Lesson Category: Fusion

Remove Panel

Shut off the laser and remove the power cord from the machine.

Remove the bottom access panel on the left side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Remove Old RF Power Supply

Unscrew the RF Power Supply cable from the side of the unit.

Disconnect the large black connector from the other side of the unit.

Use a Phillips head screwdriver to loosen the unit’s four green captive screws, two at the top near the back, and two at the bottom near the front.

Pull out the RF Power Supply. Be careful, as the unit is heavy.

Disconnect the 8-Pin connector, which resembles an Ethernet or telephone cord.

Use a 5/32” hex key to remove the three grounding wires, setting the lock washers aside.

Install New RF Power Supply

To install the new RF Power Supply, use a 5/32” hex key to attach the three grounding wires by inserting the hex screws. Make sure each grounding wire is sandwiched by two lock washers.

Insert the 8-pin connector.

Place the RF Power Supply into the compartment within the chassis.

Insert the large black connector.

Align the RF Power Supply’s green captive screws with the screw holes on the chassis.

Use a Phillips head screwdriver to tighten the four captive screws.

Screw the RF Power Supply cable into the side of the unit.

Reinstall Panel

Replace the top access panel on the left side of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Remove Panels

Shut off the laser and remove the power cord from the machine.

Use a 5/32” hex key to remove the hex screws that secure the lower panel on the rear of the machine, then remove the panel.

Remove the top access panel on the left side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Remove Old Fiber Laser Tube

The Fusion M2 Fiber Laser Tube is located on the bottom compartment of the machine.

Use a Phillips head screwdriver to remove the two plastic wire clamps securing the laser tube’s black wires.

Slide the wires out of the clamps.

In the control board compartment, disconnect the white connector at the end of one of the laser tube’s wires.

Use a 5/16” nut driver to remove the four mounting screw nuts securing the U-shaped panel on the left of the bottom compartment.

Set the panel aside and carefully pull the white connector through the rubber flap.

Use a Phillips head screwdriver to remove the large connector on the right corner of the laser tube.

Use a 5/16” nut driver to remove the four nuts securing the U-shaped panel on the right side of the compartment.

Remove the panel and rubber flap and set them both aside.

From the left side of the machine, use a 5/32” hex key to remove the four hex screws securing the laser head clamp.

Set the clamp aside, then feed the laser head down through the square hole in the bottom of the upper compartment.

Then feed the laser head through the hole at the rear of the bottom compartment.

Next use a 5/32” hex key to remove the two hex screws securing the back of the laser tube.

Use a Phillips head screwdriver to loosen the two green captive screws securing the front of the laser tube.

Carefully lift the laser tube out of the machine.

Install New Fiber Laser Tube

To install the new fiber laser tube, place the laser tube in the bottom compartment and align the front captive screws with the screw holes in the chassis.

Tighten the captive screws.

Use a 5/32” hex key to insert and tighten the two hex screws in the back corners of the laser tube.

Feed the laser head through the hole in the right side of the compartment, then up through the hole in between the two compartments on the left side of the machine.

Rest the laser head on the mount near the rear of the compartment.

Using a 5/32” hex key, insert the four hex screws to secure the clamp around the laser head, making sure the laser head is gently pressed up against the back felt pad to create a good seal.

In the back of the machine, replace the U-shaped panel and rubber flap on the right side of the compartment by using a 5/16” nut driver to secure the four nuts.

Use a Phillips head screwdriver to attach the large connector to the bottom right of the laser tube.

Feed the laser tube’s white connector through the rubber flap on the left side of the compartment, then up into the control board compartment and connect it.

Make sure the rubber flap on the left side of the bottom compartment is secure, then use a 5/16” nut driver to secure the U-shaped panel with four nuts.

Slide the two black wires into the plastic wire clamps, then use a Phillips screwdriver to secure the clamps to their respective screw holes.

Reinstall Panels

Replace the top access panel on the left side of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Use a 5/32” hex key to insert the hex screws that secure the lower panel to the rear of the machine.

Plug the machine in and turn it on.

Remove Panel

Shut off the laser and remove the power cord from the machine.

Use a 5/32” hex key to remove the ten hex screws which secure the lower panel on the rear of the machine, then remove the panel.

Remove Old Laser Tube

Disconnect the black connector from the right-hand side of the laser tube.

Remove the 8-Pin connector, which resembles an Ethernet or Telephone jack, from the left-hand side of the laser tube.

Disconnect the large black connector that connects the left-hand side of the laser tube to the circuit board in the left section of the rear compartment.

Use a 5/16” nut driver to remove the four nuts securing the U-shaped panel in the rear compartment’s central divider.

Set the panel aside and carefully pull the large black connector through the rubber flap in the central divider.

Use a Phillips head screwdriver to loosen the three green captive screws located in the right corners and the bottom left corner of the back of the laser tube.

Use a 3/32” hex key to loosen the screw in the keyhole slot in the top left corner of the back of the laser tube.

Slide the laser tube to the left so the top left screw clears the keyhole slot, then pull the tube out of the machine.

The assembly is quite heavy, so lift with caution.

Install New Laser Tube

Place the new laser tube in the machine, lining up the screw on the back of the machine with the open portion of the keyhole slot on the laser tube.

Make sure the laser tube is flush with the back of the compartment, then slide it to the right so the top left screw slides into the keyhole slot and the captive screws line up with the screw holes on the chassis.

Use a 3/32” hex key to tighten the top left screw and a Phillips head screwdriver to tighten the three captive screws.

Connect the black connector on the right-hand side of the laser tube.

Connect the 8-Pin connector to the left-hand side of the laser tube.

Feed the tube’s large black connector through the rubber flap in the central divider and plug it into the circuit board in the left section of the rear compartment.

Replace the U-shaped panel in the central divider by using a 5/16” nut driver to secure the four nuts. The open part of the ‘U’ should face the interior of the machine.

Reinstall Panel

Use a 5/32” hex key to insert the ten hex screws which secure the lower panel to the rear of the machine.

Plug the machine in and turn it on.

Before attempting to use the laser be sure to complete the laser alignment procedure.

Remove Panel

Shut off the laser and remove the power cord from the machine.

Use a 5/32” hex key to remove the hex screws which secure the lower panel on the rear of the machine, then remove the panel

Remove Old Laser Tube

Use a Phillips screwdriver to loosen the four green captive screws on the four corners of the laser tube base, as well as the two green captive screws attaching the top of the laser tube to the interior of the machine.

Unscrew the RF power supply cable from the end of the laser tube.

Disconnect the two black connectors from the other end of the laser tube.

Remove the laser tube from the machine. The assembly is quite heavy, so lift with caution.

Install New Laser Tube

Place the new laser tube in the machine, lining up the captive screws with the appropriate screw holes.

Affix the new laser tube to the machine by tightening the six green captive screws.

Reconnect the RF power supply cable to the end of the laser tube by screwing it in.

Reconnect the two black connectors at the other end of the laser tube.

Reinstall Panel

Use a 5/32” hex key to insert the hex screws which secure the lower panel on the rear of the machine.

Plug the machine in and turn it on.

Before attempting to use the laser be sure to complete the laser alignment procedure.

Remove Old Control Board

Shut off the laser and remove the power cord from the machine.

Remove any Ethernet and USB cables from the back of the machine.

Put on the anti-static wrist strap. Always wear the anti-static strap when handling the control board to avoid damaging the unit through static discharge. Clip the strap on to a metal part of the machine, other than the control board itself, as far away from the control board as the strap’s length will allow.

Use a 5/32″ hex key to remove the four screws at the corners of the control board panel.

Grasp the flanges at the top and bottom of the control board panel, then pull the assembly out and set it aside. Be sure that you are still grounded to the machine via the anti-static wrist strap.

Install New Control Board

Remove the new control board assembly from its protective anti-static bag.

On the top and bottom of the control board bay are two nylon PCB guides. Align the top and bottom of the control board assembly with these guides, then push the control board assembly all the way into the bay.

Use a 5/32″ hex key to reinsert the mounting screws at the four corners of the control board.

Plug the machine in and turn it on.

In certain circumstances you may need to use the display to input the IP address of the machine, or reconfigure the software on your computer.

Remove Lens Assembly

Remove the lens assembly by loosening the three thumb screws on its front face until they spin freely. They are captive screws and will not come out of the assembly. Slide the assembly out of its housing.

Remove Old O-Ring and Lens

With the lens assembly in the upright position, use a 5/64” hex key to remove the four screws located in the corners around the lens holder.

Support the lens holder as you turn the lens assembly over.

Continue to support the lens holder as you let it drop away from the upturned lens assembly.

Set the lens assembly aside.

Remove the lens by tipping the lens holder over and catching the lens as it falls out.

Remove the O-ring from the lens holder.

Install New O-Ring and Lens

Lay the new O-ring in the lens holder.

Place the new lens on top of the O-ring, with the curved, convex side facing the O-ring.

Be sure to handle the lens on its edge rather than either of its faces. This will limit the need for cleaning later.

Slide the lens holder up into the upturned assembly.

Then flip the entire assembly right side up.

Use a 5/64” hex key to reinsert the four screws located in the corners around the lens holder.

Gently shake the lens assembly.

If you can hear the lens moving inside, a thicker O-ring is needed and you should open the lens assembly back up and replace the O-ring.

Reinstall Lens Assembly

Once the correct O-ring has been installed, return the lens assembly to its housing and tighten the three screws on its front face.

Plug the machine in and turn it on.

Remove Bottom Right Panel

Shut off the laser and remove the power cord from the machine.

Remove the bottom access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Mark Tensioning Position

Begin by using a pencil to mark the front edge of the z-motor mounting bracket. This will be used as a guide to return the mounting bracket to the correct position later.

Remove Old Motor

Using a 5/32” hex key, loosen, but do not remove, the four mounting bracket screws located on either side of the z-motor.

Using a 5/32” hex key, loosen the two tensioning screws located on the back face of the mounting bracket. Be sure to loosen the two screws an even amount.

Disconnect the white connector that attaches z-motor to the machine’s control board housing.

Using a 9/64” hex key, remove the four screws located at the corners of the z-motor.

Remove the z-motor.

Uncover Z-Axis Belt

To help you see the z-axis belt when inserting the new z-motor, you may want to remove the outer component of the z-motor housing.

To do this, use a Phillips head screwdriver to loosen, but not remove, the four screws on either side of the z-motor housing.

Slide the outer component out and set it aside.

Install New Motor

Insert the new z-motor into the mounting bracket, looping the z-axis belt around the motor’s pulley.

Using a 9/64” hex key, reinsert the four screws located at the corners of the z-motor.

Reconnect the z-motor’s white connector.

Evenly tighten the two tensioning screws on the back face of the mounting bracket. Tighten these screws until the pencil mark you made earlier is visible.

Use a 5/32” hex key to tighten the four mounting bracket screws.

Cover Z-Axis Belt

If you removed the outer component of the z-motor housing, slide it back on and use a Phillips head screwdriver to tighten the four screws.

Reinstall Bottom-Right Panel

Replace the bottom access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Remove Panels

Remove the top access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Use a 5/32” hex key to remove the two main panels on the back of the machine.

Remove Old Motor

In the compartment below the Y-motor, disconnect the white connector that plugs the Y-motor into the machine’s control board.

Use a 5/32” hex key to loosen, but not remove, the four mounting screws located at each corner of the Y-motor.

From the right hand side of the machine, use a pencil to mark the top of the Y-motor mounting bracket. This will be used as a guide to return the mounting bracket to the correct position later.

Use a 5/32” hex key to loosen the Y-motor tensioning screw. This will loosen the Y-axis reducer drive belt.

Remove the reducer drive belt from the Y-motor pulley.

Now use a 5/32” hex key to remove the four Y-motor mounting screws.

Remove the Y-motor from the machine.

Install New Motor

Place the new Y-motor into the machine and insert, but do not tighten, the four mounting screws, making sure the screws line up with the threaded holes of the mounting bracket on the other side.

Loop the Y-axis reducer drive belt around the Y-motor pulley.

In the compartment below the Y-motor, insert the white connector.

Tighten the Y-motor tensioning screw until the pencil mark you made earlier is visible.

Tighten the four mounting screws.

Reinstall Panels

Use a 5/32” hex key to replace the two main panels on the back of the machine.

Replace the top access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug in the machine and turn it on.

Remove Panel

We’ll start by replacing the front sensor, then move on to the rear sensor.

Shut off the laser and remove the power cord from the machine.

Remove the top access panel on the left side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Remove Old Front Sensor

Locate the front sensor and disconnect the black connector that connects the sensor to the rest of the wiring.

Use a Phillips head screwdriver to remove the two screws holding the sensor in place.

The silver switch guard on the left side of the sensor will come loose once the screw is removed, so be sure not to lose it.

Use a 5/16” nut driver to remove the plastic clamp holding the sensor wires down in the track running alongside the y-axis.

Slide the wires out of the clamp.

Set the old sensor, the clamp, and the switch guard aside.

Install New Front Sensor

Use a Phillips head screwdriver to insert the two screws and secure the new sensor and the switch guard to the side of the y-axis.

Be sure to affix the switch guard on the new sensor’s left side.

Connect the black connector.

Slide the sensor wires into the plastic wire clamp and use a 5/16” nut driver to reaffix the clamp.

Remove Old Rear Sensor

Now let’s replace the rear sensor.

Disconnect the black connector that connects the rear sensor to the rest of the wiring.

Use a Phillips head screwdriver to remove the two screws holding the sensor in place.

Set the old sensor and the switch guard aside.

Install New Rear Sensor

Use a Phillips head screwdriver to insert the two screws and secure the new sensor and the switch guard to the side of the y-axis.

Be sure to affix the switch guard on the new sensor’s right side.

Connect the black connector.

Reinstall Panel

Replace the top access panel on the left side of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Remove Panels

Shut off the laser and remove the power cord from the machine.

We’ll begin by replacing the y-axis on the right-hand side of the machine.

Use a 5/32” hex key to remove the exhaust plenum on the rear of the machine.

Then remove the small panel in the top left corner.

Next use a 5/32” hex key to remove the top access panel on the left side of the machine, as well as both the top and bottom access panels on the right side of the machine.

Remove X-Axis Assembly

On the left side of the machine, find and disconnect the Air Assist tube from the x-axis assembly. Press the ring toward the rear of the engraver while pulling on the black tube.

The wire harness and its plastic guard are held secure by the wire harness clamp. With a short or offset Philips head screw driver remove the clamp screws then set the clamp aside.

Disconnect the white connector from its socket by squeezing the lock tab on the bottom of the connector and pulling it away from the circuit board. Remove the black connector as well.

Then remove the lens assembly by loosening the 3 thumb screws on its front face until they spin freely. They are captive screws and will not come out of the assembly.

Slide the assembly out of its housing and set it aside.

Now it’s time to remove the x-axis assembly.

On both ends of the assembly, loosen the 2 green captive screws until they turn freely.

Now carefully lift the assembly from its mounted position and carry it out through the right side of the machine.

We will begin by replacing the right-side Y-Axis components. If you only need to replace the left-side components, skip ahead to Remove Additional Panels

Remove Old Right Y-Axis

Use a nut driver to remove the 2 nuts securing the compartment panels on the interior side of the machine.

Use a Philips head screwdriver to remove the 3 screws securing the top of the compartment to the y-axis.

Then use a Philips head screwdriver to remove the 2 screws securing the compartment panels from underneath.

Gently pull out the compartment panels and let them rest, hanging off the side of the chassis.

On the back side of the machine use a 5/32” hex key to loosen the 2 hex screws securing the axle clamp to the y-axis.

Use a 5/32” hex key to loosen but not remove the four mounting screws located at each corner of the y-motor.

From the right-hand side of the machine use a pencil to mark the top of the y-motor mounting bracket. This will be used as a guide to return the mounting bracket to the correct position later.

Use a 5/32” hex key to loosen the y-motor tensioning screw. This will loosen the y-axis reducer drive belt.

Remove the reducer drive belt from the y-motor pulley.

Use a 5/32” hex key to remove the two hex keys securing the y-axis to the chassis near the back of the machine.

Remove the black plastic shim underneath the y-axis.

Then remove the two hex screws securing the y-axis to the chassis near the front of the machine.

Remove the black plastic shim.

Now remove the y-axis. Carefully lift it, turning it 90 degrees inward while lifting the back up and leaning the front down.

Push it slightly out the back through the open corner panel, then pull the entire axis out through the side of the compartment

Install New Right Y-Axis

To install the new y-axis begin by holding it so the wheel is positioned on top.

Slide it in through the side of the compartment, pushing the back end with the wheel out through the top corner panel on the back of the machine.

When the front end is within the chassis, straighten it out then turn the axis 90 degrees outward and rest it on its mounting brackets.

Insert the y-axis drive axle into the rear axle clamp.

Secure the front of the y-axis to its mounting bracket by using a 5/32” hex key to insert the two hex screws halfway so that the y-axis can still be lifted slightly.

Lift the y-axis and insert the black plastic shim, then tighten the 2 hex screws.

Secure the back of the y-axis to its mounting bracket the same way, using a 5/32” hex key to insert the 2 hex screws halfway.

Insert the black plastic shim, then tighten the 2 hex screws.

Slide the drive belt onto the two wheels.

Tighten the y-motor tensioning screw until the pencil mark you made earlier is visible.

Now tighten the 4 mounting screws.

Now lift the compartment panels and slide them back into place over the two mounting screws on the interior side of the compartment.

Insert the two Philips head screws from underneath.

Then use a Philips head screwdriver to insert the 3 screws that connect the compartment panels to the side of the y axis. Two of the screws will also go through and secure the wire harness clamps.

We will now replace the left-side Y-Axis components. If you do not need to do this, skip ahead to Align and Clamp

Remove Additional Panels

Now we’ll replace the y-axis on the left side of the machine.

Use a 5/32” hex key to remove the bottom access panel on the left side of the machine.

Then, while facing the back of the machine, remove the small panel on the right, near the edge.

Remove Old Left Y-Axis

Use a 5/32” hex key to loosen the 2 hex screws securing the axle clamp on the back of the machine.

Then use a Philips head screwdriver to remove the 3 screws securing the compartment panels to the y-axis.

Use a Philips head screwdriver to remove the 2 screws securing the compartment panels from underneath.

If your Fusion M2 is equipped with a fiber laser source, you will need to remove the fiber laser head to provide clearance for the compartment panels to be removed. Use a 5/32” hex key to remove the 4 hex screws securing the laser head clamp.

Set the laser head to the side so it’s out of the path of the compartment panels.

Use a Philips head screwdriver to remove the 2 screws securing the front sensor to the y-axis.

Set the small metal switch guard to the side.

Gently pull out the compartment panels and let them rest, hanging off the side of the chassis.

Use a Philips head screwdriver to remove the 2 screws securing the rear sensor to the y-axis.

Use a 5/32” hex key to remove the 2 hex screws securing the y-axis to the chassis near the back of the machine.

Remove the black plastic shim.

Then remove the 2 hex screws securing the y-axis to the chassis near the front of the machine.

Remove the black plastic shim.

Manually loosen the black plastic screw near the bottom of the periscope.

From the top compartment pull the metal tube out and set it aside.

Now remove the y-axis, rotating it 90 degrees outward while dropping it down and around the mounting brackets.

Push it slightly out the back through the open panel, then pull the entire axis out through the side of the compartment.

Install New Left Y-Axis

To install the new y-axis put the rear end of the axis into the machine with the axle pointing outward, push it slightly through the back open panel, then pull it forward into the machine, rotate it 180 degrees inward as you bring it up and over to rest on top of the brackets.

Slide the y-axis axle into the clamp in the rear of the machine.

Secure the front of the y-axis to its mounting bracket by using a 5/32” hex key to insert the two hex screws halfway so that the y-axis can still be lifted slightly.

Lift the y-axis and insert the black plastic shim, then tighten the 2 hex screws.

Secure the back of the y-axis to its mounting bracket the same way, using a 5/32” hex key to insert the 2 hex screws halfway.

Insert the black plastic shim, then tighten the 2 hex screws.

From the top compartment slide the metal periscope tube back into the housing in the bottom compartment.

Lift the tube up into the housing at the top, then manually tighten the black mounting screw at the bottom.

Use a Philips head screwdriver to insert the 2 screws that secure the rear axis sensor and switch guard to the side of the y-axis. Be sure to affix the switch guard on the sensor’s right side.

Now lift the compartment panel and slide it back into place over the 2 mounting screws on the interior side of the compartment.

Insert the 2 Philips head screws from underneath.

Use a Philips head screwdriver to insert the 3 screws that connect the compartment panels to the side of the y-axis.

Use a 5/16” nut driver to secure the 2 nuts over the 2 mounting screws.

Then use a Philips head screwdriver to insert the 2 screws that secure the front y-axis sensor and switch guard to the side of the y-axis. Be sure to affix the switch guard to the sensor’s left side.

Now put the laser head back on the mount near the rear of the compartment.

Using a 5/32” hex key insert the 4 hex screws to secure the clamp around the laser head. Be sure to create a good seal by gently pressing the laser head against the back felt pad.

Align and Clamp

Move the Y-Axis Assembly on either side of the machine as far back to the rear as they can go. This will ensure the two sides are in alignment.

Use a 5/32″ hex key to secure the clamp screws on the rear axle. There are 2 clamp screws on either side of the machine. Be sure to secure any that you loosened earlier in the process.

Replace X-Axis Assembly

Place the x-axis assembly back onto its mountings and secure it by tightening its 4 green captive screws, lining it up with the guide pins so there is no space between the bottom of the assembly and the screw mounts.

Use a short or offset Philips head screwdriver to tighten the green captive screws on both sides.

Next connect the wire harness by plugging in the black connector then the white connector.

Retrieve the wire harness clamp and position the wire harness and its plastic guard so that the harness is on top of the guard and both are under the clamp on the x-axis assembly.

Be sure that the wires between the wire harness and the circuit board have some slack and are not drawn too tight. Secure the clamp by inserting the two screws.

Reinsert the air assist tube on the left end of the assembly. The ring will pop out once the tube is successfully inserted.

Reinstall the lens assembly by sliding it into the housing and tightening the 3 screws on its front face.

Reinstall Panels

Now use a 5/32” hex key to reattach all of the panels on the machine.

Then plug the machine in and turn it on.