Maintenance
Care and Maintenance

The CarveWright is a precision machine tool.  With proper care and maintenance it will provide long, reliable service. Below are regular maintenance guides and instructions on how to properly care for your CarveWright.

WARNING:  Always unplug machine before attempting any troubleshooting or maintenance on the machine.

Dust Removal
The CarveWright 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 of the unit.  Always make sure to use low-pressure air (<80 psi) around the electronics and sensors.  High-pressure air can damage components and actually push dust into them.  The machine can be adapted to external dust removal systems.  Be sure that these vacuum systems are properly grounded because of the large static charge that they tend to generate.  The warranty does not cover electronics failures due to Electrostatic Discharge (ESD).

It is recommended to use a dust collection system such as the DC Insert sold in the CarveWright Third-Party Store

Check the Cutting Trucks for Looseness
As a matter of regular maintenance, check that the Y and Z Cutting Trucks (Figure 14) are tight and do not have any play in them.  Simply grab each one by hand and wiggle back and forth.  If either of these trucks is loose they will need to be tightened.  Failure to tighten these trucks will result in decreased carving quality.  Please call the service help line for tightening instructions.
Check Sandpaper Belts for Tears or Roll-up
Visually inspect the two sandpaper belts each time the machine is used.  Look for tears or roll-up of the end of the belt.  Roll up will always occur on the control panel side of the machine.  The ends of the belts will roll under themselves and form a doubled over raised portion on the belt end. See the video for instructions on replacing or upgrading the traction beltsSee Video
Pitch Removal
Pitch buildup is not a big problem, but should a workpiece with a high content of pitch be carved there may be some pitch deposits on the cutter bit and elsewhere.  This is easily removed using mineral spirits.See How
Clean the Muffler
The Muffler and Dust Collector Bag should be removed and cleaned out periodically to ensure a good airflow.
Removing the Head Cover
Some maintenance projects will require you to remove the head cover first. See how to do this with either this video or this PDF
Suggested Maintenance Schedule

 


 

Head Pressure

 

Check the Head Pressure

It is very important that the head pressure is checked regularly in order to maintain optimum machine performance.  Specifically, the sandpaper drive belts are prone to roll-up on the ends if the head loading drops below 60 lbs as determined by our scale test.  The head loading can change over time due to dust absorbing the grease off the four corner posts and lead screws.

Cleaning and Lubricating the Corner Posts

The vertical guide rods at the corners of the machine also need to be clean and rust free for smooth operation.  A thin coat of marine grease applied to the rods will help keep them free of rust.

Aligning the Corner Posts

Sometimes when head pressure is off, the corner posts may be out of alignment.  This is often seen after the machine has been shipped.

DOWNLOADABLE PDF INSTRUCTIONS
Checking and Adjusting the Head Pressure
Leveling the Head

 


Blow Out Compression Roller

DOWNLOADABLE PDF INSTRUCTIONS
Checking and Cleaning the Compression Rollers

 


Clean Bit Plate with WD40

Clean Idler Pulleys with WD40

Clean Rails and Bearings

The guide rods/rails upon which the cutting head assembly rides 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.  If the rails are allowed to accumulate dust and debris, the machine will halt during usage and an error message will be seen on the display with a reminder to clean the rails.  Once they have been cleaned, pressing the ENTER key on the keypad will resume operation.

 


Check Board Sensor Reading

Check Y-belt Tension

 


Check & Lubricate Flexshaft Core

The Flexshaft temperature should never rise to the point where the sheath cannot be held by hand for an extended period of time.  If the sheath ever becomes hot to the touch, immediately stop the machine and consult the Lubrication section below.  If the heating persists after lubrication please contact CarveWright Technical support.

The flexshaft core should be cleaned and re-lubricated only if it begins to exhibit heating during operation.  To access the core, first unplug the CarveWright machine from power.  Firmly grasp the flexshaft outer sheath where it is snapped into the machine’s cutting head and pull it free from the head.  The core is contained within the sheath, and should slide out freely when grasped between finger and thumb.  Inspect the core for debris and clean with a lint free cloth if necessary. The recommended lubricant is a commercially available chain lube with Moly.  Spray the lubricant onto the core and let sit for an hour.  After applying the specified lubricant slide the core back into its sheath.  When near full insertion, the core may need to be carefully rotated with the fingers to ensure that its square end engages correctly with the cutting motor.  Once the core is fully inserted in the sheath, it can once again be snapped into the cutting head.  Rotate the bit chuck if necessary to get the square end to engage with the chuck.

The flexshaft will periodically need to be replaced. The time period will depend on the duration and type of use the machine has had.

DOWNLOADABLE PDF INSTRUCTIONS
Lubricate the Flexshaft
Care of the CarveWright Flexshaft

 


Check Bits

Make sure your bits are sharp for the best machine performance. If you notice the carving or cutting becoming very rough or burning the bit is most likely dull and should be replaced.

 


Check Cover Hinge Screws

 


Remove the Head Cover

Some maintenance projects will require you to remove the head cover first.

 


Clean or Replace X-Drive Gears


Replace Y & Z Roller Bearings

Coming Soon


Replace Y Timing Belt


Replace Cut Motor Brushes


Replace Y-Motor Assembly


DOWNLOADABLE PDF INSTRUCTIONS
Replacing the Y Motor


Replace Flexshaft Core


Replace Bits

Make sure your bits are sharp for the best machine performance. If you notice the carving or cutting becoming very rough or burning the bit is most likely dull and should be replaced.


Rotate Top Hat


Re-calibrate Machine
Calibrating the Machine Offsets

The “Calibrate Offsets” function allows the user to fine tune the machine’s calibration settings for best tracking and measuring performance.  There are three calibration settings that can be changed by the user: the X axis (in and out direction), the Y axis (side-to-side direction) and the board thickness settings can all be adjusted.Calibrating the X-AxisThe most frequently calibrated setting is the X-axis.  You will want to consider calibrating the X-axis if you are consistently getting an incorrect board length measurement or if you are replacing the factory sandpaper belts with the rubber belts.

To do this calibration you will need a board roughly 36″ long that is clean and straight.  It is very important that the board edge that is placed into the machine up against the squaring plate be very clean and free of defects.  This is the edge that the board tracking sensor roller will be running on and measuring.

Measure and record your board length with as much accuracy as you can get.  Make sure to perform the measurement in the center of the board width, as this is where the machine will also measure (Hand Measured Length – _______inches).  Load the board into your machine and measure it using the “Measure Board” function.  This can be accessed by pressing the “7″ (Measure) key on the keypad or by using the up/down arrows to navigate to the measure function from the CarveWright Main Menu.  The display will then ask for the direction the user wishes to measure.  

Press the “1″ key on the keypad to measure the Length.  Record the number (Machine Measured Length – ________inches) and compare it to the length you measured by hand.  At this point you have to decide if the difference in the length measurements warrants recalibrating your machine.  If you would like to recalibrate your machine continue reading this document.

Before recalibrating, make sure that you have the latest CarveWright firmware version running on your flash card (version 1.161 or later).  Next, navigate to the recalibration menu by following the directions and flow chart below.

  1. Turn on your machine and navigate to the Configurations Menu from the CarveWright Main Menu pressing the “0″ (Options) key on the keypad.
  2. Navigate to the Calibrate Offsets menu item by using the up/down arrows and press ENTER, or select item 6 by pressing the “6″ key.
  3. Navigate to the Manual X Axis Cal menu item by using the up/down arrows and press ENTER, or select item 4 by pressing the “4″ key.

You are now at the screen that shows you the default calibration numbers (factory calibrated) as well as the current calibration setting for the length measurement.  You now have two options:

  1. Pressing “1″ (Default) will restore the current value to the factory default value.
  2. Pressing “2″ (New) will allow you to type in a new value to adjust for the difference in measured lengths.  New numbers can be entered with decimal or fractional values.  Press ENTER to save once a value is entered.

To calculate the value to enter, first take a look at the difference in the measured lengths.  If the hand measured length is longer than the machine measured length you will need to add units to the displayed current value, and conversely, if the hand measured length is shorter than the machine measured length you will need to subtract units from the current value setting.

To find the magnitude of the change to the current value subtract the two numbers (Length difference – _________inches).  Although not an exact correlation, you should change the current value setting by 1 unit for every 0.03″ (or for every 1/32nd of an inch).

So now you have a direction (add or subtract) to change and a magnitude (number of units).  As an example:  say you have a board that measures exactly 36″ long by your tape measure and the machine measures board at 35.875″, adjust the X axis cal number by -4.  If the current value was set to 890.000, change it to 894.000.  Or if the machine measures 36.125″, adjust the X axis cal number +4.

Once the new value is entered you will see it appear as the Current value on the display.  Go back and measure the board with the machine again and see how much closer the measured values become.  Rerun the calibration routine as many times as necessary to attain the level of accuracy that you desire.

Calibrating the Y-Axis

You will want to consider calibrating the Y-axis if you are consistently getting an incorrect board width measurement or if you are seeing an offset in the centering of a project in the side-to-side direction.  To do this calibration you will need a board at least 6″ wide that has clean and straight edges. Wider boards allow for better calibration accuracy.

Before recalibrating, make sure that you have the latest CarveWright firmware version running on your flash card (version 1.161 or later).  Next, navigate to the recalibration menu by following the directions and flow chart below.

There are two options in the Manual Y-Axis Calibration menu:

  1. Calibrate Width – This calibration will allow you to adjust the machine if it is measuring the width incorrectly.
  2. Calibrate Y Offset – This calibration will allow you to adjust the machine’s Y position if it is not placing a pattern in the right location in the side-to-side direction (i.e. not centering in the Y direction).

Calibrate Width Option

To begin the width calibration you will want to do a hand measurement and machine measurement of your board width.  Measure and record your board width with as much accuracy as you can get in roughly the center of the length (Hand Measured Width – _______inches).  Load the board into your machine making sure that it is centered under the Y-Truck, and measure it using the “Measure Board” function.  This can be accessed by pressing the “7″ (Measure) key on the keypad or by using the up/down arrows to navigate to the measure function from the CarveWright Main Menu.  The display will then ask for the direction the user wishes to measure.

Press the “2″ key on the keypad to measure the Width.  Record the number (Machine Measured Width – ________inches) and compare it to the width you measured by hand.  At this point you have to decide if the difference in the width measurements warrants recalibrating your machine.

If you would like to recalibrate your machine continue reading this document.  If you wish calibrate the width measurement select “1″ from the Select Y Calibration menu shown above.  You are now at the screen that shows you the default calibration numbers (factory calibrated) as well as the current calibration setting for the width measurement.

You now have two options:

  1. Pressing “1″ (Default) will restore the current value to the factory default value.
  2. Pressing “2″ (New) will allow you to type in a new value to adjust for the difference in measured widths.  A screen will then appear that prompts you to input whether your hand measurement was Narrower (option 1) or Wider (option 2) than the machine measurement.  (For example, if your board measures 6.1″ wide by hand but measures 6.05″ by the machine, you will select “2″ to tell the machine that the actual measurement is wider.

The machine will then ask for the amount by which the measurement is off.  Enter the new value in decimal or fractional form.  In the example above type .05 and press ENTER to save the value.  Repeat the board measure test and repeat the calibration steps as necessary.

Calibrate Y-Offset Option

If you are having issues with a pattern being carved off-center (even though it is centered in the software), select the Calibrate Y-Offset menu item.

The first step in this calibration is to carve a rectangular test region or shape centered on the board width.  Run the project in the machine and tell it to center on width if it asks due to the board size.  Measure the distance from each side of the board to the edge of the square.  Obviously if the pattern is centered the offsets will be the same.

If they are not the same, record both the amount by which the two measurements differ (Difference = ______inches) and the direction in which the pattern needs to move in order to center it on the board.  You will want to know whether the pattern needs to move Towards the keypad side of the machine or Away from the keypad side of the machine to achieve proper centering.

Once you select the Calibrate Y-Offset menu item you will see the screen that shows the default calibration numbers (factory calibrated) as well as the current calibration setting for the Y-Offset.

You now have two options:

    1. Pressing “1″ (Default) will restore the current value to the factory default value.
    2. Pressing “2″ (New) will allow you to type in a new value to adjust for the difference in measured offsets.  A screen will then appear that prompts you to input whether the pattern needs to be moved Towards the Keypad (option 1) or Away from the keypad (option 2) for proper centering.  For example, you carve a square and it is off-center by 0.1″ in the direction away from the keypad side of the machine.  In this case you want to select option “1″ to tell the machine that the pattern needs to move Towards the keypad side of the machine. The machine will then ask for the amount by which the measurement is off.  Enter the new value in decimal or fractional form.  In the example above, type .1 and press ENTER to save the value.  Repeat the cut test and repeat the calibration steps as necessary.

DOWNLOADABLE PDF INSTRUCTIONS
CarveWrigh User Callibration


Replace Belt Guides

See the replacing belts video

DOWNLOADABLE PDF INSTRUCTIONS
Replacement of Sandpaper Drive Belts
Installation of Heavy Duty Traction Belts


Replace Z-Truck

DOWNLOADABLE PDF INSTRUCTIONS
Replace the Z truck


Replace Z-Motor Assembly

DOWNLOADABLE PDF INSTRUCTIONS
Replacing the Z Motor


Replace X-Motor Assembly

Coming Soon


Rebuild Cut Motor

Coming Soon