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BEFORE STARTING Be sure to unplug your machine from the wall outlet before starting this procedure!
Metal flakes and chips from rotary engraving can also damage electrical components, so be sure to vacuum and wipe any chips from the Wizzard cover and engraving pan area before you remove the cover. Make sure you have plenty of room on your work table. If you have an XL, allow room to place the machine cover to the right of the machine, and extra room in the back to place the pan assembly.
Tools Needed
3/32 & 5/32 hex wrenches. If possible the 5/32 needs to the long T-handle type for reaching the back pan screws.
TURN THE POWER OFF AND UNPLUG THE WIZZARD.
Take off the motor belt, the spindle, and the center support bar, vacuum chip removal (if installed) and the clamping bars.
Push the workholding vise truck back by placing your thumbs on either side of the clamping knob (to tigheten the vise that holds your plates) on the front and pushing back firmly until the knob is clear of the cover.
Pick up the front of you Wizzard and gently rest it on it’s back as shown in Illustration . Using your 3/32 hex wrench remove the 8 screws and washers that hold the cover (need to have numbers for each screw)..
Gently set the Wizzard down in its normal upright position.
make sure you have enough room on your table to place the cover on its side, directly to the right of the XL. Lift the cover up VERY SLOWLY AND GENTLY, and tilt it on its right side. Be careful not to yank the multi-colored ribbon cable that runs from the job storage cartridge slot on the top cover to the main board on the inside the XL. There will also be a black cord running from the back inside of the XL to the cooling fan on the inside of the XL cover. After noting the position of the fan cord, disconnect the plug from the fan.
Removing The Pan
The pan is the assembly that contains the engraving table
Using a 5/32 hex wrench, unscrew the 4 black screws that hold the pan assembly to the base; these screws are labeled (Illustration 2). You can push the spindle assembly (cutter box) over to one side to get to the back two screws.
If there is a black internal vacuum hose on the back of your pan (usually found on Wizzard/Wizzard II only), unscrew it and pull it out, leaving the black nozzle in place.
Find the cable that leads from the spindle/engraving motor to the brown 3-wire plug on the AC distribution board (back of machine). Unplug it by squeezing the clips on either side and pulling up firmly. Also unplug the green ground wire from the back of the pan assembly. It is also conneced to the 3-wire plug you disconnected on the AC distribution board.
GENTLY AND SLOWLY lift the pan up and tilt the front front edge up so you can rest it on it’s back side just behind the XL. Be careful not to yank any wires still connected to the inside of the XL. If you are only replacing chips on the main board, you have your XL torn down, otherwise, continue with the next step.
With a thin, wide blade screwdriver, VERY GENTLY and EVENLY pry up the multi-colored job storage cable connector on the main board. The connector pins are fragile, so take your time to avoid bending or breaking.
Place the top cover out of your way, making sure the job storage cable does not get stepped on.
Before removing the 4 sets of wires from the pan assembly to the main board, note their positions, and make sure the X, Y, & Z wires are marked accordingly for ease of replacement. The axes are marked on the stepper driver board if the labels have been removed from your wires. The black wires are your limit switch connections.
GENTLY raise the front of the pan assembly up so that you remove the three multi-colored wires (X, Y, & Z axes) directly below the front, right side of your pan assembly. Before removing the 3 connectors note the positions, make sure the X, Y, & Z wires are marked accordingly for ease of replacement. The axis are marked on the main board if the labels have been removed from your wires. Next remove the red connector with the black set of wires directly below the left side of your pan assembly. This is the connection between the limit switches and the main board.
Replacing The Pan And Cover
XL & XL Xtra owners.
With your pan assembly in the upright position behind your XL, carefully connect your X, Y, & Z and limit switches to the main board.
GENTLY place the pan assembly back on the XL, aligning the pan screw holes with the rubber grommet screw holes. Make sure that no wires have gotten between the bottom of the pan assembly and the rubber grommets.
Plug in the brown 3-prong connector from the engraving motor to the AC Distribution board. Also re-connect the green ground wire to the rear of the pan assembly/
Install only the two BACK screws for the pan assembly.
Place the top cover on it’s side as it was before you removed the fan cable and job storage cable.
Plug in the black connector to the cooling fan.
Make sure the pins on the job storage cable connector are very straight. While lifting up on the front of the pan assembly, you can CAREFULLY & ACCURATELY reinsert the connector to the main board.
Test the connections by putting the XL in the slew mode. Press and hold down all 5 light blue mechanical keys simultaneously while pressing the red power switch. Release the keys when the spindle assembly starts moving.
Watch the movement of the spindle assembly; it should move to the right side, do a cutter down and a cutter up, then move back to the left. The workholding truck should move at the same time all the way to the back and forward again.
Cancel the slew mode by pressing the STOP key, and wait for the spindle to return to HOME. Check to see if you can load a job from your job storage cartridge to make sure you haven’t bent any of the connector pins. Turn off the power and unplug the XL. If any of the above actions didn’t work, check your connections or other work.
Replace the 2 screws holding the front of the pan assembly.
Push the workholding vise truck back by placing your thumbs on either side of the clamping know on the front of the truck and pushing back firmly until the black knob is far enough back that it will not interfere with the replacement of the cover.
CAREFULLY AND SLOWLY, AND WITHOUT FORCE, replace the top cover. Make sure you do not crimp the job storage cable between the case and the power switch module. After it drops in place, turn the XL around and see if your fan cord or spindle motor cord is sticking out the back. Gently tuck them in.
Hold both sides of the XL, grasping both the top and the bottom together. Tilt the XL on its back, and screw in the eight screws that hold the cover on. Gently set the XL in its normal upright position.
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