Carbide 3D Shapeoko HDZ 4.0 User manual

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ASSEMBLY GUIDE
HDZ 4.0

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Table of Contents
INTRODUCTION ................................................................................................................ 4
BELTED-X/Z TO HDZ ASSEMBLY GUIDE .............................................................................. 5
Prior to Assembly & Installation .....................................................................................................................5
Inventory.........................................................................................................................................................6
Disassemble the Existing X/Z-Carriage..........................................................................................................11
Assemble the HDZ.........................................................................................................................................15
Install the Drag Chain Support System .........................................................................................................20
Insert the Proximity Switch Cables into Drag Chain .....................................................................................24
Install the HDZ...............................................................................................................................................26
Install the Drag Chain....................................................................................................................................30
Install the Proximity Switches.......................................................................................................................32
Connect the Wiring .......................................................................................................................................34
Cleanup the Cables .......................................................................................................................................36
Z-PLUS TO HDZ ASSEMBLY GUIDE.................................................................................... 39
Prior to Assembly & Installation ...................................................................................................................39
Inventory.......................................................................................................................................................40
Disassemble the Existing Z-Plus Carriage......................................................................................................45
Assemble the HDZ.........................................................................................................................................48
Install the HDZ...............................................................................................................................................53
Install the Proximity Switches.......................................................................................................................57
Connect and Cleanup Wiring ........................................................................................................................58
POST ASSEMBLY.............................................................................................................. 59
Update the Software Settings.......................................................................................................................59
Re-Calibrate the BitSetter.............................................................................................................................60
Maintenance .................................................................................................................................................61
Tramming Instructions..................................................................................................................................62

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Introduction
We’re here to help! If you encounter any issues during assembly, please contact us at: [e-mail].
The HDZ kit includes everything you need to upgrade your existing X/Z-carriage to the HDZ, or heavy-duty X/Z. The HDZ
kit also includes new inductive proximity switches to replace the original homing switches on the belted-X/Z machines.
How to Use this Assembly Guide
For simplicity, we’ve split up this assembly guide to individually address the two existing machine versions:
•For Belted-X/Z to HDZ Assembly Guide, please go to page 5.
•For Z-Plus to HDZ Assembly Guide please go to page 39.
Special Instructions and Call-Outs
There are minor differences in the installation procedures between Shapeoko 3, XL, and XXL models AND between
Shapeoko models shipped pre-Dec 2019 and post-Dec 2019. We’ve added special notes to guide you whenever these
differences require alternate instructions:
Throughout the guide you will also find information that we’ve called out for you to pay particular attention to. We use
two additional types of call-outs, WARNINGS and NOTES:
Directional References
In this guide, any reference or instructions with regard to direction or placement, such as: Front, Back, Left, Right, etc.
are given from the perspective of one standing in front of and facing the machine. This is true, even when a photo is
taken from the rear of the machine.
Also, we use the term “Y1” in place of “Y-Axis Left” and “Y2” in place of “Y-Axis Right” to help avoid directional
confusion.
IMPORTANT Software Information
You must run Carbide Motion 4.17 or later with the HDZ. Download it from: carbide3d.com/carbidemotion/download/
SPECIAL INSTRUCTIONS: These call-outs will draw your attention to special instructions for different models.
WARNING: This is a warning—please pay close attention.
NOTE: This is a note—information that points out critical steps or information for future reference.
WARNING: After installing the HDZ, you must update your GRBL settings. DO NOT HOME UNTIL YOUR
SETTINGS HAVE BEEN UPDATED!

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Belted-X/Z to HDZ Assembly Guide
Prior to Assembly & Installation
Disable the BitSetter
Before beginning the HDZ upgrade:
1. Connect your machine to Carbide Motion.
a. Plug in your USB cable.
b. Open Carbide Motion.
c. Turn on your Shapeoko.
d. Click the Connect to Cutter button.
2. Click Settings in the top menu bar.
3. If you have the BitSetter checkbox checked, go ahead and uncheck it.
You will need to re-calibrate the BitSetter after successful homing with your new HDZ. See pages 59-61 for
instructions.
Gather the Required Tools
A basic mechanical know-how and an understanding of how the Shapeoko is assembled is required. Installation will
take approximately 2 hours.
Required tools:
•Metric hex keys: 1.5mm –5mm
•Wrenches: 8mm and 10mm
•2 flat head screw drivers for prying
•Flush cut pliers
•Needle nose pliers
•Permanent marker
•Masking tape
Machines With BitSetter: Please complete the following steps before moving on to “Gather the Required Tools”
section below.

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Inventory
Belted-X/Z to HDZ Kit Contents
The HDZ kit comes with the components listed in the tables on the following pages and shown in Fig. 1 and Fig. 2.
Figure 1

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HDZ Box
The HDZ box components are listed in the tables below and shown in Fig. 1.
Item
Description
Qty
A
HDZ (Heavy-Duty Z/X Carriage)
1
B
EZ-Tram Plate
1
HDZ Kit Components and Hardware Bag
Item
Description
Qty
Motor Mount Baggie (1)
C
M5 × 25mm X-Motor Standoff
4
D
M5 × 10mm Socket Head Cap Screw
8
X-Motor Idler Baggie (2)
E
M8 Guide Bearing
4
F
M8 Spacer
2
G
M8 Washer
2
H
M8 × 30mm Button Head Cap Screw
2
EZ-Tram Plate Hardware Baggie (3)
I
M5 × 18mm Socket Head Cap Screw
2
J
M5 × 10mm Socket Head Cap Screw
2
K
HD Eccentric Spacer (Non-Threaded)
2
V-Wheel Baggie (4)
L
Replacement V-Wheel
4
M
M5 × 25mm Socket Head Cap Screw
4
N
M5 Washer (Shim)
4
O
HD Eccentric Nut (Threaded)
2
Belted-X/Z Proximity Switch Kit Box
Proximity Switch Baggie
The proximity switch baggie components are listed in the table below and shown in Fig. 1.
Item
Description
Qty
P
X-Axis Proximity Switch (2675mm for XXL, 2350mm for XL, and 712mm for Shapeoko 3)
1
Q
Y-Axis Proximity Switch (2540mm for XXL, 2220mm for XL, and 610mm for Shapeoko 3)
1
R
Z-Axis Proximity Switch (200mm for XXL, XL, and Shapeoko 3)
1
S
Z-Axis Proximity Switch Extension Cable (2438mm for XXL, 2235mm for XL, none Shapeoko 3)
1

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Figure 2

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Proximity Switch Kit Baggie
The proximity switch kit baggie components are listed in the table below and shown in Fig. 2.
Item
Description
Qty
X-Axis Proximity Switch Mount Baggie
T
X-Axis Proximity Switch Mount
1
U
M5 × 25mm Socket Head Cap Screw
2
V
M3 × 18mm Socket Head Cap Screw
2
Y-Axis Proximity Switch Mount Baggie
W
Y-Axis Proximity Switch Mount
1
X
M5 × 35mm Socket Head Cap Screw
2
Y
M3 × 18mm Socket Head Cap Screw
2
Z-Axis Proximity Switch Mount Baggie
Z
Z-Axis Proximity Switch Mount
1
AA
M4 × 6mm Button Head Cap Screw
1
BB
M3 × 18mm Socket Head Cap Screw
2
CC
PCB Riser Board
1
X-Axis Drag Chain Bracket Baggie
1
DD
X-Axis Drag Chain Head Bracket
1
EE
Drag Chain Middle Bracket [Used with Post-Dec 2019 Extrusion Rails Only]
2
FF
Drag Chain Tail Bracket [Used with Post-Dec 2019 Extrusion Rails Only]
1
GG
M5 × 8mm Socket Head Cap Screw
2
HH
M4 × 6mm Socket Head Cap Screw [Used with Post-Dec 2019 Extrusion Rails Only]
6
II
M3 × 6mm Flat Head Cap Screw [Used with Post-Dec 2019 Extrusion Rails Only]
3
Y-Axis Drag Chain Bracket Baggie
JJ
Y-Axis Drag Chain Head Bracket
1
KK
Drag Chain Middle Support Bracket [Used with Post-Dec 2019 Extrusion Rails Only]
1
LL
Drag Chain Tail Support Bracket [Used with Post-Dec 2019 Extrusion Rails Only]
1
MM
M5 Nut
2
NN
M5 × 16mm Socket Head Cap Screw
2
OO
M4 × 6mm Socket Head Cap Screw [Used with Post-Dec 2019 Extrusion Rails Only]
4
PP
M3 × 6mm Flat Head Cap Screw [Used with Post-Dec 2019 Extrusion Rails Only]
3
Drag Chain Support Plate Baggie [Used with Pre-Dec 2019 Extrusion Rails Only]
QQ
Drag Chain Middle Support Plate
2
RR
Drag Chain Tail Support Plate
2
SS
M3 × 6mm Flat Head Cap Screw
2
TT
Alcohol Wipes
2
Cable Tie Cleanup Baggie
UU
Cable Tie Mount
5
VV
M4 × 6mm Button Head Cap Screw
5
WW
Cable Ties (Pack of 100)
1

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Shapeoko Carryover Components
The HDZ utilizes several parts from the existing Shapeoko setup. All components and hardware to be carried over are
listed in the table below and shown in Fig. 3.
Throughout this guide, carryover parts will be called out by
the words: CARRY OVER.
Item
Description
Qty
XX
Drag Chain
1
YY
X-Rail Belt and Hardware: Belt Clip (1) and M5 × 10mm Socket Head Cap Screw (1)
3
ZZ
X-Motor
1
AAA
Z-Motor
1
BBB
Spindle/Router Mount
1
CCC
M5 × 16mm Button Head Cap Screw
2
DDD
Router Mount Adapter Ring (Optional)
1
Figure 3
NOTE: Please use the replacement screws
provided in the HDZ Kit.

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Disassemble the Existing X/Z-Carriage
Disconnect Cables and the X-Axis Belt
1. Turn off your machine, unplug it, and disconnect the USB and power cables.
2. Clip all cable ties.
3. Unplug the router/spindle and remove it from the spindle mount.
a. Use a 4mm hex key to loosen the two (2) M5×55mm SHCS on the front of the mount.
4. Free the Y2-end of the X-Axis belt from the Y2-carriage. (No need to remove the Y1-end).
a. Use a 4mm hex key to remove the M5×10mm SHCS securing the belt clip.
b. Remove the clip from the end of the belt and pull the belt free from the X-motor pulley and idlers.
c. CARRY OVER the belt,belt clip, and M5×10mm SHCS.
5. Label all motor lead cables AND their gray extension cables.
a. Use a permanent marker or piece of tape to label all the white male/female connectors of the X-, Y1-,
Y2-, and Z-stepper motor lead cables AND the gray X-, Y1-, Y2-, and Z-stepper motor extension cables.
6. Disconnect all cables.
a. Remove the Carbide Motion board enclosure cover.
b. Disconnect the X-, Y1-, Y2-, and Z-motor leads from their extension cables AND disconnect all
extension cables and homing switches from the Carbide Motion board.
WARNING: Do NOT disconnect motor connectors by pulling on the wires or by prying at the latch. Use
pliers to gently grip the base of each white connector and pull apart.
NOTE: As you complete the disassembly process, you may find it helpful to keep each carryover component
and its associated hardware together and away from the new HDZ parts to avoid any mix ups.

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Remove the Homing Switches, Drag Chain,
and Belted-X/Z
1. Remove the Z-Axis homing switch plate from the
front of the X/Z-carriage. See Fig. 4.
a. Use a 3mm hex key to remove the four (4)
M5×10mm BHCS securing the plate. (No
need to separate any of the switches from
their mounting plates.)
2. Remove the X-Axis homing switch plate from the
rear of the X/Z-carriage.
a. Use a 4mm hex key to remove the two (2)
M5×35mm SHCS and two (2) 1-inch
spacers.
3. Remove the Y-Axis homing switch plate from the
outside of the Y2-carriage.
a. Use a 4mm hex key to remove the two (2)
M5×35mm SHCS and two (2) 1-inch
spacers.
4. Disconnect the X-Axis drag chain from the X-Axis
head bracket on the rear of the X/Z-carriage. See
Fig. 5.
a. Use a 2mm hex key and needle nose pliers
to remove the two (2) M3×6mm FHS and
two (2) M3 nylon lock nuts securing the
drag chain to the head bracket.
5. Disconnect the Y-Axis drag chain from the Y-Axis
head bracket on the outside of the Y1-carriage.
a. Use a 2mm hex key and needle nose pliers
to remove the two (2) M3×6mm FHS and
two (2) M3 nylon lock nuts securing the
drag chain to the bracket.
6. Remove the drag chain from the rails and lay it on
the baseframe as shown in Fig. 6.
a. Pry the tail ends of the drag chain from
the VHB tape securing them to the rails.
b. Remove the VHB tape from the rails.
c. CARRY OVER the drag chain.
Figure 4
Figure 5
Figure 6
Shapeoko 3 Machines: Skip 4-7 and move ahead
to 8 on the next page.

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7. Remove the Y-Axis drag chain head bracket from the outside of the Y1-carriage.
a. Use an 8mm wrench and a 4mm hex key to remove the two (2) M5 nuts AND the two (2) M5×16mm
SHCS.
8. Remove the lower two V-wheels from the X/Z-carriage.
a. Hold the eccentric nuts steady with an 8mm wrench and use a 3mm hex key to remove the V-wheels.
9. Lift the X/Z-carriage away from the X-rail and lay it on the baseframe.
Disassemble the X/Z-Carriage
1. Separate the Z-carriage from the X-carriage. See
Fig. 7.
a. Remove the springs from both sides of the
X/Z-carriage.
b. Loosen the tensioning screw at the
bottom of the X-carriage plate.
i. Use a 3mm hex key to loosen the
tensioning screw.
c. Loosen the idler assembly at the bottom
of the X-carriage and free the belt.
i. Use a 4mm hex key and a 10mm
wrench to loosen the nut holding
the idler in place.
ii. Free the belt from the idler and
the Z-motor pulley.
d. Slide the smaller Z-carriage down and away from the larger X-carriage.
2. Remove the router/spindle mount from the Z-carriage plate.
a. Use a 3mm hex key to remove the two (2) M5×16mm BHCS securing the mount.
b. CARRY OVER the router/spindle mount and M5×16mm BHCS.
3. Remove the X-motor (lower motor) from the back of the X-carriage plate.
a. Use a 4mm hex key to remove the four (4) M5×10mm SHCS securing the motor.
b. CARRY OVER the X-motor.
Figure 7

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4. Remove the Z-motor (upper motor) from the back
of the X-carriage plate.
a. Use a 4mm hex key to remove the four (4)
M5×10mm SHCS securing the motor.
5. Remove the drive pulley from the Z-motor drive
shaft.
a. Use a 1.5mm hex key to loosen the two
(2) set screws on the drive pulley.
b. Use even pressure to pry off the drive
pulley with a couple of screwdrivers,
needle nose pliers, or both. DO NOT
BEND THE DRIVE SHAFT. See Fig. 9.
c. CARRY OVER the Z-motor.
Figure 9
WARNING: Do not mix up the X- and Z-motors.
The orientation of the X motor’s drive pulley on
the drive shaft is very important for the HDZ
assembly. See Fig. 8.
Figure 8

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Assemble the HDZ
Get Familiar with the HDZ
1. Take a minute to familiarize yourself with the front and back of the HDZ. See Fig. 10.
Figure 10
NOTE: The application of a blue (i.e. light/medium grade) thread locker is at your discretion. We suggest adding
it post-assembly if any screws happen to work their way loose during use.

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Install the Idlers, X-Motor Standoffs, and X-Axis Proximity Switch Mount
Located in HDZ Kit:
Item
Description
Qty
E
M8 Guide Bearing
4
F
M8 Spacer
2
G
M8 Washer
2
H
M8 ×30mm Button Head Cap Screw
2
C
X-Motor Standoff
4
T
X-Axis Proximity Switch Mount
1
U
M5 ×25mm Socket Head Cap Screw
2
1. Assemble the two X-motor idlers in this order:
a. M8×30mm BHCS
b. M8 washer
c. M8 guide bearing, flange TOWARD BHCS
head
d. M8 guide bearing, flange AWAY FROM
BCHS head
e. M8 spacer
2. Install idlers onto the back of the HDZ. See Fig. 11.
a. Use a 5mm hex key to secure the idlers to
the two M8 screw holes in the center of
the plate.
2. Hand-screw the standoffs to the back of the HDZ.
See Fig. 11.
a. Do NOT use tools or overtighten the standoffs.
b. Screw the standoffs into the four evenly-spaced M5 screw holes at center of the plate just above the
idlers.
3. Install the X-Axis proximity switch mount to the back of the HDZ. See Fig. 11.
a. Align the mount with the two M5 screw holes on the Y2-side of the X-motor standoffs.
b. The two M3 PEM nuts face out (away from X-motor standoffs).
c. Use a 4mm hex key and two (2) M5×25mm SHCS to secure.
d. Before fully tightening the screws, slide the mount toward the X-motor standoffs as far as it will go.
Figure 11

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Install the X-Axis Drag Chain Head Bracket, Z-Axis Proximity Switch Mount, and
V-Wheels
HDZ Kit:
Item
Description
Qty
DD
X-Axis Drag Chain Head Bracket
1
GG
M5 ×8mm Socket Head Cap Screw
2
Z
Z-Axis Proximity Switch Mount
1
AA
M4 ×6mm Button Head Cap Screw
1
L
V-Wheel
2
M
M5 ×25mm Socket Head Cap Screw
2
N
M5 Washer (Shim)
2
1. Install the X-Axis drag chain head bracket to the
back of the HDZ. See Fig. 12.
a. Align the bracket with the two vertical M5
screw holes above and to the Y2-side of
the X-motor standoffs.
b. Use a 3mm hex key and two (2) M5×10mm
SHCS to secure.
2. Install the Z-Axis proximity switch mount to the
back of the HDZ. See Fig. 12.
a. Align the mount with the M4 screw hole at
the top of the HDZ.
b. Use a 2.5mm hex key and one (1)
M4×6mm BHCS to secure the mount at
the top of the HDZ.
3. Assemble the top two V-wheels in this order:
a. M5×25mm SHCS
b. V-wheel
c. M5 washer (shim)
4. Install the top two V-wheels on the back of HDZ, in line with the idlers. See Fig. 12.
a. Use a 4mm hex key to secure the V-wheels to the M5 screw holes to the outside of the idlers.
b. Check wheel spin. If shims are properly placed between wheels and carriage plate, the wheels will spin
with little to no resistance.
Figure 12

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Install the Z-Motor
HDZ Kit + Carryover Components:
Item
Description
Qty
D
M5 ×10mm Socket Head Cap Screw
4
AAA
Z-Motor [CARRYOVER]
1
1. Install the Z-motor at the top of the HDZ. See
Fig. 13 and Fig. 14.
a. Insert the Z-motor drive shaft into the
motor coupling at the top of the HDZ.
b. Position the motor with the lead cable
toward the back of the HDZ.
c. Use a 4mm hex key and four M5×10mm
SHCS to secure the motor.
d. Use a 2.5mm hex key to tighten the set
screw at the top of the motor coupling.
Figure 13
Figure 14
NOTE: Ensure both set screws on the coupling are
tight. Failure to do so will lead to slippage. Using a
small amount of blue thread lock on the motor
shaft and ball screw shaft is acceptable.

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Install the Router/Spindle Mount and EZ-Tram
HDZ Kit + Carryover Components:
Item
Description
Qty
B
EZ-Tram Plate
1
I
M5 ×18mm Socket Head Cap Screw
2
J
M5 ×10mm Socket Head Cap Screw
2
K
HD Eccentric Spacer (Non-Threaded)
2
BBB
Router/Spindle Mount [CARRYOVER]
1
CCC
M5 ×16mm Button Head Cap Screw [CARRYOVER]
2
1. Attach the EZ-Tram plate to the router/spindle
mount. See Fig. 11.
a. Align the front of the plate with the M5
screw holes on the back of mount.
b. Ensure the plate’s recessed holes face out
and the oval through-holes are on top.
c. Use a 3mm hex key and the two (2)
M5×16mm BHCS to secure.
2. Assemble eccentric spacers in this order:
a. M5×18mm SHCS
b. HD eccentric spacer (nut side TOWARD
screw head).
3. Loosely attach the EZ-Tram to the front of the
HDZ. See Fig. 12.
a. Align the EZ-Tram with corresponding M5
screw holes on the front of the HDZ.
b. Insert M5×18mm SHCS and spacers into the
through-holes at the top of the EZ-Tram.
c. Finger-tighten the SHSC and position the
eccentric spacers with the dimple facing up.
d. Insert the two (2) M5×10mm SHCS into
the EZ-Tram’s bottom through-holes and
finger-tighten.
Figure 11
Figure 12
NOTE: See Tramming Instructions at the end of this
guide for information on how to tram the HDZ.
NOTE: Be careful not to confuse the eccentric spacers
and eccentric nuts. Eccentric spacers are non-threaded.

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Install the Drag Chain Support System
Install the Y-Axis Head Bracket
HDZ Kit:
Item
Description
Qty
JJ
Y-Axis Drag Chain Head Bracket
1
MM
M5 Nut
2
NN
M5 ×16mm Socket Head Cap Screws
2
1. Install the Y-Axis drag chain head bracket to the
outside of the Y1-carriage. See Fig. 17.
a. Use a 4mm hex key and two (2)
M5×16mm SHCS to replace the
Y1-motor’s top two screws
b. Place the head bracket, flange down,
onto the protruding screws.
c. Use an 8mm wrench and two (2)
M5 nuts to secure the bracket to the
screws.
Identify Your Extrusion Rail Version
1. Examine your X- and Y1-Rails. You will have
either:
•Pre-Dec 2019 extrusion rails. See Fig. 18.
oX-Rail: No screw holes.
oY1-Rail: Two M5 threaded screw holes in
the center.
Figure 17
Figure 18
Shapeoko 3 Machines: Skip ahead to the “Install the HDZ” section on page 26.
Pre-Dec 2019 Rails: Your setup may look slightly
different than the setup pictured in this document.