Tools
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Using a 2.5mm hex key, remove the two M3 screws securing the bracket to the top of the extruder carriage.
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Remove the bracket.
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Cut the wires down to approximately 22cm in length and strip 8mm off the ends.
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Crimp on the pins.
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Remove the following wires from the harness:
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Pins 5, 6: Two (thick red) to the heater cartridge
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Pins 9, 10: Two (thin, one black and one red) to the heat sink blower fan
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Pins 17, 18: Two (thin, one black and one red) to the hotend thermistor
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To remove a pin, push in on the small metal tab on the side of the harness then push down on the pin with a flat object and pull the wire free.
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Pin diagram from Lulzbot's documentation: http://download.lulzbot.com/Mini/1.0/oha...
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Using a 1.5mm hex key, remove the two M2 screws securing the X-axis endstop to the stock layer cooling fan shroud and lay the endstop aside with the wires still connected.
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Set the washers aside for reuse, but screw the screws back in to place temporarily after the endstop has been removed. We will use them to remove the inserts in the next step.
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Using the soldering iron, heat up one of the screws until you can pull both it and the insert out of the stock shroud.
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Repeat for the other three screws and inserts.
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Using a 2mm hex key, remove the six M3 screws securing the electronics case to the printer.
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Unplug the old blower fan wire from the main circuit board.
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Fit the new plate around the top of the E3D hotend as shown.
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Install the newly wired pins into the harness using the diagram from disassembly.
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The new E3D heat sink fan wires correlate to pins 9 and 10.
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The new heater cartridge wires correlate to pins 5 and 6.
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The nozzle ground wire is reinstalled into pin 16.
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The layer cooling fan wires correlate to pins 7 and 8
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The thermistor wires correlate to pins 17 and 18.
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Using a 4mm hex key, reattach the extruder assembly to the main carriage using the three M5 screws from disassembly.
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The new E3D hotend is 5.5mm longer than the old Hexagon. We need to make an adjustment to the firmware file so that the printer knows its own total Z axis height and does not crash into the bed or wiping surface.
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On line 388 of Configuration.h, change the value of Z_MAX_POS from 159 to 153.5.
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Bring the hot end up to temperature (260°C), then tighten down the nozzle with a 7mm wrench.
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One Comment
In the guide you state “Edit the printers firmware”, Can you be a bit more specific? I tried entering the Lulzbot mini firmware file into “Arduino”, but it will not load a Hex file? it only accepts “ino” files. Also I cant find the “Mini Rambo’ Board in the Board list? All of the current Lulzbot firmware from the Lulzbot site is only “Hex” file extension! Is there a way to enter the Z-MIn changes using the Cura Control Panel inside of “Cura for Lulzbot”, like would be done for adjusting “Z offset”? Please provide a better explanation on how to Change the settings for “line 388 of Configuration.h, change the value of Z_MAX_POS from 159 to 153.5”? Or explain how to Change the settings of my existing Lulzbot Mini firmware as installed on my existing Mini Rambo board!