Carbide 3D HDZ 3.3 User manual

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HDZ 3.3 Assembly Guide
Intro
Thank you for purchasing the HDZ. We know you’ll enjoy your purchase!
If you run into any issues during assembly, please contact us at
[email protected]
.
Prior to fitting the HDZ please ensure you can rotate the ball screw by hand and move the carriage to the top and
bottom of travel. If you cannot do this please contact us at
[email protected]
.
If you can encounter binding or movement issues please contact us at support. We request that you do not attempt to
diagnose or dismantle the HDZ.
IMPORTANT Software Information
You must run Carbide Motion 4.17 and onwards with the HDZ.
Download it from:
carbide3d.com/carbidemotion/beta
.
WARNING: After installing the HDZ, you must update your GRBL settings. DO NOT HOME UNTIL YOUR
SETTINGS HAVE BEEN UPDATED!
Assembly Video
Check out the assembly overview video for help with the assembly process:
https://youtu.be/ojVpMMRCeVU
.
NOTE: The only items you need to transfer from your existing X/Z-carriage are the X- and Z-homing switches,
X- and Z-motor, spindle mount, spindle/router.

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Required Tools and Parts
To carry out this modification, you need basic mechanical skills and
an understanding of how the Shapeoko is assembled. The installation
should take under 2 hours. You will need basic shop tools, a set of
metric hex keys and wrenches. The tool kit that came with your
Shapeoko should be adequate.
Your HDZ comes 95% ready to fit; however, a number of parts (listed
below) will need to be transferred from your existing X/-carriage. As
of this document, the HDZ comes with replacement guide bearings
and spacers (these no longer need to be removed from the old
carriage as stated in the overview video above).
It is important to use the screws provided in the HDZ kit. Please note
that the screws used are METRIC, usually M5.
This assembly process is uniform for the Shapeoko 3, 3XL, and 3XXL.
Dust Caps
There are 10 small green dust caps included in your HDZ kit. These fit
to the HDZ slider rails. See
Figure 1
. They have not been pre-fitted as
there is a small chance you may need to re-align your rails. To fit
these, you may need to use a small dab of rubber-based adhesive or
CA glue. In most cases they can be pressed in using the ball-end of a screwdriver.
Figure 1

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Components Needed from Your Existing Shapeoko Setup
The only components you need to transfer from your existing X/Z-carriage are:
• X- and Z-Homing Switches and Hardware
• X- and Z-Motor
• Spindle Mount
• Spindle/Router
HDZ Kit Contents
Each HDZ comes with the following standard hardware (everything required to install it to your Shapeoko):
• EZTram Router/Spindle Mounting Plate (1)
• M5 x 18mm Screw for Top of EZTram Plate (2)
• M5 x 10mm Screw for Bottom of EZTram Plate (2)
• Eccentric Spacer (non-threaded) for EZTram (2)
• Z-Motor Shaft Coupling (1)
• M5 x 25mm Male-Female Threaded Standoff for the
X-Motor (4)
• M5 x 10mm Screw for Motor Standoffs (8)
• HD Eccentric Nut (2)
• Replacement V-Wheel (4)
• V-Wheel Shim (4)
• M5 x 25mm Screw for V-Wheel (4)
• M8 x 30mm X-Motor Idler Bolt (2)
• M8 Washer (2)
• M8 Spacer (2)
• M8 Guide Bearing (4)
• Green Dust Cap (10)
• Black Sledge (4)
Disassemble and Remove the Existing X/Z Carriage
The first step is to disassemble and remove the existing X/Z-carriage from your Shapeoko.
1. Turn off your machine and unplug it. Disconnect the USB cable.
2. Unplug the router or spindle and remove it from the spindle mount.
3. Remove one of the belt clips securing the x-axis belt to the X-rail. Unfeed the belt from the X/Z-carriage idler
pulleys and put the free end of the x-axis belt, the belt clip, and the M5 x 10mm screw to the side—you will
need to re-install them later.
4. Label, then disconnect the Z- and X-motor wires.
5. Remove the z-axis homing switch from the front of the X/Z-carriage.
6. Remove the z-axis homing switch from its mounting plate. Set the z-axis homing switch hardware, the M3
screw, washer, and lock nut, aside for the HDZ assembly (we won’t be needing the mounting plate or the four
M5 screws).
7. Remove the x-axis homing switch from the rear of the X/Z-carriage, below the drag chain bracket. Set the two
M5 x 35 mounting screws and 1-inch spacers aside, we’ll need them to re-install the homing switch onto the
HDZ.
8. Remove the x-axis homing switch from the mounting plate. Set the mounting plate and hardware, the M3
screw, washer, and lock nut, aside for re-installation.

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9. Remove the drag chain bracket from the rear of the X/Z-carriage, next to the Z-motor. Set the two screws and
standoffs aside (the bracket will
remain attached to the drag chain).
10. Use a hex key to loosen the v-wheels
at the bottom of the X/Z-carriage and
remove them. You will not be reusing
these v-wheels; the HDZ ships with
four v-wheels and two heavy duty
eccentric nuts.
11. Lift the X/Z-carriage off your machine.
12. Remove the springs from either size of
the carriage (not needed for the HDZ).
13. Loosen the idler assembly at the
bottom of the carriage.
14. Remove the belt from the idler and
the motor pulley at the top of the
carriage and slide the Z-carriage down
and off the X-carriage.
15. Remove the M5 x 16mm screws attaching the spindle mount to the Z-carriage. Set the spindle mount and
screws aside we will need for installation on the HDZ.
16. Remove the X-motor from the standoffs at the back of the carriage. Set the motor aside (you will not need the
screws or standoffs for the HDZ).
17. Remove the Z-motor from the top of the carriage.
18. Remove the gear pulley on the front of the Z-motor:
a. Loosen the two small motor pulley set screws (grub screws) and pry off the gear pulley.
b. The pulley may be hard to slide off. We recommend using a screwdriver, needle nose pliers, or the
back of a claw hammer to lever the pulley off the Z-motor. See
Figure 2
.
c. Set the Z-motor to the side (you will not need the M5 screws).
Assemble the HDZ
HDZ Assembly Tips
The quickest and easiest way to fit the HDZ is to assemble the majority of the HDZ components
BEFORE
fitting it to the
Shapeoko.
Upon assembly it’s up to you if you use thread lock or not. We suggest adding it post-assembly if any screws become
loose during use. If you decide to use thread lock, use blue (i.e. light/medium grade).
Figure 2

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Fit the Eccentric Nuts
You will need:
• HD Eccentric Nut (2)
1. Press the two supplied M5 eccentric
threaded nuts into the holes on the
bottom of the HDZ.
2. Rotate them so the dimples on one
side of the eccentric nuts face
upwards—this is the loose/open
position. See
Figure 3
.
Install the Z-Motor and Coupling
You will need:
• Z-Motor Coupling
• M5 x 10mm Screw (4)
• Z-Motor from your existing setup
1. Place the Z-motor coupler on the ball
screw at the top of the HDZ and slide it
down as far as it will go.
2. Tighten the lower side of the coupler
as shown in
Figure 4
.
Figure 3
Figure 4

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3. Slide your motor shaft onto the coupler and secure it using
four (4) of the M5 x 10mm screws. Tighten the screws in a cross
pattern. See
Figure 5
.
4. Once the motor is fitted, tighten the coupling at the motor
side. See
Figure 6
.
NOTE: Ensure both 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.
Install the X-Motor Idlers
You will need:
• M8 x 30mm X-Motor Idler Bolt (2)
• M8 Washer (2)
• M8 Spacer (2)
• M8 Guide Bearing (4)
1. Slide a washer onto one of the bolts, then slide on two (2)
of the bearings (with the flanged edges to the outside),
then an M8 spacer. See
Figure 7
.
Do the same for the second bolt.
2. Once both bolts are assembled, fit them to the two M8
holes on the rear of the HDZ.
When fitted correctly, your X-motor idlers will look like
Figure 7
and the bolts will not poke through the front of the
plate. Pay special attention to the order and orientation of each item on the bolt.
Figure 5
Figure 6
Figure 7

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Install the X-Motor
Standoffs
You will need:
• M5 x 25mm Male-Female Threaded
Standoffs for the X-Motor (4)
1. There are four M5 threaded holes in
the center of the carriage just above
the M8 bolts. Insert the four (4)
M5x25mm X-motor standoffs into the
four holes. Do
NOT
over-tighten the
motor standoffs; they are made of
aluminum. See
Figure 8
.
Install the V-Wheels
You will need:
• V-Wheel (4)
• M5 Shim (4)
• M5 x 25mm Screw (4)
The HDZ comes with a set of four v-wheels. You can save your old v-wheels for replacements. The top set of v-wheels
will be installed to the outside of the X-motor idlers.
1. Fit the top two V-wheels first using the provided 25mm M5 screws. Ensuring there is a shim between the back
plate and the V-wheel.
Figure 8

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2. Use two (2) of the provided M5 x 25mm screws to fit
the top v-wheels. See
Figure 9
.
3. When the top v-wheels have been fitted, lift the
carriage onto the X-axis rail.
4. Fit the bottom v-wheels in the same manner. As you
fit them, ensure the v-wheel grooves are on the rail. See
Figure 10
.
5. Once the bottom v-wheels have been fitted, ensure
the HDZ moves freely left/right along the X-rail.
6. To properly seat the HDZ, tighten the lower M5
screws. As they tighten, they will rotate the eccentric
nuts, applying pressure to the v-wheels. The v-wheels
should move freely as you move the HDZ. If you need
to, you can hold the screw in place and tighten
(CLOCKWISE) the eccentric nut a fraction with a wrench.
If your V-wheels are not turning freely check the shims
are fitted correctly.
Figure 9
Figure 10

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Install the X-Motor
You will need:
• M5 x 10mm Screw (4)
• X-Motor from your existing setup
1. Thread the free end of the x-axis belt under the idlers
at the back of the HDZ.
2. Create a large loop between the idlers. See
Figure 11
.
3. Fit your X-motor to the X-motor standoffs using the
four (4) M5 x 10mm screws. See
Figure 12
.
Figure 11
Figure 12

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Re-Install the X Belt
You will need:
• Belt Clip from your existing setup
• M5 x 10mm Screw from your existing setup
1. Place the x-axis belt along the x-axis extrusion rail and
re-fit the belt with the belt clip and M5 screw from your
existing setup. Tighten the belt so it is taut. See
Figure 13
.
Install the Drag Chain Bracket
You will need:
• M5 x 10 mm screws from your existing setup (2)
The drag chain bracket fits to the two threaded M5
holes up and to the right of the X-motor (when viewed
from the front of the machine).
1. Install the drag chain bracket using your two (2)
existing M5 x10mm bracket screws. See
Figure 14
.
Figure 13
Figure 14

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Install the X-Axis Homing Switch
You will need:
• M5 x 35mm Screw from your existing setup (2)
• 1-Inch Spacer from existing setup (2)
• Z-Axis Homing Switch, Mounting Plate, and Hardware
from your existing setup
1. Mount the x-axis homing switch to the mounting
plate with your existing hardware, the M3 screw,
washer, and lock nut.
2. Use your two (2) existing M5x35 screws and two (2)
1-inch spacers to install the x-axis homing switch plate
onto the rear of the HDZ. The homing switch mounts to
the two threaded M5 holes on the right side of the
X-motor (when viewed from the front of the machine).
See
Figure 15
.
Connect the Motors
1. Connect the X- and Z-motor. Ensure each is
connected correctly.
2. Tidy up your wiring with zip ties. See
Figure 16
.
Figure 15
Figure 16

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Install the Spindle Mount
You will need:
• Spindle Mount and Screws from your existing setup
• EZTram Router/Spindle Mounting Plate
• M5 x 18mm Screw (2)
• M5 x 10mm Screw (2)
• M5 Eccentric Spacer (2)
The EZTram mounting plate is a great feature on the
HDZ. It’s easy to fit and makes tramming your spindle
much easier through the use of two eccentric spacers.
1. Fit your existing spindle mount to the EZTram
mount using the existing M5 x 16mm screws.
Ensure the recessed holes accommodate the
screw heads and then tighten down the spindle
mount. Feel free to use thread lock to secure the
screws. See
Figure 17
.
2. Fit the two (2) eccentric spacers onto the two (2)
M5 x 18 mm screws.
3. Place the EZTram mount on the lower front of
the HDZ and thread the M5 x 18 screws and
spacers through the top holes in the EZTram and
into the HDZ. See
Figure 18
.
4. Lightly tighten the screws so the eccentric
spacers can still move When the spacers are
turned so that the grooved side faces up, this
indicates the EZTram mount is at its lowest
point. Tramming instructions are below.
5. Fit the two (2) M5 x 10mm screws through the
lower holes in the EZTram mount and finger
tighten.
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 mount. Use the provided M6 bolts. Note you will
to use two washers on each of the lower screws.
Figure 17
Figure 18

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Install the Z-Axis Homing Switch
You will need:
• Z-Axis Homing Switch and Hardware from your existing
setup
1. Fit your existing z-axis homing switch directly to the
outside edge of the Z-motor mounting plate using your
existing hardware, the M3 screw, washer, and lock nut.
See
Figure 19
.
Tramming Instructions
Once your spindle has been re-fitted you can tram it using the EZTram mount. You can now tram your spindle quickly
and easily. As a starting point, have all your EZTram bolts finger tight and rotate both eccentric spacers to their lowest
points (groove up) then rotate them as needed to level out your Z-axis. Tighten your screws.
1. Tram the spindle from front to back, using aluminum foil as a shim.
2. Once you’re happy with the front-back, move onto left/right.
3. Loosen the four (4) EZTram screws so they are finger tight
4. Use a wrench to rotate the upper eccentric spacers clockwise. This will lower or raise one side of the mount,
adjust accordingly to tram your axis.
5. Once satisfied, lock down the position of the eccentric spacers by tightening the screws. You might need to
repeat this process a few times doing a small surfacing cut in between each adjustment to analyze your level.
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 the Super Lube 41160) on the rails and ball screw every now and then does not hurt. 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.
Figure 19

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The black plastic sledges are used on the off chance you have to remove a slider block. As the block slides off a rail,
slide the sledge into the block. Please
DO NOT
remove a slider block unless advised to do so by support— ball bearings
can fall out.
Update the Software Settings
WARNING: The HDZ is supported by Carbide Motion 4.0.17 onwards. Do NOT try to use an older version of
Carbide Motion.
After confirming all your homing switches
and motors are connected correctly and
you have ensured that there is nothing
restricting the Shapeoko’s movement, you
will be ready to turn the Shapeoko back on
to 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 THE SHAPEOKO OR JOG IT before applying the settings.
6. Select your Shapeoko type from the dropdown list, then tick the
Use Shapeoko HDZ checkbox
. See
Figure 20.
7. Click the
Send Config Data button
.
8. The config data will send. Wait until this has finished before moving on.
Figure 20

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Test Homing Switches
As you have disconnected multiple
switches it is good practice to test the
homing switches.
1. Pressing each switch in turn and
check to see if it is highlighted in
the “Active Inputs” on the Settings
dialogue page. See
Figure 21
.
Home Your Shapeoko
Once all switches have been checked, you
are ready to use your Shapeoko again!
1. Click the
Jog button
in the top
menu bar and then proceed to
home your Shapeoko with the HDZ.
Happy milling!
Figure 21