Carbide 3D Shapeoko HDZ 4.0 User manual

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ASSEMBLY GUIDE
HDZ 4.0

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Introduction
If you encounter any issues during assembly, please contact us at:
[email protected]
.
This assembly process is uniform for the Shapeoko 3, 3XL, and 3XXL. The installation process is also the same across all
HDZ units.
Prior to Installation
Before you assemble or install the HDZ, check the rotation of the ball screw. To test, stand the HDZ on end, grasp the
sides with both hands, and press down on the top of the Z-carriage plate with both thumbs. Move the carriage plate
through its full range of motion, both up and down. With moderate pressure the carriage will glide smoothly and the
ball screw will rotate freely.
We request that you do not attempt to diagnose or dismantle the HDZ. If you cannot move the carriage plate by hand,
or if you encounter any movement issues, please contact us at [email protected].
IMPORTANT Software Information
You must run Carbide Motion 4.17 or later with the HDZ.
Download Carbide Motion from:
https://carbide3d.com/carbidemotion/download/.
WARNING: After installing the HDZ, you must update your GRBL settings. DO NOT HOME UNTIL YOUR
SETTINGS HAVE BEEN UPDATED!
Assembly Video
An assembly and installation overview video can be found here:
https://youtu.be/ojVpMMRCeVU
.
NOTE: The only components you now need to carry over from your existing X/Z-carriage are the X- and Z-
homing switches, X- and Z-motors, spindle mount, and spindle/router.
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 – 6mm
• Wrenches: 8mm and 10mm
• 2 flat head screw drivers for prying
• Needle nose pliers
• Permanent marker
• Masking tape

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Inventory
HDZ Kit Contents
The HDZ comes with the components
listed in the table below and show in
Fig. 1
.
Item
Description
Qty
A
HDZ (Heavy-Duty Z/X Carriage)
1
B
EZTram Plate
1
C
M5 x 18mm Socket Head Cap Screw
2
D
M5 x 10mm Button Head Cap Screw
2
E
HD Eccentric Spacer (non-threaded)
2
F
M5 x 25mm Male-Female Threaded Standoff
4
G
M5 x 10mm Socket Head Cap Screw
8
H
Z-Motor Shaft Coupling
1
I
Replacement V-Wheel
4
J
M5 Washer (Shim)
4
K
M5 x 25mm Socket Head Cap Screw
4
L
HD Eccentric Nut (threaded)
2
M
M8 Guide Bearing
4
N
M8 Spacer
2
O
M8 Washer
2
P
M8 x 30mm Bolt
2
Figure 1

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Shapeoko Carryover
Components
The HDZ utilizes several parts from the
existing machine. All components and
hardware to be carried over are listed
in the table below and shown in
Fig. 2
.
Throughout this guide, carryover parts
will be called out by the words:
CARRY OVER
.
NOTE: It is important to use the
screws provided in the HDZ kit.
Item
Description
Qty
Q
Spindle/Router Mount
1
R
M5 x 16mm Button Head Cap Screw
2
S
Router Mount Adapter Ring (optional)
1
T
Z-Motor
1
U
X-Motor
1
V
X-Rail Belt
and Hardware: Belt Clip (1) and M5 x 10mm Socket Head Cap Screw (1)
3
W
X-Axis Drag Chain Bracket (attached to drag chain)
1
X
M5 x 10mm Button Head Cap Screw
2
Y
Z-Axis Homing Switch
and Hardware: M3x12mm Socket Head Cap Screw (1) and M3 Washer (1)
3
Z
X-Axis Homing Switch Assembly
and Hardware: 1-inch Round Spacer (2), M5 x 35mm Socket Head
Cap Screw (2) [Switch Assembly Includes: X-Axis Homing Switch (1), Mounting Plate (1),
M3 x 12mm Socket Head Cap Screw (1), M3 Washer (1), M3 Nylon Lock Nut (1), Cable Tie (1)]
10
Figure 2

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Disassemble and Remove the Existing X/Z-Carriage
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.
Disconnect Cables and the X-Axis Belt
1. Turn off your machine, unplug it, and disconnect the USB and power cables.
2. Unplug the router/spindle and remove it from the spindle mount.
a. Use a 4mm hex key to loosen the two (2) M5x55mm SHCS, if necessary.
3. 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 M5x10mm 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
,
M5x10mm SHCS
, and
belt clip
.
4. Label male/female ends of the white X- and Z-motor connectors behind the X/Z-carriage and disconnect.
a. Use a permanent marker or piece of tape to mark both male/female connectors.
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.
Remove the Homing Switches, Drag Chain, and V-Wheels
1. Label the X- and Z-Axis homing switches with a piece of tape (if needed).
2. Remove the Z-Axis homing switch from the front of the X/Z-carriage.
a. Use a 2.5mm hex key to remove the M3x12mm SHCS.
b.
CARRY OVER
the
Z-Axis homing switch
,
M3x12mm SHCS
, and
M3 washer
.
3. Remove the X-Axis homing switch plate (keep switch attached to plate) from the rear of the X/Z-carriage.
a. Use a 4mm hex key to remove the M5x35mm SHCS and 1-inch spacers.
b.
CARRY OVER
the
X-Axis homing switch assembly
,
M5x35mm SCHS
, and
1-inch spacers
.
4. Remove L-shaped X-Axis drag chain bracket (keep drag chain attached to bracket) from rear of X/Z-carriage.
a. Use a 3mm hex key to remove the M5x10mm BHCS securing the L-bracket.
b.
CARRY OVER
the
bracket
and
M5x10mm BHCS
.
5.
Remove the lower two V-wheels of the X/Z-carriage.
a. Use a 3mm hex key and 8mm wrench to remove the lower two V-wheels.

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6. Lift the X/Z-carriage away from your Shapeoko.
Disassemble the X/Z-Carriage
In this section you will remove and
CARRY OVER
the
X-Axis stepper motor
,
Z-Axis stepper motor
, and the
router/spindle mount and hardware
. You will also remove the motor pulley from the Z-Axis stepper motor drive shaft.
Separate the Z-Carriage from the X-Carriage
1. Remove the springs from both sides of the X/Z-carriage.
2. Loosen the belt tensioning screw at the bottom of the X-carriage.
a. Use a 3mm hex key to loosen the tensioning screw.
3. Loosen the idler assembly at the bottom of the X-carriage and free the belt.
a. Use a 4mm hex key and a 10mm wrench to loosen the nut holding the idler in place.
4. Slide the small Z-carriage down and off the larger X-carriage.
Remove the Router/Spindle Mount
5. Remove the router/spindle mount from the Z-carriage plate.
a. Use a 3mm hex key to remove the two M5x16mm BHCS securing the mount.
b.
CARRY OVER
the
M5x16mm BHCS
, and
router/spindle mount
.
Remove the Stepper Motors
6. Remove the X-motor (lower motor) from the back of the X-carriage.
a. Use a 4mm hex key to remove the four M5x10mm SHCS securing the motor.

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b.
CARRY OVER
the
X-motor
.
7. Remove the Z-motor (upper motor) from the
back of the X-carriage.
a. Use a 4mm hex key to remove the
M5x10mm SHCS securing the motor.
8. Remove the drive pulley from the Z-motor
drive shaft. (The Z-motor has the shorter lead
cables.)
a. Use a 1.5mm hex key to loosen the
two 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. 3
.
c.
CARRY OVER
the
Z-motor
.
Figure 3

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Assemble and Install the HDZ
HDZ Assembly Tips
We recommend assembling as much of the HDZ as possible before installing it onto the Shapeoko; this process is
described in the steps below.
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.
Insert the Eccentric Nuts
Located in HDZ Kit:
Item
Description
Qty
L
HD Eccentric Nut
2
1. Insert the two HD eccentric nuts into
the bottom of the HDZ. See
Fig. 4
.
a. Rotate the eccentric nuts into
their fully open position with
the dimple facing up.
NOTE: Be careful not to confuse the HD
spacers and the HD eccentric nuts. The HD
eccentric nuts are threaded, the HD
eccentric spacers are non-threaded.
Figure 4

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Install the Z-Motor and
Coupling
HDZ kit + Carryover Components:
Item
Description
Qty
H
Z-Motor Shaft Coupling
1
G
M5 x 10mm Socket Head
Cap Screw
4
T
Z-Motor*
[CARRYOVER]
1
*Z-Motor has shorter lead cables and bare drive shaft.
1. Install the Z-motor coupling onto the
ball screw at the top of the HDZ. See
Fig. 5
.
a. Use a 2.5mm hex key to loosen
both set screws.
b. Press the Z-motor coupling
onto the ball screw shaft until
fully seated.
c. Tighten the bottom set screw.
2. Install the Z-motor at the top of the
HDZ. See
Fig. 6
.
a. Insert the motor drive shaft
into the coupling (position
motor with leads toward the
back of the HDZ).
b. Use a 4mm hex key and four
M5x10mm SHCS to secure the
motor.
Figure 5
Figure 6

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d. Use a 2.5mm hex key to secure
coupling to Z-motor drive shaft.
See
Fig. 7
.
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.
Assemble and Install Idlers
HDZ Kit:
Item
Description
Qty
P
M8 x 30mm Idler Bolt
2
O
M8 Washer
2
M
M8 Guide Bearing
4
N
M8 Spacer
2
1. Assemble the two idlers in this order:
a. M8x30mm idler bolt
b. M8 washer
c. M8 guide bearing, flange
TOWARD
bolt head
d. M8 guide bearing, flange
AWAY FROM
bolt head
e. M8 spacer
2. Install idlers onto the back of the HDZ. See
Fig. 8
.
a. Use a 6mm hex key to secure the idlers to the two M8 screw holes in the center of the plate.
When fitted correctly the idler bolts will not protrude through the front of the plate.
Figure 7
Figure 8

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Install the X-Motor Standoffs
HDZ Kit:
Item
Description
Qty
F
M5 x 25mm Male-to-
Female Threaded Standoffs
4
1. Hand-screw the standoffs to the back of
the HDZ. See
Fig. 9
.
a. Do NOT use tools or
overtighten the standoffs.
b. Screw M5x25mm standoffs into
the four evenly-spaced M5
screw holes at center of the
plate just above the idlers.
Assemble and Install
V-Wheels
HDZ Kit:
Item
Description
Qty
I
V-Wheel
4
J
M5 Washer (Shim)
4
K
M5 x 25mm Socket Head
Cap Screw
4
1. Assemble the four V-wheels in this
order:
a. M5x25mm SHCS
b. V-wheel
c. M5 washer (shim)
2. Install top two V-wheels on the back of HDZ, in line with the idlers. See
Fig. 10
.
a. Use a 4mm hex key to secure 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.
3. Lift the HDZ onto the X-rail, aligning the V-wheels with the upper V-rail.
Figure 9
Figure 10

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4. Install the bottom two V-wheels on the
back of the HDZ.
Fig. 11
and
12
.
a. Be sure V-wheels are properly
seated on lower V-rail.
b. Use a 10mm wrench to hold
eccentric nuts in the fully open
position (dimples up).
c. Use a 4mm hex key to secure
both V-wheels to the HD
eccentric nuts.
d. Check HDZ movement by rolling
carriage back-and-forth along
the X-rail.
5. Tension the HD eccentric nuts.
a. Rotate the eccentric nuts
CLOCKWISE
to tension. Reach
under and spin the V-wheel
with your finger. If it rotates
freely, keep tightening until you
feel some friction against the
rail.
NOTE: If your V-wheels are not turning
freely, check to make sure the shims are
correctly positioned between the V-wheel
and carriage plate.
Figure 11
Figure 12

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Install the X-Motor
HDZ Kit + Carryover Components:
Item
Description
Qty
G
M5 x 10mm Socket Head
Cap Screw
4
U
X-Motor
[CARRYOVER]
1
1. Thread the free end of the X-Axis belt
under the idlers at the back of the HDZ.
2. Push a large loop up between the idlers.
See
Fig. 13
.
3. Attach the X-motor to the four
standoffs on the back of the HDZ.
Position motor leads to either side.
a. Use a 4mm hex key and four (4)
M5x10mm SHCS to secure.
See
Fig. 14
.
4. Pull the slack out of the belt.
Figure 13
Figure 14

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Install the X-Axis Belt
Carryover Components:
Item
Description
Qty
V
X-Axis Belt and Hardware:
Belt Clip (1), and M5x10mm
Socket Head Cap Screw (1)
[CARRYOVER]
3
1. Install and tension the X-Axis belt. See
Fig. 15
a. Attach the belt clip to the free
end of the belt.
b. Place the belt flat along the rail
leaving a ¼-inch gap between
the clip and carriage plate.
c. Use a 4mm hex key and the
M5x10mm SHCS to secure.
d. Tighten until an audible tone
can be heard when the belt is
plucked.
Install the Drag Chain
Bracket
Carryover Components:
Item
Description
Qty
W
X-Axis Drag Chain Bracket
(attached to drag chain)
[CARRYOVER]
1
X
M5x10mm Button Head Cap
Screw
[CARRYOVER]
2
1. Attach X-Axis drag chain bracket to back
of the HDZ. See
Fig. 16
.
a. Align bracket with the M5
screw holes on the Y2-side of the X-motor (right side when viewed from front).
b. Use a 3mm hex key and two (2) M5x10mm BHCS to secure.
Figure 15
Figure 16

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Install the X-Axis Homing
Switch
Carryover Components:
Item
Description
Qty
Z
X-Axis Homing Switch
Assembly and Hardware:
1-inch Round Spacers (2),
M5x35mm Socket Head Cap
Screw (2)
[CARRYOVER]
5
1. Assemble the X-Axis homing switch
plate in this order:
a. M5x35mm SHCS (2)
b. Homing switch plate
c. 1-inch spacer (2)
2. Attach X-Axis homing switch plate to back of HDZ. See
Fig. 17
.
a. Align assembly with M5 screw holes on Y2-side of the X-motor.
b. Ensure homing switch body is on drag chain side of plate with the blue switch facing the Y2-carriage.
c. Use a 4mm hex key to secure.
3. Move the HDZ to the Y2-carriage and ensure the homing switch fully engages with the Y2-carriage. Adjust if
necessary.
Figure 17

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Install the Z-Axis Homing
Switch
Carryover Components:
Item
Description
Qty
Y
Z-Axis Homing Switch and
Hardware: M3x12mm Socket
Head Cap Screw (1), and M3
Washer (1)
[CARRYOVER]
3
1. Assemble the Z-Axis homing switch in
this order:
a. M3x12mm screw
b. M3 washer
c. Z-Axis homing switch
2. Attach the switch to the Y2-side of the Z-motor mount at the top of the HDZ. See
Fig. 18
.
a. Position the homing switch alignment peg into the front hole in the motor mount, with the blue switch
pointing down.
b. Use a 2.5mm hex key to secure.
Connect the Motors
1. Connect the X- and Z-motor lead cables
to the appropriate extension cables.
See
Fig. 19
.
a. Connectors are polarized. Be
sure to align properly.
2. Tidy up your wiring with cable ties. See
Fig. 19
.
Figure 18
Figure 19

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Install the Spindle Mount
HDZ Kit + Carryover Components:
Item
Description
Qty
B
EZTram Plate
1
C
M5 x 18mm Socket Head
Cap Screw
2
D
M5 x 10mm Button Head
Cap Screw
2
E
HD Eccentric Spacer (non-
threaded)
2
Q
Spindle/Router Mount
[CARRYOVER]
1
R
M5 x 16mm Button Head
Cap Screw
[CARRYOVER]
2
1. Attach EZTram plate to router/spindle
mount. See
Fig. 20.
a. Align the front of the plate with
the M5 screw holes on the back
of spindle 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 two
M5x16mm BHCS to secure.
2. Assemble eccentric spacers in this
order:
a. M5x18mm SHCS
b. HD Eccentric spacer (nut side
TOWARD
screw head).
3. Loosely attach EZTram to the front of
the HDZ. See
Fig. 21.
a. Align the EZTram with corresponding M5 screw holes on the front of the HDZ.
b. Insert M5x18mm SHCS and spacers into oval through holes at the top of EZTram. See
Fig. 21.
c. Loosely tighten the SHSC with your fingers. Rotate both eccentric spacers until the dimple is facing up.
d. Insert the two M5x10mm BHCS into the bottom of the EZTram plate and finger tighten.
4. Complete tramming instructions below.
Figure 20
Figure 21

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Tramming Instructions
Once your spindle is re-installed you can tram it quickly and easily using the EZTram plate.
1. Loosen the four (4) EZTram screws so they are just finger tight. Rotate both eccentric spacers to their lowest
points (dimple up).
2. Then level out your Z-Axis.
a. Rotate the eccentric spacers as needed to tram the spindle from front to back, using aluminum foil as
a shim.
b. Once you’re happy with the front-back, move on to left/right.
c. Use a 10mm wrench to rotate the upper eccentric nuts CLOCKWISE. This will lower or raise one side of
the mount, adjust accordingly to tram your Z-Axis.
3. Once your Z-Axis is level, lock down the position of the eccentric nuts by tightening the M5x18mm SHCS.
You might need to repeat this process a few times doing a small surfacing cut in between each adjustment to analyze
your level.
NOTE: If you are using the 80mm spindle mount, there should be no need to tram the motor left/right, as it is
precision milled. Fit the 80mm mount directly to the holes on the front of the HDZ using the M6 bolts provided
in the 80mm spindle mount kit.
A detailed video on tramming your Shapeoko can be found here:
https://www.youtube.com/watch?v=rGOGlNurglE
.
For additional advice on tramming, check out the Carbide 3D community:
community.carbide3d.com
.
Maintenance
The HDZ is pretty much maintenance-free. We recommend keeping it as dust-free as possible. A quick coat of
synthetic grease (such as Mobil Vactra No. 2 Oil) on the rails and ball screw every 6 months. All the parts are rubber-
sealed. You can also inject grease by removing the central M4 screw from the end of a bearing block and injecting
machine grease through a syringe.

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Update the Software Settings
WARNING: The HDZ is supported by Carbide Motion 4.17 onwards. Do NOT use an older version of
Carbide Motion.
Update Settings
Download and install Carbide Motion from:
https://carbide3d.com/carbidemotion/download/.
Confirm all of the homing switches and motors are
connected correctly, then, ensure that there is
nothing restricting the Shapeoko’s movement.
Now, you’re ready to turn the Shapeoko on and
make the required software changes.
1. Plug in your USB cable.
2. Open Carbide Motion.
3. Turn your Shapeoko on.
4. Click the
Connect to Cutter button
.
5. Click
Settings
in the top menu bar.
WARNING: DO NOT TRY TO HOME OR JOG
THE SHAPEOKO before applying the
updated settings.
6. In the Settings window, choose your Shapeoko size from the
Size dropdown list
, the choose “HDZ, Full X Travel
(Ballscrew)” from the
Z-Axis Type dropdown list
, and “Inches” or “MM” from the
Units dropdown list
. See
Figure 22
.
7. Click the
Send Configuration Data button
in the middle of the dialog window.
8. The config data will send. Wait until this has finished before moving on to test your homing switches.
Figure 22