Step One:

Assemble the Rear and Front Frame with the two Side Frame Channels as shown with 10-24 x
screws and keps nuts.

Step Two:
Place the five table channels inside the frame and loosely fasten with 10-24 screws. Leave the screws
loose and take a tape measure and measure the Frame diagonally to make sure it is square. Both
dimensions must be the same to ensure squareness of the Frame. If frame is out of square lightly tap
the corner with the longer dimension and measure again until the dimensions are the same. Once you
have the frame square tighten the screws for the table channels.

Step Three:
Place the Right and Left Upright assemblies on a flat surface and slide a 36x 1 precision shaft
through the bearings in the upright. Remove the screws holding the white HDPE shaft blocks to the
Frame and slide a shaft block on each end of the shaft. Then place the Upright and shaft between the
Rear and Front Frame and reattach the HDPE shaft blocks with the 10-24 x 1 screws and nuts. Repeat
for the other side until the machines looks the same as shown below.

Step Four:
Attach the Back Support as shown with 10-24 screws and keps nuts. Make sure that the both uprights
are vertical. Tighten securely.

Step Five:
Place the Z-axis assembly on a flat surface. Slide the two 48 x 1 precision shafts through the
bearings. Remove the four HDPE shaft blocks from the uprights and slide onto the shafts. Place the Zaxis between the uprights and reattach the HDPE shaft blocks with the 10-24 screws and keps nuts.
Tip: It is helpful if you have two people to lift each end of the shafts while reattaching the screws. If
you are assembling by yourself stack something (box or books) on the table channels to set the Z-Axis
enclosure on while attaching the HDPE shaft blocks. Check to make sure that the Z-axis enclosure
moves freely back and forth as you tighten the screws.

Step Six:
Slide the two 36 Acme Lead Screws through the large hole in the Rear Frame Channel and thread
through the Black Acme Anti-Backlash Nut in the Upright until the lead screw is in the HDPE Lead
screw block. Slide the shaft of a Nema 23 stepper motor into the coupling. Fasten the motor with four
10-24 x 1/2 screws. Once the motor is securely fastened to the frame gently pull the lead screw back
towards the motor then tighten the coupling with a 7/64 allen wrench.

Step Seven:
Slide the 48 Acme Lead Screw through the large hole in the Upright and thread through the Black
Acme Anti-Backlash Nut on the Z-axis enclosure until the lead screw is in the HDPE Lead screw
block. Slide the shaft of a Nema 23 stepper motor into the coupling. Fasten the motor with four 10-24
x 1/2 screws. Once the motor is securely fastened to the frame gently pull the lead screw back towards
the motor then tighten the coupling with a 7/64 allen wrench.

Step Eight:
Slide the shaft of a Nema 23 stepper motor into the coupling in the Z-axis Enclosure as shown below.
Fasten the motor with four 10-24 x 1/2 screws. Once the motor is securely fastened to the top of the
Z-axis enclosure gently push the lead screw upwards towards the motor from underneath the enclosure
then tighten the coupling with a 7/64 allen wrench.

Step Nine:
Now you are ready to attach the wires from the controller to the stepper motors. NEVER plug or
unplug motor wiring while power is turned on to the controller. The motor wires from the controller
box are identified by a color band at the end of each wire. Plug the Green wire into the wire from the
stepper motor on the Z-axis. Plug the Red wire into the wire from the stepper motor from the X-axis.
Plug the Yellow and Blue wires into the two motors on the Y-axis. Since the motors are slaved
together in the software it doesn't matter what color each Y-axis motor gets as long as it is the Yellow
and Blue. Make sure you have the software installed and configured completely before powering up
the controller. There are screen shots on the enclosed CD that show you how to properly set-up the
software. Once the software has been installed and configured you are ready to begin running. Please
read the Mach 3 manual on the CD before operating your machine.