings with US (restore with UR).[13,18]
• Semiannually at 40 h/week: all pinions replaced, Z extrusion stripped, cleaned and re-set, collets replaced as required.[13]

Students clean accessible surfaces, inspect tooling and report problems. Mechanical adjustments, electrical checks, lubrication and servicing below are staff tasks, not permission to power down or open the machine.

Daily, before cutting [MS 3]

1. Run C5 (9000, 10 000 and 12 000 rpm for 3 min each). Confirm the spindle fan runs.
2. Check the bit, collet and collet nut for wear and debris. Keep the spindle body, fans and airways clean. Tapers, shafts and collets must be scrupulously clean. Use the tightening method demonstrated during induction; do not substitute a torque for another nut.
3. Square the gantry against the end stops, hold it there, and press reset.
4. Push-pull test each motor area: X1, X2, Y, Z. A slight click is acceptable, but no movement beyond a few thousandths. If there is play, adjust the motor-mount spring (3½ turns after slack is removed) and/or tighten the set screws.
5. Move the machine around at both M and J speeds, or run a short warm-up routine.
6. Run C3.
7. Run C2.
8. Verify the zero with MZ,0 over the surface.
9. Visually inspect the machine, wiring, dust hoses and table.
10. Check that the dust collector works.

Also daily [QS 18]:

• Clean bits with solvent and discard dull or damaged ones.
• Check cables for cuts and pinch points.
• Keep the rails and gear racks clear of chips.

Every 40 h of use [MS 3]

1. Rack greasing: Clean the X, Y and Z racks and pinions with a small brush. Add a BB-sized blob of light grease every 6″. Run each axis to its extents about 10 times. Wipe off the excess and redo the X/Y push-pull test.
2. Clean the Z-assembly V-bearing edges with Scotch-Brite and WD-40, then wipe with light grease or machine oil. Clean and adjust the V-rollers as needed.
3. Scrub the X and Y V-rails with Scotch-Brite soaked in WD-40, then wipe clean. Clean roller buildup with a small brass brush.
4. Repeat the push-pull test and adjust the motor-mount springs (3½ turns past contact) or set screws.

Grease (staff):

• MS says light grease [MS 3].
• TM recommends heavy automotive or industrial grease [TM 7].
• UG says any regular bearing grease, and that grease does not trap debris badly [UG 63].
• The Quick-Start, by contrast, says to remove excess grease from the collet and nut, so keep grease off tooling [QS 15].

Monthly (from Troubleshooting Mechanicals)

• Drop and re-engage the X and Y pinions, at least monthly or whenever there is play. Press with 15–20 lb while tightening the 4 motor-plate screws [TM 4–5].
• Check that the YZ-car lower rollers are seated [TM 9].
• Check that the spindle is tight in its bracket [TM 17].

Quarterly (40 h/week) to semi-annual (20 h/week): everything above, plus [MS 3–4]

1. With the motors removed or disengaged from the racks, move each axis through its full travel. Check for looseness or binding.
2. With the motors removed, spin-test every X and Y car V-roller.
3. Tighten all pinion set screws. Replace pinions and key stock if they show movement.
4. Adjust the Z-axis V-roller bearing eccentrics with the provided flat wrench.
5. Check the spindle is square and aligned.
6. Remove the lower YZ-car V-roller dust covers and adjust the eccentrics.
7. Update software and firmware.
8. Back up settings with US (a C:\SB BKUP folder exists if ShopBot did a support visit). Restore with UR.

Semi-annual (40 h/week) to annual (20 h/week): everything above, plus [MS 4]

1. Replace all pinions. TM also says pinions are consumables, to be replaced every 6–12 months [TM 7].
2. Remove, clean, inspect, reassemble, lubricate and adjust the complete Z extrusion assembly.
3. Replace the collets, and the collet nuts if they are damaged.

Z bearing adjustment outline (staff task)

• Too loose: the top or lower bearings spin freely and do not touch the inner captured rail. The Z axis shows sideways "slop" [TM 18].
• Too tight: Z loses steps, binds or stops abruptly. The inner rail wears early [TM 18].
• Adjust the eccentrics with the flat wrench a little at a time [MS 4]. The full procedure is ShopBot's "Adjust PRS Z Car Bearings" document [TM 18].
• Uneven or slanted step-downs: first check the spindle is tight in its bracket, then the Z bearings [TM 17].

YZ-car lower wheel adjustment outline (staff task)

• Test: grip the bottom of the YZ car and pull it toward you. It must not move away from the cross-beam [TM 9].
• Symptom when wrong: a part cuts correctly on 3 sides with a bad 4th side, consistent with cut direction [TM 9].
• Hint: drop the Y pinion out of the rack first, so you can feel how freely the car rolls while held against the beam. Re-engage the pinion afterwards [TM 10].
• Adjustment: the two lower bearings have eccentric nuts. Rotate each slightly counter-clockwise to tighten [UG 64]. The full procedure is "Adjusting the Lower Wheels on the YZ car" [TM 10].

Squareness check

• Cut or scribe a large rectangle (for example 30″×50″) and compare the diagonals. They should be equal [TM 19].
• If they differ, first re-square the gantry against the end stops [TM 19–20].