This document provides troubleshooting steps for shuttle motion failures on a ProJet 1000/1500 3D printer. Common causes include overfill or cured material in the material tray, material buildup on the shuttle rails, or worn bearings. The document outlines how to check for overfill, clean the shuttle plate assembly, test the home switch, and check that the actuator motor is securely mounted. If errors persist after troubleshooting, the actuator motor may need replacement.

1. ProJet 1000/1500 Training
Shuttle Motion Failure

2. Shuttle Motion Failure Symptoms
o System Alerts
o
o
“Shuttle failed to home”
“Shuttle failed to move”
o Overfill in material tray
o Under fill in material tray
o Noisy or vibrating during scrape or coat

3. Shuttle Motion Failure Causes
o Overfill & Under fill
O fill U d
o Cured material on the film
o Material build-up on shuttle rails
o Sleeve and slide b i
l
d lid bearings may b worn
be
o Loose actuator motor
o Shuttle home switch

4. Try This First
o Occasional, random shuttle errors may occur during normal operation
o
often the result of system EMI noise
y
o Example Alert: “Shuttle failed to home”
o If this is a one time occurrence try rebooting the printer – if resolved
occurrence,
resolved,
troubleshooting will not be necessary
o If unresolved, please continue to “Troubleshooting Shuttle Motion Failure”

5. Troubleshooting Shuttle Motion Failure
1. Remove the material tray and inspect for overfill (material beneath the tray)
1.
1
2.
3.
Overfill can cause delamination which can contribute to cured material sticking to the tray film
Cured material on the film can cause the coater bar to collide with the cured material and result
in a shuttle motion error
If overfill exists, please refer to “Overfill” training module for corrective action
2. If there are no signs of overfill, return the material tray to its correct position
Screen towards the front of
printer, notch towards the back

6. Troubleshooting Shuttle Motion Failure
3. Ensure that the material tray has no cured material or any other obstructions
o
If obstructions are present, clean or replace the material tray
p
,
p
y
4. Confirm proper fill level (see webGUI Tips-Videos) and perform motion test
using diagnostics
o
If no errors occur run a test print
5. If you continue to experience shuttle motion errors, go to “Cleaning Shuttle
Plate Assembly”

7. Cleaning Shuttle Plate Assembly
A clean printer is a happy p
p
ppy printer!
Material build up and/or a worn bearing may
cause shuttle motion errors
Disassemble the shuttle plate assembly and clean

8. Cleaning Shuttle Plate Assembly
Wear gloves when disassembling and cleaning
ON/OFF Switch
/
Caution: Power off and disconnect power
cord from power outlet
Disconnect Ethernet cable from printer
Power Cord
Ethernet cable

9. Cleaning Shuttle Plate Assembly
Using a flat screw driver,
remove the left and right
side panels
Turn the wing nuts inside the
front side panels to unlock – lift
panels away

10. Cleaning Shuttle Plate Assembly
Close cartridge lid and
remove material cartridge

11. Cleaning Shuttle Plate Assembly
Press the lock function on the interface
to bring the shuttle forward
Close cartridge door
Unlock shuttle plate

12. Cleaning Shuttle Plate Assembly
Clean residual material from top of shuttle and lift shuttle assembly
Cl
id l
t i lf
t
f h ttl
d
h ttl
bl

13. Cleaning Shuttle Plate Assembly
p
y pulling down
g
Remove scraper bar by p
from the shuttle fingers – place
coater bar in the material tray
Clean spring fingers and surface of
residual material

14. Cleaning Shuttle Plate Assembly
Remove the two retaining screws on each side of
y
g /
the shuttle assembly using a 9/64 Allen wrench

15. Cleaning Shuttle Plate Assembly
Remove the end piece and clean any residual resin

16. Cleaning Shuttle Plate Assembly
Lift out the actuating arm while supporting the shuttle – carefully
remove the sleeve bearing
Slide the shuttle out of the assembly

17. Cleaning Shuttle Plate Assembly
Be careful not to lose the four (4) glide bearing located
on the pins on the side of the shuttle plate

18. Cleaning Shuttle Plate Assembly
Clean the shuttle assembly rails
Re-install shuttle in reverse order

19. Cleaning Shuttle Plate Assembly
Perform motion test using diagnostics – if no errors occur run a test print

20. Check for Loose Actuator Motor
A loose actuator motor can cause motion errors and material fill issues
1. Remove the right side panel
2. Check the actuator motor and confirm that it is securely mounted to
the chassis – if it is loose, tighten accordingly
Bracket
Chassis
h

21. Test Shuttle Home Switch
1. Remove the left side panel and inspect the shuttle home optical switch for
proper alignment – align if necessary
2. Go to Advanced > Diagnostics > Shuttle Motion and test the shuttle home
optical switch for proper homing operation
1. Select “Move Home” button – when the shuttle moves to home position, the “Home Sensor”
box should toggle (if it does not toggle, select the “Move to Coat” button and confirm that the
box is toggled and that the sensor is functioning correctly)
2. Replace optical switch if necessary

22. Shuttle Motion Error Tree
If shuttle motion errors cannot be resolved using the troubleshooting
techniques, the actuator motor may need to be replaced – contact 3D
System Service for further assistance
Error
Component
Obstruction
Home switch
Shuttle Motion Failure
Actuator Motor
Bearings
Issue
y
Material tray in backwards
Cured material in tray
Material build up in rails
Bad home switch
Home switch out of line
Loose mounting bolts
Defective encoder
Defective motor
Actuator arm sleeve bearing
Slide bearings
Resolution
Re-install tray in correct position (screen will be to the front of the printer
y
p
(
p
Clean cured material from tray
Disassemble shuttle assembly and clean w/IPA and lint free cloth
Replace home switch
Adjust home switch and test
Tighten mounting bolts
Replace actuator motor
Replace actuator motor
Replace bearing
Replace bearings

23. Review Questions
Cured material on the film will not cause a shuttle error
True
False

24. Review Questions
Cured material on the film will not cause a shuttle error
True
False

25. Review Questions
When experiencing a shuttle error, what should you try first
Replacing the material cartridge
Replacing the material tray
Cleaning the bearings
Rebooting the printer

26. Review Questions
When experiencing a shuttle error, what should you try first
Replacing the material cartridge
Replacing the material tray
Cleaning the bearings
Rebooting the printer

27. Review Questions
System EMI noise can cause random shuttle errors during normal operation
True
False

28. Review Questions
System EMI noise can cause random shuttle errors during normal operation
True
False

29. Review Questions
A loose actuator motor should always be replaced
True
False

30. Review Questions
A loose actuator motor should always be replaced
True
False

31. Review Questions
Remove which panel to inspect the shuttle home optical switch for proper alignment
Right
Left

32. Review Questions
Remove which panel to inspect the shuttle home optical switch for proper alignment
Right
Left