Maintenance On The Wizzard 

Do you know what the #1 cause of breakdowns or loss of time for the Wizzard? Lack of proper maintenance!

For maintenance on the Wizzard engravers, we recommend the use of two lubricates, BREAK-FREE and white lithium grease. The effects of BREAK-FREE are long term. It leaves a film that inhibits further deposits of grit, salt and other foreign mater. White grease should be used only on the left side of the eccentric bar - no other place, please! Both lubricants are available through the Network.

Avoid the use of an oil squirt can, or spraying lubricants in an area that can run or drip onto the Wizzard's sensitive internal electrical components. Excessive grease of any kind on the left can drop into the inside of the engraving machine, and damage sensitive electrical components. If you are using a spray can, spray the lubricant onto your hand or a paper towel. Never lubricate a bearing on any part of the Wizzard.

CAUTION: Always turn the power OFF and disconnect the power cord at the wall outlet before attempting any maintenance procedure.

DAILY/WEEKLY CLEANUP

• Check for worn cutters, and replace as needed.
  
  
• Use an air hose or vacuum cleaner to remove all chips from the engraver and surrounding work area. An excessive buildup of chips around your machine can cause static electricity. Avoid `blowing off' the keyboard, especially if you do not have a plastic keyboard overlay/cover. Use your vacuum cleaner's brush attachment for best results.
  
  
• Never vacuum your machine with the brush attachment while it is running. Several members have noted excessive static buildup caused by the brush, which caused damage to sensitive electrical components.
  
  
• Remove the spindle retainer nut and nosecone. Clean out the engraving chips beneath the nosecone, around the bearing casing, with a small toothbrush or rigid paint brush. Never use an air source - it will force engraving debris up into the bearings.
  
  
• Never, never oil your spindle! The oil will break down the seals on your bearings.
  
  
• Use a cloth lightly saturated with BREAK-FREE to wipe the entire surface of the silver cutter up/down, or eccentric bar (Z- axis).
  
  

EVERY 300 HOURS OR AS NEEDED

• Clean the air filter on the XL (See cleaning your XL fan filter at the end of this section).
  
  
• Check your engraving motor belt for excessive wear.
  
  
• Lubricate only the left end of the silver eccentric bar using white grease. The end of the bar fits into a plastic/Teflon socket, and a lack of lubrication will result in wear on the socket, and more noise from the bar. Using your finger or a Q-tip, apply a dab of white grease where the bar rotates, between the silver bar and the plastic socket. Again, don't over lubricate this area. Excessive white grease can be forced through the opening and fall on the internal CRT or motherboard. Avoid using BREAK-FREE in this area. Due to it's viscosity, it will eventually flow through the opening and damage internal parts.
  
  
• Using lacquer thinner or other solvent and a rag, clean the X and Y-axes leadscrews to remove any excessive buildup of engraving particles. To clean the Y-axis, first remove the `AB' jigs so that you can reach the leadscrew.
  
  
• Using a clean rag saturated with BREAK-FREE, lubricate both the front and rear portions of the Y-axis leadscrew and the left and right portions of the X-axis lead- screw.
  
  
• After cleaning and lubricating the leadscrews and eccentric bar, put the Wizzard in the slew mode to evenly distribute the lubricant.
  
  
• Clean and lubricate the rails and V-wheels on both your X and Y axis.
  
  

The rails are actually round rods that the V-wheels ride on (see illustration below). There are two rails for each axis. By feeling the rails beneath the X and & axis with your finger tips, you can determine if there is a buildup of grease, rust and debris. After cleaning, the rails should be as smooth as glass.

 

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Through many of hours of testing and servicing Wizzard's, we have determined a very good test to determine if you need to clean or lubricate your leadscrews, V-wheels and rails. Lightly rub your finger tips over the surface of the rails. If you do not get a film of lubricant, they are too dry and need lubricating. If you do get a film and it's dark or dirty, you need to first clean the rails with lacquer thinner or other solvent and lubricate with BREAK-FREE.

It is easier to get to the front V-wheels (X-axis) from the back of the machine while slewing, and the back V-wheels can be reached from the front side. Use the extender tube on BREAK-FREE to lubricate V-wheels (sparingly).

• Using lacquer thinner, clean the surface of the X-bridge where the ground brush contacts (see illustrations previous page). Avoid getting lubricant on this area as it will ruin the grounding brush and prevent proper grounding.

Note: The machined surface of the X-bridge (on the underside of the X-bridge, and between the back side of the bridge and the leadscrew) is barely visible when you view the bridge looking up from the back side of your Wizzard. It is a machined area silver in color, about 3/4 inches wide.

• Put a couple of drops of Break Free on the threads of the black knob that screws into the cutter box and holds the spindle in place.
  
  
• Also make sure you lubricate your threaded rod and donut on your clamping assembly. Also the two base guides that the clamping assembly rides on.
  
  
• Be sure and press HOME before starting a job.
  
  

EVERY 500-600 HOURS

• Change the motor brushes after 500-600 hours of operation to prevent electrical motor interference.
  
  
• Check the V-wheels that the spindle motor belt rides on. Make sure each one spins freely. Bad bearings in these V-wheels can reduce belt and spindle life.

Other Maintenance Notes

Some spare parts that should be considered are:

• 2 extra motor spindle belts
  
  
• 2 sets of motor brushes
  
  
• If you do a lot of plastics or rubber stamp engraving, keep an extra spindle motor in stock.
  
  
• 2 RIFA chips. Usually only one axis will go bad, and there are two for each axis. If you own a Genie, Wizzard, or Wizzard II, always have a set of 6 on hand.
  
  
• Keep a maintenance and trouble shooting log. Write down any problems you may have encountered. Also record updates and replacements parts you've installed on your Wizzard. It will help your service technician to identify problem areas or symptoms.
  
  
• Clean the gold contacts on both sides of the External Font Cartridge where it plugs into the Wizzard. Dirty contacts will cause problems in reading logos/fonts. Also keep your logo chips stored to prevent damage and the legs on the chips from getting damaged.
  
  
• Wizzard XL Fan Cleaning The original manual for the Wizzard XL doesn't state anything about this maintenance procedure, but never the less it is just as important as lubricating the leadscrews. Neglecting to clean the filter can cause it to become saturated with dust and dirt. This in turn reduces the air flow circulating through the XL, and allows heat to build inside the machine. Remove and clean the filter with soap and water; allow to dry. This maintenance procedure needs to be done once a month, at the same time you lubricate the leadscrews. If you operate your Wizzard XL in a dusty or dirty environment, you may need to check the filter more often.