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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Using a 4mm hex key, remove the three M5 screws securing the extruder assembly to the carriage.
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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 2.5mm hex key, remove the two M3 screws securing the layer cooling fan and lay the still-connected fan off to the side.
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Reinstall the screws into the layer cooling shroud. They will be used to extract the insets for reuse in a few steps.
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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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Set an insert on top of one of the holes in the new layer cooling fan shroud and apply heat with the tip of the soldering iron.
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Once the insert is heated enough, it will slide into place.
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Repeat for the other three inserts.
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Using a 2mm hex key, remove the M3 screw securing the extruder nozzle ground wire to the heater block and lay the still-connected wire aside.
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Using a 3mm hex key, remove the two M4 bolts securing the extruder mount plate to the extruder body and set the plate aside.
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The stock hex mount plate is not reused and will be replaced with a new part.
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The hot end can now be completely removed.
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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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Pull the case off the body of the printer and lay it down flat.
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Unplug the case fan from the socket on the main circuit board.
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Unplug the old blower fan wire from the main circuit board.
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Remove the plastic connector from the end of the old blower fan wire.
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Unwind the wires so they have as far a reach as possible.
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Connect the old blower fan wire directly to the power supply.
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Yellow goes to +V
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Black goes to -V
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Fit the new plate around the top of the E3D hotend as shown.
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Insert the nuts that you saved from disassembly into the hex holes on the top side of the extruder assembly.
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Using a 3mm hex key, install the M4 bolts to hold the hotend assembly to the rest of the carriage.
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Install the nozzle ground wire from earlier under the screw securing the heater cartridge inside the heat block.
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Using a 2.5mm hex key, reattach the layer cooling fan shroud with the two M3 screws from earlier.
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Using a 1.5mm hex key, reattach the X axis end stop to the layer cooling fan shroud with the two M2 screws from earlier.
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Using a 2.5mm hex key, reattach the layer cooling fan with the two M3 screws from earlier.
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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 the orientation as shown, route the wires to the right of the heat sink fan, under the carriage and above the layer cooling fan shroud.
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Bundle the wires using zip ties and the shroud you removed during disassembly.
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With the wires routed and bundled properly, the extruder carriage should now look something like this.
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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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Plug in the harness back in.
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Make sure the wires fit inside and use a 2.5mm hex key to reinstall the two M3 screws securing the top bracket.
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Plug in the USB cable to the printer.
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Plug the other end of the USB cable into the computer.
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Plug the power cable into the wall, then plug the other end into the printer.
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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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