8000 & 8500 Gantry Replacement Instructions

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Wizard™ International, Inc., 4600 116th St. SW, PO Box 66, Mukilteo, WA 98275 888/855-3335 Fax: 425/551-4350 wizardint.com

Gantry Replacement Instructions for the Model 8000/8500

Cautions1. NEVER SKIP AHEAD ON ANY STEP!2. Never pull/push on the Drive Shaft to move the Gantry. Use the Gantry Arm to Move/Pick up the Gantry.3. Do not pick up the Head using only the Blade Depth knob or the Head Cover. Pick up the Head by holding the “D-Shaped” Upper and Lower Head Plates.

Fig A. Fig B.

Fig A: The Drive Shaft is the thin cylindrical bar on the left that runs the length of the Gantry. The Gantry Arm is the rectangular thick housing on the right that runs the length of the Gantry.

Fig B: Pick up the Head by the “D-Shaped” Upper and Lower Head Plates.

Straight Line Trimmer RemovalFollow these instructions if you have a Straight Line Trimmer installed, otherwise skip ahead to “Head Removal”.1. Turn the shut off valve on the Blue Air Line, and unplug the Blue Air Line before removing the Straight Line Trimmer.2. Turn the bottom locking knob Clockwise to loosen. 3. Turn the top locking knob Counter-Clockwise to loosen. 4. Slide the Straight Line Trimmer off of the Board and set aside in a safe place.

Fig A. Fig B. Fig C.

Fig A: Turn shut off valve and unplug Blue Air Line. Fig B: Turn bottom locking knob Clockwise. Fig C: Turn top locking knob Counter-clockwise.

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Wizard

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Wizard

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Head Removal1. Click Reset Motors button (Fig A) to turn off power to the motors. Remove the Blade Cartridge from the Head. Turn off the Air. 2. Remove the plastic hood from the lower part of the Gantry by unscrewing the screw that holds it in place and set aside (Fig B). 3. Move the Gantry to the right side of the Board until the Foot Block is off the Board (Fig C).


Fig A: Click Reset Motors. Fig B: Remove the bottom hood from the lower part of the Gantry. Fig C: Move Head to right of Board until the Foot Block is off the Board.

4. Look at the right side of the Head and locate the Head Grabber Arm (on the right side of Gantry just above the Head). Unconnect the Head Power Plug (square connection) from the Head Grabber Arm (Fig D). Disconnect the Air from the Head Grabber Arm by untwisting the two Air Fittings (Fig E). Remove the two 5/32” screws from the Head Grabber Arm and set aside (Fig F), taking care to support the Head so that it doesn’t roll/fall off the Gantry.

Fig D. Fig E. Fig F.

Fig D: Unplug Head Power Plug. Fig E: Unconnect Air Connections from the Head Grabber arm. Fig F: Remove the two 5/32” screws.

5. Pull the Head slowly to the bottom of the Gantry until it comes away from the Gantry and carefully set aside (Figs G-I).

Fig G. Fig H. Fig I.

Fig G-I: Pull Head slowly downward along Gantry until it comes free.



Gantry Removal

NEVER SKIP AHEAD ON ANY STEP!

Remove Hood and Screws1. Remove the Head. See Head Removal for information.2. Remove the plastic hood from the upper Gantry by unscrewing the screw that holds it in place and set aside; there is one screw holding the hood (Fig A). 3. Remove the 3/16” Stop Screw from the left Bottom Rail (located on the top of the Bottom Rail) and set aside (Fig B).4. Remove the 5/32” Allen Screws and washers from the lower Gantry Plate (Fig C). These were placed here to assist in removing the Gantry.


Fig A: Remove plastic hood from upper part of Gantry. Fig B: Remove Stop Screw from left side of the Rail. Fig C: Re-move the Allen Screws from the lower Gantry Plate.

Disconnect Gantry1. Disconnect the Air Lines to the Gantry by untwisting the two Air Fittings. 2. Disconnect the Board Cable by turning the Black Locking Ring until it comes away from the Gantry (Fig B).

Fig A.

Fig A: Disconnect Air Lines and Board Cable from Gantry.

Look for Red Dots (only these screws are to be touched).



Removing the Toothed Belt from the Rail1. Loosen one full turn only the 3/16” Allen Belt Tensioner Screw from the right bottom side of the lower Rail marked with a red dot (Fig A). Only loosen it enough so that there is some movement in the Belt Tensioner; about one full turn (Fig B). Belt Tensioner springs should be visible (Fig C).

WARNING: Make sure you do not over loosen this screw. One full turn is usually sufficient.

Fig A. Fig B. Fig C.Fig A: Loosen the Allen Belt Tensioner Screw. Fig B: There should be some movement in the Belt Tensioner. Fig C: Belt

Tensioner springs will be visible.2. Locate the hole on the end of the Belt Tensioner for the 5/32” Allen Screw (Fig D). Place the 5/32” Allen Screw and washer into the Belt Tensioner hole (Fig E). Tighten it until Belt Tensioner is flush with the rail and the springs are not visible (Fig F). 3. Go back and tighten the 3/16” Allen Belt Tensioner Screw from the right bottom side of the lower Rail marked with a red dot (Fig G).

Fig D. Fig E. Fig F. Fig G.

Fig D: Locate the hole on the end of the Belt Tensioner for the 5/32” Allen Screw. Fig E: Screw the 5/32” Allen Screw and washer into the hole. Fig F: Tighten until flush with the Belt Tensioner and springs are not visible. Fig G: Retight-

en the Belt Tensioner Screw.

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4. Lift the Toothed Belt End out of the slot/recess of the Belt Tensioner Slot (Fig H and Fig I), wind up the Toothed Belt, and rubberband it (Fig J). May need to push the Toothed Belt End a bit to the right in order to get a hold of it.

Fig H. Fig I. Fig J.Fig H: Locate the screw of the Belt End. Fig I: Lift the Belt End screw from the Belt Tensioner. Fig J: Roll up and rub-

berband Toothed Belt.5. Repeat steps 1 through 4 with the upper Rail.

Pull off Gantry1. Move the Gantry slightly to the left to dislodge the Belt Anchors that are sunk into the left ends of the top and bottom Rails, to which the Toothed Belts are attached (Fig A-B). If they are in your way, lay the Belt Anchors over the Toothed Belt and rubberband them together. 2. Grasp the Gantry on the bottom and along the Gantry Arm and gently roll the Gantry off the Rails on the left side of the Board and set aside (Fig C). A second person can stand in front of the Board, grasping the Gantry at the bottom and along the Gantry Arm, if you need two people. The Gantry only weighs about 30 lbs, but it is large and awkward.


Fig A: Pull the Gantry off the left side of the Board. Fig B: Belt Anchor in place. Fig C: The Belt Anchor, which is at-tached to the Toothed Belt, should slide off the end of the Rail.



Gantry Installation

NEVER SKIP AHEAD ON ANY STEP!

Put the Gantry on the Board1. Before installation, look at the bottom set of Gantry wheels. The bottom wheels are spring-loaded, the top wheels are on a center-pivot (Fig A). Move the top set of wheels as needed for ease of installation (picture shows Gantry being put on Rail from back) (Fig B).

Fig A. Fig B.

Fig A: Bottom set of wheels: Bottom are spring-loaded, top wheels are on a middle-pivot. Fig B: View from back of wheels being loaded onto Rail.

2. Before installation, look at the top set of Gantry wheels. Both sets of wheels are spring-loaded (Fig C). Wheels may need to be eased over the Rails (picture shows Gantry being put on Rail from back) (Fig D).

Fig C. Fig D.

Fig C: Top set of wheels: Both are spring-loaded. Fig D: View from back of wheels being loaded onto Rail.3. Hold the Gantry near the left side of the Board and line up the upper then lower wheels of the Gantry to the center chan-nel of the rails (Fig E). NOTE: Installation is easier if you line up the upper wheels first, then slide the lower wheels onto the Rail. Sometimes having a second person for this step helps a lot.4. Carefully ease the Gantry onto the left side of the Rails, taking care that all the wheels line up. Make sure that the Toothed Belt lies within the channel on either side and is not pinched between the Gantry and the Rail (Fig F). Upper and lower Gantry ends must be slid on at the same time.



5. Roll Gantry past where the Stop Screw was removed. Replace the 3/16” Stop Screw into the left Bottom Rail (Fig G). Roll the Gantry to the far right of the Board and back to the left to make sure it moves smoothly.

Fig E. Fig F. Fig G.

Fig E: Line up the Gantry wheels to the Rail channels. Fig F: Make sure Toothed Belt lies within the Rail channel and doesn’t get tangled. Fig G: Replace the Stop Screw.

Installing the Toothed Belt onto the Rail1. On the left side of the Board, slide the Belt Anchor into place (Fig A). Lightly pull on the coiled Toothed Belt toward the right to take up the slack which puts the Belt Anchor flush with the end of the Board (Fig B). Loosely lay the rolled up Toothed Belt along the Rail channel (Fig C).

Fig A. Fig B. Fig C.Fig A: Push Belt Anchor into place. Fig B: Pull on Toothed Belt to take up slack. Fig C: Make sure Toothed Belt lies in

the Rail channel.2. If necessary, rotate the Toothed Pulley so that the red mark is on the top (Fig D). Line up the red mark of the Toothed Belt to the red mark of the Toothed Pulley; this may require moving the Gantry a bit in either direction (Fig E). Pull Toothed Belt on the right to take up slack (Fig F). Do not move the Gantry after red marks line up.

Fig D. Fig E. Fig F.Fig D: If necessary, rotate the Toothed Pulley so that the red mark is on top. Fig E: Line up the red mark of the Toothed

Belt to the red mark of the Toothed Pulley. Fig F: Pull on the Toothed Belt to take up slack (viewed from upper Rail).

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3. Remove the rubberband from the Toothed Belt and pull the loose Belt End to the right, making sure that the Toothed Belt is not twisted and that the teeth are facing down toward the Board into the Rail channel (Fig G). Slide the screw of the Belt End (Fig H) into the Belt Tensioner slot and click it into the slot/recess on the end (Fig I). Go back and make sure red lines are still lined up.

Fig G. Fig H. Fig I.

Fig G: Toothed Belt. Fig H: Slide the screw of the Belt End into the Belt Tensioner. Fig I: Click it into the channel.4. Locate 5/32” Allen Screw on Belt Tensioner (Fig J). Remove the 5/32” Allen Screw and washer from the Belt Tensioner (Fig K and L) and set aside.Leave the Gantry where it is.

Fig J. Fig K. Fig L.

Fig J: Locate the Allen Screw on lower Belt Tensioner. Fig K: Remove Allen Screw. Fig L: Allen Screw is removed.5. Loosen one full turn only the 3/16” Allen Belt Tensioner Screw from the right bottom side of the lower Rail marked with a red dot (Fig M). The Belt Tensioner should spring fully into place (Fig N).

WARNING: Make sure you do not over loosen this screw. One full turn is usually sufficient.

Fig M. Fig N.

Fig M: Loosen the lower Belt Tensioner Screw. Fig N: Belt Tensioner should spring into place.



6. Repeat steps 1 through 5 with the upper Rail.7. Place the Allen Screws and washers removed from the Belt Tensioner into the lower Gantry Plate in the holes provided (Fig O). These multi-purpose Allen Screws will be used during the lifetime of your Wizard, so it is important to place them here. Only screw in enough until the screw slightly protrudes from bottom of plate.8. Go back and snugly tighten the 3/16” Allen Belt Tensioner Screw from the right bottom side of the lower Rail and the right bottom side of the upper Rail marked with a red dot (Fig P).

Fig O. Fig P. Fig O: Place Allen Screws into the lower Gantry Plate in the holes provided. Fig P: Retighten screw on both the top and

bottom Rail

Hook Up Gantry1. Install the Head. See Head Installation for more information.2. Connect the Air Lines to the Gantry by connecting the two Air Fittings, matching colors. The Red Air Line from the top of the Gantry plugs into the Air Regulator (fits on only one side). The Blue Air Line from the top of the Gantry plugs into the Blue Air Line for the Air Clamps on the back of the Board.3. Plug in the Board Cable. Note that the Board Cable has three sets of four pins set in a \__/ pattern (Fig A). Align the plug so that the \__/ pins are aligned properly, gently insert plug, then turn Black Locking Ring until it seats itself and clicks into place (Fig B). If forced in incorrectly, the pins will bend/break, causing a malfunction of the CMC. The Wizard is now connected.

Fig A. Fig B. Fig C. Fig D.

Fig A: Connect the Air Lines and the Board Cable. Fig B: Connect to the Air Regulator. Fig C: Connect to the Air Clamp Air Lines. Fig D: Connect the Board Cable.

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Head Installation1. Keep the Gantry to the right edge of the Board. 2. Point the Head so that the Foot Block faces toward the Board and the wheels are close to the bottom of the Gantry (Fig A). Line up the wheels on the Head to the center channels of the Gantry arm. Ease the Head onto the Gantry (Fig B).

Fig A. Fig B.

Fig A: Line up Head wheels to bottom of Gantry. Fig B: Ease Head wheels onto Gantry channels.3. Roll the Head up on the Gantry until it lines up to the Head Grabber Arm (attached to the right side of the Gantry) (Fig C-D).NOTE: If you are installing the Head and having difficulty getting the Head Wheels onto the Gantry, see “Head Wheel Adjustment”.

Fig C. Fig D.

Fig C: Head Grabber Arm. Fig D: Close up of Head and Head Grabber Arm.4. Make sure that the Head and the Head Grabber Arm line up together neatly to ensure correct fitting. Replace the two 5/32” screws by making sure they go into both the Head and into the Head Grabber Arm (Fig E) then tighten firmly. Con-nect the Air to the Head by twisting the two Air Fittings together, matching colors (Fig F). Connect the Head Power Plug (square connection) to the Head Grabber Arm (Fig G).

Fig E. Fig F. Fig G.

Fig E: Replace the two 5/32” screws making sure they go into both the Head and into the Head Grabber Arm. Fig F: Reconnect the Air Lines, matching colors. Fig G: Reconnect the Head Power Plug.

5. Lift the Head up carefully from the Board as you roll the Gantry to the left so that the Foot Block does not strike the side of the Board (Fig H).

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6. Reinstall the bottom hood onto the lower part of the Gantry, replacing the screw you removed earlier (Fig I).7. Turn on the Air.

8. You have installed the Head. IMPORTANT: PROCEED TO HEAD WHEEL ADJUSTMENT IN-STRUCTIONS.

Fig H. Fig I.

Fig H: Lift the Head up carefully away from the Board as you roll the Gantry to the left to avoid striking the Foot Block against the edge of the Board. Fig I: Replace the bottom hood on the lower part of the Gantry.

Head Wheel AdjustmentNOTE: FOLLOW THESE DIRECTIONS AFTER INSTALLING THE HEAD.

WARNING: Do not loosen the Head Wheel Screws without first Aligning the Head to the middle of the Board to avoid damage to the Head.

1. Manually move the Head and the Gantry (Fig A) to the middle of the Board, design any mat (we will not be cutting it) and click Power on the Cut Screen (Fig B) to Align the Head in this position (Fig C).


Fig A: Move Head/Gantry to middle of Board. Fig B: Click Power to Align Head. Fig C: Head is Aligned in middle of Board.

2. Locate the Head Wheel Adjustment Allen Screws by looking at the left side of the Head just under the Blade Depth Adjustment Plate. They are located next to the Head Wheels and are marked with red dots. Do not touch the Allen Screws attached to the Wheels themselves.NOTE: Pictures shown have the lower hood removed to reduce the photo reflections; it is not necessary to remove the lower hood. 3. Loosen each Head Wheel Adjustment Allen Screw until the Wheels are loose; about two full turns (Fig D). The Wheels are spring-loaded and will pop into place. NOTE: If you are installing the Head and having difficulty getting the Head Wheels onto the Gantry, loosen the Head Wheel Adjustment Screws, roll the Head onto the Gantry, then continue with the following instructions.



4. Grasp the Head with both hands and GENTLY rock it back and forth to ensure that the Wheels are lined up to the Gantry Grooves (Fig E).

Fig D. Fig E.

Fig D: Loosen the Head Wheel Adjustment Allen Screws. Fig E: Tighten the Head Wheel Adjustment Allen Screws.5. Retighten the Head Wheel Adjustment Allen screws consecutively; tighten the top screw half a turn, then the bottom screw half a turn, back to the top and continue until they are both tight (Fig F). 6. Check each of the Head Wheels to make sure there is no movement in them (Fig G). There are the two visible Wheels on the left side of the Head under the Blade Depth Adjustment Plate, and two wheels on the backside of the Gantry, which can be felt with your hand. They should be firmly into the Gantry groove and be difficult to turn. If not, repeat these steps of loosening the Wheels, gently rocking the Head back and forth, then retightening the Wheels.

Fig F. Fig G.Fig F: Retighten the Head Wheel Adjustment Allen Screws consecutively. Fig G: Make sure there is no movement in the

wheels; wheels should line into the groove and be difficult to turn.7. The Head Wheels have now been Adjusted. Click on the Reset Motors button (Fig H) and return the Head to the home position (Fig I-J). Check the Blade in the Blade Cartridge and reinstall if necessary.

Fig H. Fig I. Fig J.

Fig H: Click Reset Motors Button. Fig I: Return the Head to the home position. Fig J: Rotate Foot Block into the 12 0’Clock start position.



8. Remember to rotate the Foot Block into the 12 O’Clock Position, which is the start position. The Foot Block is upright with the Blade Cartridge on top of the Head (Fig J-K). Holding it about an inch above the bottom rail, slide the Gantry and the Head assembly to the left edge of the CMC until it stops, then Slide the Head down until the Foot Block stops or rests against the Head Alignment Stop.NOTE: Pulling the Head to the left during the Align the Head procedure is the most commonly overlooked step. If your borders/openings are off in a Horizontal direction, Realign the Head, making sure you have pulled the Head completely to the left.

Call Customer Support if you have any questions at 425/551-4300 or 888/855-3335.

9. Reinstall the hoods onto the Gantry, replacing the screws you removed earlier (K).

Fig K.Fig K: Replace the hoods on the Gantry.

Straight Line Trimmer Reinstallation

Slide on the New Straight Line TrimmerNOTE: A Blade has been installed, so take care when handling the Straight Line Trimmer.

1. Look at the backside of the Trimmer and locate the T-Nut on the glides (Fig A). Make sure that the T-Nut lines up with the glide on both the upper and lower sections of the Trimmer.

2. Holding the Straight Line Trimmer steady (a second person helps here), carefully slide the Trimmer onto the channels on the right side of the Board, making sure that the T-Nuts slide into the channel of both the upper and lower rails (Fig B). Move the Straight Line Trimmer to the left until it stops (Fig C).


Fig A: Make sure the T-Nut lines up to the glide. Fig B: Carefully slide Trimmer onto the channels on the right side of the Board (viewed from back). Fig C: Slide Trimmer until it stops.



Hook Up Straight Line Trimmer1. Slowly tighten the bottom locking knob COUNTER-CLOCKWISE until it is snug (Fig A).

2. Slowly tighten the top locking knob CLOCKWISE until it is snug (Fig B).

3. Plug in the Blue Connector Air Line from the ST 500 into the Blue shut off valve on the “Y” Con-nector.

4. Turn on the Blue shut off valve on the “Y” connector to turn on the air.


Fig A: Turn bottom knob Counter-Clockwise. Fig B: Turn top knob Clockwise. Fig C: Plug in the Blue Air Line and turn on the air.

Test CutDo a test cut. Cut a rectangle that is about 2x24”, NOT cutting the outside, with 2” borders. Measure the borders to the opening at the bottom of the mat closest to the vertical clamps, then measure the borders to the opening at the top of the mat closest to the vertical clamps. If the borders are not mea-suring 2” in both places, call Customer Support for assistance.

Call Customer Support if you have any questions at 425/551-4300 or 888/855-3335.

8000 & 8500 Gantry Replacement Instructions

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