⬢Take the printed part Adapter-printer and insert the steel ball in.
⬢Roll with the ball to all sides to ensure smooth movement.
In case of any rough surface, remove the ball and clean the inside of the printed part.
⬢Place the printer part together with the steel ball in the Extruder-body. See the rounded protrusion on the printed part. It must fit to the groove in the Extruder-body. The surfaces of both parts should be almost aligned.
DON'T use any screw to secure the Adapter-printer. It should hold inside the Extruder-body by itself.
⬢Take a piece of the 1.75 filament. You can use the bundled one 2x25g samples, don't use the black nylon, which is too thick. Straighten the filament as much as possible.
⬢Place the filament along the path and align the gear properly.
⬢The filament will be always slightly bent. Use it anyway for the initial alignment.
⬢For a final check replace the filament with an Allen key. Bear in mind, the key has slightly different size than the filament.
⬢Tighten the screw slightly to temporarily fix it, we will make the final check and tightening later on. Be careful, you can strip the thread.
Don't use any glue to fix the screw in place, you won't be able to release it, in such case you might have to replace the entire motor.
⬢Take two M3x10 screws and insert them in the holes. Doing this now makes the assembly slightly easier, but both holes are shallow and the screws might fall out. If this happens, you can continue without them and put them back later on (you will be notified later). Also note, that in few upcoming pictures the screws might be missing.
⬢Place the hotend next to the Extruder-body, see the grooves in the printed part, which are in the shape of the hotend.
⬢Correctly placed hotend. The hotend cables should point to the left, we will align them in the next step.
In order to protect the hotend cables and ensure proper orientation, it is highly recommended to use a box. Use the one provided in the kit.
⬢Place the Extruder-body with the hotend on the box and make sure the cables are on the left side and pointing down.
⬢Place your finger temporarily on the longer magnet and place the extruder motor assembly on the Extruder-body. The Bondtech gear might pull the magnet out while assembling parts together.
⬢Make sure both parts are aligned.
⬢Place the Extruder-cover on the Extruder-body. Again, make sure that all three parts are properly aligned.
⬢Insert two M3x40 screws, you've prepared earlier. Tighten them, but be careful, they are slightly longer (2-3 mm), than the thickness of the entire assembly.
Place the extruder aside for few steps, we need to prepare another part. Leave it on the box to prevent damaging the cables.
For the following nut insertion USE A SCREW. THAT'S AN ORDER!!! Seriously, use a screw to pull the nuts in, both have to be properly seated in the X-carriage.
⬢Take both M3n nuts and using pliers (or screw) push them in the X-carriage, then using a screw from the other side, pull them all the way in.
⬢Don't forget to remove the screw.
⬢Take all four M3nS nuts and insert them in. Ensure correct alignment using the Allen key.
From now on, keep in mind the nuts are inside, avoid rotating the X-carriage "downwards", or the nuts might fall out.
⬢Take the IR-sensor cable and locate the end with the smaller connector.
⬢Place cable in the X-carriage, use the small printed overhangs to keep the cable inside.
⬢The distance between the connector and the X-carriage should be around 15 mm (0.6 inch). We will adjust it later.
⬢Guide the cable through the slot. Carefully inspect the slot to memorize its shape since it is the best visible now. You'll need to guide other cables through here later.
Following cable management is CRUCIAL for the extruder TO WORK PROPERLY! Read the instructions carefully.
⬢Start by making a small loop just below the extruder motor. Leave a slack about 2-3 cm (0.8 - 1.2 inch). This is comes handy for easier disassembly in the future.
⬢Then guide the cable in the "channel" all the way to the back.
⬢Slightly bend the cable down to form it around the edge.
Also, prepare X-carriage, both M3x10 screws (if you haven't used them already) and the longest Allen key with the ball-end, you will need it.
Following cable management is CRUCIAL for the extruder TO WORK PROPERLY! Read the instructions carefully.
Before you assemble the X-carriage, check the nuts in the Extruder body are still in place. The upper nut sometimes falls out.
⬢Grab the X-carriage and place it onto the back of the extruder assembly as shown in the picture.
⬢Make sure the motor cable follows the channel both in Extruder-body and X-carriage. In the X-carriage the motor cable will follow the path of the IR-sensor cable.
⬢ENSURE NO WIRE IS PINCHED! Then use the M3x10 screw and Allen key with ball end to connect both parts together. If you are inserting the screw at this moment, it will be slightly inclined in the beginning, but it will "straighten up" after few turns. Don't tighten the screw completely, we need to adjust the IR-sensor cable.
⬢Turn the extruder to the other side and if needed insert the second M3x10 screw. Don't tighten the screw, we need to adjust the IR-sensor cable.
⬢Place the IR-sensor on the top of the Extruder-body and secure it with the M2x8. Make sure the black plastic "u-shaped" part is facing down.
Tighten the M2x8 screw, the sensor shouldn't be able to move, but be careful the PCB isn't indestructible ;)
⬢Connect the cable, mind the correct orientation of the connector and wires.
⬢Leave a slack behind the sensor like in the picture. Don't create too big loop as it might interfere with the frame. If needed adjust the length by gently pulling/pushing the cable.
⬢Ready? Ok, check once more no cable is pinched and tighten both M3x10 screws installed previously.
⬢Version B - the fan cable bundle is not covered. There is a combination of blue, pink and black wires. If your kit includes this version, follow this step: Hotend fan parts preparation (version B)
⬢Each fan uses different fasterners (included in the package). You will be informed in the relevant steps. The assembly procedure is the same for both.
The fans were tested and optimized to have the same cooling performance.
⬢For easier fan installation, remove temporarily the black twist tie from the cable bundle and release at least one loop. Then tie the bundle back, see the picture.
⬢Before you move to the next step, take an Allen key and GENTLY PUSH the motor cable to the channel to create space for the fan cable.
The fan has two sides, one has a sticker. Make sure, this side is facing inside the extruder.
⬢First, create a loop on the cable. Make sure the black protective wrap is close to the edge of the fan. See the picture.
⬢Place the fan on the extruder and proceed in the following way:
⬢Start by placing the fan's cable in the upper channel
⬢Slide the fan close to the X-carriage and GENTLY PUSH the cable in using an Allen key. Before you push the fan all the way to the left, place the cable in the X-carriage channel.
FINAL CHECK! The fan is oriented with the cable facing up, then the cable goes through the upper channel all the way to the X-carriage. In the X-carriage don't forget to use both channels. Make sure the CABLE ISN'T PINCHED along the way!
⬢Use the three M3x14 screws to fix the fan in place. Don't over tighten them, you can break the fan's plastic casing. Also make sure the fan can rotate freely.
Note that the screws are "self-tapping" in the printed parts. There are no nuts.
⬢For easier fan installation, remove temporarily the black twist tie from the cable bundle and release at least one loop. Then tie the bundle back, see the picture.
⬢Before you move to the next step, take an Allen key and GENTLY PUSH the motor cable to the channel to create space for the fan cable.
The fan has two sides, one has a sticker. Make sure, this side is facing inside the extruder.
⬢First, guide the fan cable as shown in the picture. Maintain this orientation.
⬢Place the fan on the extruder and proceed in the following way:
⬢Make sure the motor cable is fully inserted in the channel
⬢The hotend fan cable must be guiding from the top left around the corner down.
⬢Slide the fan close to the X-carriage and GENTLY PUSH the cable in using an Allen key. Before you push the fan all the way to the left, place the cable in the X-carriage channel.
FINAL CHECK! The fan is oriented with the cable facing up, then the cable goes through the upper channel all the way to the X-carriage. In the X-carriage don't forget to use both channels. Make sure the CABLE ISN'T PINCHED along the way!
⬢Use the three M3x16b screws to fix the fan in place. Don't over tighten them, you can break the fan's plastic casing. Also make sure the fan can rotate freely.
Note that the screws are "self-tapping" in the printed parts. There are no nuts.
⬢Insert the pulley in idler as shown in the picture.
⬢Slide the shaft through the idler and pulley. Use reasonable force or you will BREAK the printed part. The shaft should be flush with the surface of the printed part.
⬢Place your finger on the bearing and ensure it can rotate freely.
⬢Use the M3x40 screw with the spring to introduce tension to the Extruder-idler.
Hold the Extruder-idler on the other side, until the screw reaches the nut.
⬢Since there is only one screw, you need to introduce a large force. The head of the screw should be roughly aligned/flush with the surface. This can be adjusted later.
IMPORTANT: Similar to previous steps, there are two types of hotend fans. For this step, they differ in the screw's length. The remaining parts are the same.
⬢Version A - the fan cable bundle is covered in a black sleeve. Parts are shown in the first picture.
⬢Version B - the fan cable bundle is not covered. There is a combination of blue, pink and black wires. Parts are shown in the second picture.
⬢First, slide the fan in the Fan-shroud and make sure it is aligned properly.
⬢Second, fix the fan in place using one M3x20 screw. Tighten carefully, or you will damage the fan's casing.
⬢Turn the extruder around and insert the M3n nut. No need to pull it in, we will use the screw.
If you have trouble inserting the nut, try pulling it in with the fan removed, by using a shorter screw from the SPARE bag. Be careful so the other nut doesn't fall off!
⬢Attach the remaining M3x20 screw from the other side of the print fan and tighten it up. Be careful, you might damage the fan casing.
⬢Guide the cable according to the picture in the channel. Bend it slightly towards the extruder. DON'T stretch the cable!
⬢Insert the zip ties in the X-carriage like in the picture.
⬢Lower the X-axis at about 1/3 from the top.
⬢Turn the printer like in the picture with X-axis motor and shorter extrusions facing towards you. Align the bearings similarly to the picture. The exact position of the lower bearing doesn't matter for now.
⬢Turn all three bearings so that the markings are facing you.
⬢Place the extruder onto the bearings from the other side. Make sure the bearing openings in the X-carriage are facing towards you (together with the shorter extrusions on the frame) and the top bearings fit perfectly into the groove.
⬢Before you continue to guide the belt through the X-axis, please release two M3 screws on the X-end until they detach from the motor. It must be possible to move the motor freely to the sides.
⬢Rotate the X-axis motor as indicated towards the frame.
⬢Insert the flat part of the X-GT2 belt into the X-carriage as in the second picture.
Use a screwdriver or the smallest Allen key to push the belt in.
There will be belt overhang on this side, DON'T TRIM IT yet.
⬢Using right hand rotate the motor to its original position and hold it (tension is applied to the belt).
⬢Using two fingers on your left hand push the belt together. Very small force should be needed for bending the belt, BUT the belt shouldn't be bent by its own weight before being pressed with your fingers, it must be straight.
If you are struggling to rotate the motor back into position, the belt tension is too high.
⬢Depending on the belt being under or overstretched, adjust the amount of the belt in the X-carriage.
⬢When done, rotate the motor to its original position and tighten the M3 screws again.
⬢Both top and bottom part of the belt should be parallel (above each other).
⬢To adjust the belt position, release the screws on the pulley and move it slightly until you reach the best position.
⬢Tighten both screws on the pulley.
If you are having a problem with the belt alignment, check the orientation of the pulley. Make sure it is oriented in the same way as seen in the picture.
⬢Use the technique described below to test if the belt is properly stretched.
⬢Use pliers to hold the X-axis motor shaft.
⬢Move the extruder towards the X-axis motor. Don't use excessive force.
⬢If the belt is stretched properly, you should feel a resistance and the extruder won't move at all. If the belt is too loose, it will deform (create a "wave") and jump over the teeth on the pulley.
Belt too loose? Return to step 49 and repeat all steps until now. You have to rotate the motor and retighten the belt in the X-carriage. Shortening the belt length by moving one or two teeth outside X-carriage should be enough.
For the following step we recommend getting a white marker, but you can also trim the belt without it.
⬢Measure the part, which must be trimmed and gently take the end of the belt away, from the X-carriage, but make sure at least 3-4 teeth are still in the X-carriage, as you don't want to lose the tension. If possible make a mark, where to cut the belt.
⬢Ensure again your mark is in the correct position and the belt is still stretched.
⬢Using pliers cut the belt and push it inside X-carriage. Use screwdriver or Allen key, if needed.
In this step, we will finish tensioning the belt. Please read the instructions first, your belt might have proper tension already, then there is no need for additional screw adjustment.
⬢First, slightly release all the screws holding the motor, otherwise, the "tensioner" won't work (the motor must be able to move).
⬢Using ball-end Allen key start tightening the screw on the rear side of the X-end-motor, but after each turn or two check the tension in the belt.
⬢For the optimal performance, the belt must be a bit harder to press with your fingers. Move the extruder all the way to the X-end-idler and try the belt tension in the middle of the X-axis.
⬢When you achieve optimal tension, please tighten the screws again.
In case you experience X-axis failure during calibration or skipped layers in the X direction, you can adjust this screw accordingly. Tightening the screw stretches the belt. Releasing the screw has opposite effect. Each time don't forget to release the screws on the motor first.
⬢Locate the hole for the NYLON filament just above the bottom bearing. Refer to the picture to make sure it is the correct one. Using the smallest Allen key, ensure there are no obstacles inside.
⬢Using the pliers insert the NYLON filament with the pointed end into the slot. Twist the filament while pushing it in. Hold the extruder with your other hand.
BE EXTREMELY CAREFUL as the pliers tend to slide and you can easily damage the wires!!!
⬢To check if the filament is seated properly, gently pull it with your hand. The X-axis should bend a little, but the filament must remain in the slot.
⬢If you have issues, try to adjust the tip on the filament.