Operator's Manual CRIIFTSM CompuCarve TM System Model Number: 183.217540 Please save this manual for future reference. CAUTION: Read and follow all Safety Rules and Operating Instructions before using this product. Sears, Roebuck and Co.
The CompuCarve TM System, with its computer-controlled 3D carving and general woodworking capabilities, is a revolutionary breakthrough in bench-top power tool design. This manual will explain the many features of the CompuCarve machine to help make creative carving operations pleasant and rewarding. Safety, performance, and design of the CompuCarve operator's manual before attention to the Rules For the CompuCarve System it will provide many hours dependability have been given top priority in the System.
INTRODUCTION TABLE .................................................................................................. OF CONTENTS SPECIFICATIONS SAFETY .................................................................................... ............................................................................................... ................................................................................................................. ELECTRICAL GLOSSARY CONNECTIONS THE ...................
Package Size ................................................. 28.5" Long x 20.25" Wide x 18" Deep Package Weight ............................................................................ 78 Ibs (35.4 kg) Machine Weight ............................................................................. 70 Ibs (31.8 kg) Cut Motor Speed (No Load) ................................................................. Cut Motor Horsepower (Peak) ....................................................................
General Safety Rules For Power Tools A CAUTION ALWAYS WEAR EYE PROTECTION. The operation of any power tool can result in foreign objects being thrown into the eyes, which can result in severe injury. Before beginning tool operation, always wear safety goggles or safety glasses with side shields and a fullface shield when needed. A Wide Vision Safety Mask is recommended for use over eyeglasses or standard safety glasses with side shields. Always wear eye protection that is marked to comply with ANSI Z87.1.
• • • • • • • • • • • • NEVER LEAVE A RUNNING TOOL UNATTENDED. Turn the power off and do not leave the tool until it comes to a complete stop. USE THE PROPER EXTENSION CORD. Make sure the extension cord is in good condition. Use only a cord heavy enough to carry the current the product will draw (see under Electrical Connections the proper gauges and lengths to use.) DISCONNECT TOOL from the outlet when not in use or before servicing. DRESS PROPERLY.
• • • • • • • • • • • • • • • • • • DO NOT PLACE HANDS ON THE GRIT SURFACE DRIVE BELTS DURING OPERATION. Belts in motion could drag a hand into the machine and cause injury. AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause hands to move into the cutting area. NEVER OPERATE THE MACHINE WITHOUT THE MUFFLER BAG IN PLACE. The bag captures dust and debris from machining operations. NEVER LOOK INTO THE VACUUM OUTLET DURING MACHINE OPERATION.
To reduce exposure to these chemicals: • Work in a well ventilated area • • Work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles Keep the machine and work area clean IMPORTANT NOTE: Servicing requires much care and specialized knowledge of the system and should be performed only by a qualified service technician. For service, return the machine to the nearest repair center in the original packaging.
Bevel Cut A cut made across a workpiece the table surface. that results in an angle other than 90 ° to Cross Cut A cutting operation across the grain or width of the workpiece. Head Screw The threaded shaft on each side of the machine by which the head is raised and lowered when activated by the head crank. Joint or Jointing A trim cut parallel to the grain of the wood on the edges of a board to create 90-degree angle with the top and bottom surface.
Items included with the CompuCarve A) B) C) D) E) F) G) H) I) J) K) System CompuCarve Machine CarveWright Software CD Operation Manual CarveWright Memory Card Programmer CarveWright Memory Card 1/16" Diameter Tip Tapered Carving Bit with Bit Adapter 1/8" Diameter Cutting Bit with Bit Adapter 3/32" Allen Wrench Muffler Dust Collector Bit removal Tool Crank Handle Ball and Shoulder Bolt Items Included With the CompuCarve System \,i?,, // /iY // FIGURE MEMORY 1: FIGURE2: CARVEWRIGHT CARD PROGRAMME
Unpacking and Setting Up the CompuCarve System 1. Remove the top packaging foam: After opening the shipping box, carefully remove the top molded foam packing from the machine. Located in the top tray are items B through K listed above. 2. Remove the machine from box: With a helper, lift out the machine and place it on a sturdy table or bench. Fold down the Outfeed Support Tables. Remove the plastic film covering the top clear safety cover. 3.
End Of Flexshaft Assembly Shaft Receptacle Ball Detent FIGURE 9" INSERTING THE FLEXSHAFT 6. Prepare cutting bits: If you have bits that are un-assembled please see the section titled Bit Adapter Assembly on page 26. Make sure the shaft of the bits extend all the way through the bit adaptor and always make sure the setscrews are tight and oriented to the flats on the shank. On the 1/4"shank bits, use a drop of permanent thread cement to prevent them from loosening. 7.
The key features of the CompuCarve multi-purpose tool and their locations are shown in the following illustrations. Flexshaft Cable Top Safety Cover Cutting Trucks Head Head Locking Lever (Shown in Non-Locked Position) Head Crank Handle _.
HARDWARE FEATURES (cont.) Air Intake ,,Cutting Motor Squaring Plate Muffler and Dust Collector Bag Sliding Guide Plate Folding Outfeed Table (rear) Outfeed Table Height Adjustment FIGURE11 : FEATURES Top Compression Roll e rs - REAR VIEW '_"_:"_ FIGURE12: (OUTFEED FEATURES, TABLE VIEW FROM BELOW NOT SHOWN FOR CLARITY) Sensor Sears, Roebuck and Co. CompuCarve TM System (Rev 1.
HARDWARE FEATURES (cont.) Vertical Moving Truck (Z-Truck) Y-Truck Guide Horizontal Moving Truck (Y-Truck) Z-Truck Guide Rails FIGURE13: CUTTING HEAD ASSEMBLY Overhead View of Machine (with workpiece) 1 Z-Axis is up/down Workpiec_ Far-side 1 This corner (near left) of the workpiece is the coordinate origin for all board measurements FIGURE 14: DIRECTIONAL CONVENTIONS Sears, Roebuck and Co. CompuCarve TM System (Rev 1.
Using the CompuCarve System Before the CompuCarve can begin to function, the CarveWright memory card must be installed. With the power off, push the memory card gently into the memory card slot until it stops, making sure the label is up. WARNING: Never remove the memory card from the machine while it is on. Doing so can result in damage to the workpiece. At any point during operation the CompuCarve machine can be stopped by pressing the STOP key or by lifting the cover.
Navigating the Menus Via the Keypad and LCD For input and display of information the CompuCarve machine employs a tactile keypad and LCD display. ALL operations require the user to input information at the actual machine location via the keypad (as opposed to information input and passed through the design software). The amount of information needed is dependent on the operation requested. The layout of the keypad is shown below.
Keypad Data Entry When a menu option asks for numerical data, such as length or depth dimensions, the keypad is used to enter the data. When fractional values are involved, data may be entered as either decimals or fractions. Decimals are the simplest. To enter a decimal simply type the whole number then the decimal point (down arrow key) followed by the decimal part (i.e. 12.345). Fractions are entered simply by placing the '/' (located on the up arrow key) between the numerator and denominator.
_ and ARNING: output quality, From the it is standpoint important of to safety, follow machine all instructions longevity, concerning the proper bit to be used for each built-in function. For approved router bits, visit the CarveWright website. Rip or Cross Cut This function is provided to allow a board to be sized by width and/or length. A Rip cut (along the grain or long axis) will size a board to the desired width; a cross cut (across the grain or narrow axis) will size a board to the desired length.
If it is desired to square both ends, or joint both sides, of a board, simply reverse the board in the machine and repeat the operation. If there is a significant crown to the board, place the highest point of the crown under the cutting head. This will allow the machine to measure the highest point of the crown and will prevent the machine from taking and excessive cut. Use the Repeat shortcut key as many times as necessary _ to eliminate the crown.
Measuring a Board The Measure Board length of an existing press Key #7 on the display will then ask Carving function allows the user to measure the width or board. Simply load a board in the typical way and keypad or use the arrows from the main menu. The for the direction the user wishes to measure. a Project A project is a set of related design elements (patterns or figures) created with the CarveWright design software and stored on the memory card.
Sliding Guide Plate Traction Drive Sliding Guide Plate Release Lever Squaring Plate, Board Tracking Sensor Board Sensor Detail FIGURE17: INSERTION , , WORKPIECE Release Lever Detail DETAILS Gently push the sliding plate up against the inside edge of the workpiece. DO NOT push the sliding plate against the workpiece with significant force. The sliding plate is used to guide the workpiece and is not intended to lock the piece in position.
, Next, lower the head by turning the head crank handle counterclockwise until the clutch clicks several times (at least 5 clicks recommended). The clutch is intended to load the board against the traction drive with consistent force. In certain cases the machine can sense if the workpiece is not loaded enough and repeatably display "Please Load Board" on the LCD. Most often this decreased loading is caused by insufficient lubrication of the four vertical corner posts or the two vertical leadscrews.
Workpiece Preparation Before carving can begin a number operations must be navigated. of menu prompts and machine The machine will ask if the workpiece is to Stay Under Rollers. Keeping the workpiece under the top rollers is a way of avoiding undesirable snipe in the cut and maintaining contact with the Board Tracking Sensor at all times.
If possible, measure the workpiece that you are going to carve before starting your project layout in the software. This will help guide your design and prevent unintended scaling issues if the project design is different then the available workpiece. If the inserted workpiece is larger than the project design then the available options are: Keep Original Size, Scale the project to fit the workpiece, or Load New Board.
Jogging the Cutting Truck As described above, the machine offers several options for positioning the carving on the workpiece, one of which is "Jog to Position." This is accomplished using the up and down arrows on the keypad to move the cutting truck across the width of the workpiece (near to far), and the left and right arrows will move the workpiece along its length (left or right). This option allows the user to place a carving at some location on a workpiece other than center or left corner.
(which may result in undesired machine operation), manually jig the project, or allow the machine to automatically jig the project (Auto-Jig). When Auto-Jig is selected, the machine will prompt for a workpiece that is slightly wider or longer than the project's dimensions in order to prevent interference with the machine's mechanics. When the project is complete the machine can cut off the extra material if desired.
Bit Adapter Assembly The CompuCarve utilizes a patented quick release chuck system to make changing bits fast and easy. To use this system the bits must first be installed into the bit adaptors. For 1/2" shank bits, insert threaded bit adaptor into the chuck assembly and then insert bit into threaded collet (See Figure 20) and tighten the collet with a wrench. Position the bit in the adapter as shown in Figure 22. Verify that the collet is also securely tightened.
Proper Bit Installation A B C (I ncorrect) (I ncorrect) (Correct) FIGURE22: CORRECT BIT ASSEMBLY A IS TOO LOW IN EXAMPLE Approved IS SHOWN IN EXAMPLE C. AND TWO HIGH IN EXAMPLE THE BIT B. Bits ,ili il ,ili / [ S' k A D # A B C D E F G H E Bit Family Name 1/8" Cutting 1/16" Tapered Carving V-Groove Round Nose Straight- Jointing Round-Over Roman Ogee Classical Ogee FIGURE23: Sears, Roebuck and Co.
Cocking the Quick Release Chuck The quick release chuck must be cocked in order to install a bit. To cock the chuck, press all the way up on the chuck release flange (See Figure 25) and release. The outer flange will snap up when the chuck is prepared to receive the bit assembly. Any time difficulty is encountered inserting a bit and adapter simply pull up on the flange to insure the chuck is cocked.
Bit Assembly Removal To remove a bit quickly, a thumb should be placed on the Z-Truck Grip Ridge (see Figure 25 below) and the Chuck Release Flange should be pulled up while pulling lightly on the bit with the opposite, gloved hand. WARNING: Use caution to avoid being cut by the sharp cutting edges of the router bit. Use caution if the bit has recently been in use; it may be HOT and a glove will be required to handle it.
The CompuCarve is a precision machine tool. With proper care and maintenance it will provide long, reliable service. ,_ WARNING: Always unplug machine before attempting troubleshooting or maintenance on the machine. any Dust Removal: The CompuCarve is designed to tolerate a considerable amount of carving system dust, but to ensure proper operation it should be kept free of debris as much as possible. Periodically blow or vacuum out any dust or debris from the recesses the unit.
adaptor and the chuck assembly during heavy use. Avoid overlubricating the chuck as this will only attract dust and could result in staining the workpiece. The guide rods/rails upon which the cutting head assembly rolls need to be kept free of cutting debris. They should be wiped or blown off before carving a project, and wiped occasionally with a thin coat of light oil for lubrication.
CUT DEPTH for any operation not allow deeper operations. "_" MAXIMUM is 1.0 inch. The machine will "_" ALL MOTORS ARE DISABLED when the front safety cover is open. The cover must be closed before the machine can proceed. "_" USE A SUPPORT FOR LONG WORKPIECES. To minimize the risk of over stressing the machine, use sturdy roller stands (additional accessory) for workpiece support when carving long workpieces more than 36 inches in length.
o Warped, bowed, or cupped pieces should be used only if this condition is minor and if the Board Tracking Sensor can follow it. A workpiece with slight cups or bows should be inserted curve down. o Avoid creating very thin features that protrude from the surface of the carving. Very thin features that are raised are prone to chipping. "_'WHEN CARVING IN PLASTIC, there are several issues to keep in mind.
WARNING: Always unplug machine before attempting troubleshooting or maintenance on the machine. any Checking the Board Sensor: There are several reasons why the machine will prompt the user to "Check the Board Sensor". o There is dust obscuring the sensor. Please see the next section titled "Cleaning of the Board Sensor" for details on how to address this situation. o There are existing features on the workpiece, like holes or other carved features, which prevent the sensor from tracking the top surface.
Troubleshooting the Board Sensor If the board sensor error cannot be resolved by cleaning the sensor as in the above steps you can further troubleshoot the problem. To check the status of the board edge sensor, go to the Main Menu-OptionsSensor Check menu (Item 7). Use the arrow keys to find Board Sensor on the bottom line of the display and press ENTER. Do the following checks: O O Load a board lower the head and check the reading displayed on the LCD.
Calibrating Machine Offsets: The "Calibrate Offsets" function is a simple procedure to allow the user to fine-tune the CompuCarve machine for improved accuracy. To perform the offset calibration you will need: A board at least 2" wide by 10" long between 1/2" and 3/4" thick. The CompuCarve branded 3/8" Jointing Bit (using a nonCompuCarve branded bit will affect accuracy). The CompuCarve sensor calibration will vary slightly depending on the color and darkness of the material.
Head Top Compression Rollers FIGURE 30" HEAD SHOWING COMPRESSION ROLLERS Checking the head pressure is very easy using a standard bathroom scale. 1. Before starting, make sure that the sliding plate is moved all the way to the far side of the machine and is out of the way of the scale. 2. Place the scale on the traction drive like you would a regular workpiece.
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