⬢For this chapter, please prepare:
⬢T10 Torx key (screwdriver)
⬢2.5mm Allen key
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- Original Prusa XL Enclosure
- 3. Printer upgrade
3. Printer upgrade
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- Original Prusa XL Enclosure
- 1. Introduction
- 2. Enclosure assembly
- 3. Printer upgrade
- 1. Tools necessary for this chapter
- 2. XL base covers removing
- 3. XL Base nuts: parts preparation
- 4. How to insert the nuts
- 5. XL base nuts inserting
- 6. Lower bellows holder: parts preparation
- 7. Few tips before we start
- 8. Right bellows magnet spacer
- 9. Left bellows magnet spacer
- 10. Lower magnets
- 11. Lower bellows holder securing: left side
- 12. Lower bellows holder securing: right side
- 13. CoreXY inserts: parts preparation
- 14. CoreXY inserts
- 15. Upper magnet cover: parts preparation
- 16. Few tips before we start
- 17. Upper magnet cover assembly
- 18. Upper magnets attaching
- 19. Upper magnet cover securing: right side
- 20. Upper magnet cover securing: left side
- 21. Connection box: parts preparation
- 22. Connection box assembly
- 23. Fixing brackets: parts preparation
- 24. Fixing bracket front left attaching
- 25. Fixing bracket front left securing
- 26. Fixing bracket front right securing
- 27. Fixing bracket rear left securing
- 28. Connection box securing
- 29. Fixing bracket rear right securing
- 30. Removing the rear Wi-Fi antenna
- 31. XL buddy box
- 32. Side antenna: cover removing
- 33. Rear antenna: connector removing
- 34. Nextruder unplugging
- 35. Back cover removing
- 36. Back cables releasing
- 37. Fan & PE cable: parts preparation
- 38. PE cable securing
- 39. PE cable connecting
- 40. Fan cable connecting
- 41. Installing LED cable
- 42. Installing LED cable
- 43. Enclosure cables securing
- 44. Securing the cables
- 45. Back cover: parts preparation
- 46. Back cover attaching
- 47. Antenna cover attaching
- 48. Antenna & Nextruder connecting
- 49. XL buddy box covering
- 50. CAUTION: Lubricant Handling
- 51. Lower belt release
- 52. Upper belt release
- 53. Belt clamp: parts preparation
- 54. Lower belt clamp replacing
- 55. Lower belt securing
- 56. Upper belt clamp replacing
- 57. Upper belt securing
- 58. Belt tightening
- 59. Belt tensioning: video
- 60. Bellows: parts preparation:
- 61. Bellows installation
- 62. Good job
- 4. Nextruder upgrade (Multi-Tool)
- 5. Nextruder upgrade (Single-Tool)
- 6. Enclosure secure
- Manual changelog XL Enclosure kit
3. Printer upgrade
Relevant for:
Last updated 11 days ago Difficulty
Moderate Steps
62 Available languages
⬢From the front face of the printer:
⬢Pull out the right extrusion cover.
⬢Pull out the left extrusion cover.
⬢For the next steps, please prepare:
⬢M3nEs nut (4x)
⬢Fit the M3nE nut and push it into the profile in the direction of the pins.
⬢Turn the M3nE nut into the profile to secure it.
⬢Good job, the nut is secured.
⬢Insert two M3nEs inserts into the left profile.
⬢Insert two M3nEs inserts into the right profile.
Insert the nuts approximately as shown in the photo.
⬢For the next steps, please prepare:
⬢Lower bellows holder (1x)
⬢Bellows magnet holder (2x)
⬢Bellows magnet spacer (2x)
⬢Magnets (2x)
⬢M3x6 screw (4x)
⬢M3x8bT screw (4x)
⬢Keep the magnets apart at a sufficient distance. They can break each other!
⬢Take bellows magnet spacer and place in on the bellows magnet holder.
⬢Insert the bellows magnet spacer with bellows magnet holder under the cutout in the lower bellows holder.
⬢Secure the assembly with two M3x8bT using a T10 Torx screwdriver.
⬢Take bellows magnet spacer and place in on the below magnet hoder.
⬢Insert the bellows magnet spacer with bellows magnet holder under the cutout in the lower bellows holder. Secure the assembly with two M3x8bT using a T10 Torx screwdriver.
⬢Take a magnet and carefully and slowly place it in the left cut-out. The polarity of the magnet is not important.
⬢Take a magnet and carefully and slowly place it in the right cut-out. The polarity of the magnet is not important.
⬢Attach the lower bellows holder assembly on the XL base with magnets facing up.
Hint: You can align the M3nEs nuts with the M3 hole in the lower bellows holder using the square holes and an Allen wrench.
⬢Insert the M3x6 screw to the left front hole and tighten the screw using a 2.5 mm Allen key.
⬢Insert the M3x6 screw to the left rear hole and tighten the screw using a 2.5 mm Allen key.
Hint: You can align the M3nEs nuts with the M3 hole in the lower bellows holder using the square holes and an Allen wrench.
⬢Insert the M3x6 screw into the right front hole and tighten the screw using a 2.5 mm Allen key.
⬢Insert the M3x6 screw into the right rear hole and tighten the screw using a 2.5 mm Allen key.
The bellows will be attached to the printer at the end of the assembly manual.
⬢For the next steps, please prepare:
⬢M3nEs nut (4x)
⬢From the bottom side of the CoreXY:
⬢Insert two M3nEs inserts into the left extrusion.
⬢Insert two M3nEs inserts into the right extrusion.
Insert the nuts approximately as shown in the photo.
⬢For the next steps, please prepare:
⬢Upper magnet cover (2x)
⬢Upper magnet holder (2x)
⬢Magnets (4x)
⬢M3x8bT screw (8x)
⬢Lockwasher (4x)
⬢Keep the magnets apart at a sufficient distance. They can break each other!
⬢Take two Lockwashers and place them on the upper magnet holder.
⬢Place the upper magnet cover on the washers with the upper magnet holder.
⬢Secure the assembly with two M3x8bT screws using a T10 Torx screwdriver.
The Lockwasher have to be flattened by the tightening.
⬢Follow the same procedure to assemble the second upper magnet cover.
Be careful, the magnets are strong!
⬢Carefully and slowly attach the magnets on the bottom side of the upper magnet holder on both upper magnet covers. The polarity of the magnet is not important.
⬢Carefully and slowly insert the magnets into the cut-out in the upper magnet covers. The polarity of the magnet is not important.
⬢There are two magnets on each upper magnet holder. Check that the assembly looks as shown.
⬢Insert the first upper magnet cover assembly into the right CoreXY extrusion.
Hint: You can align the M3nEs nuts with the M3 hole in the upper magnet cover using the square holes and an Allen wrench.
⬢Insert two M3x8bT screws and secure them with the T10 Torx screwdriver.
⬢Insert the second upper magnet cover assembly into the left CoreXY extrusion.
Hint: You can align the M3nEs nuts with the M3 hole in the upper magnet cover using the square holes and an Allen wrench.
⬢Insert two M3x8bT screws and secure them with the T10 Torx screwdriver.
⬢For the next steps, please prepare:
⬢XL Enclosure board cover (1x)
⬢XL Enclosure splitter (1x)
⬢M3x6 screw (2x)
⬢Ensure that the longer metal section is facing away from you.
⬢Insert the XL Enclosure splitter as shown in the picture (PRUSA logo facing you).
⬢Secure the XL Enclosure splitter with two M3x6 screws.
⬢For the next steps, please prepare:
⬢Fixing bracket front right (1x)
⬢Fixing bracket front left (1x)
⬢Fixing bracket back left (1x)
⬢Fixing bracket back right (1x)
⬢M3x10rT screw (7x)
⬢On the upper left side CoreXY:
⬢Using a T10 Torx screwdriver, remove the M3x8bT screw.
⬢Attach the fixing bracket front left onto the metal cover.
⬢Ensure the front left fixing bracket is correctly positioned:
⬢The fixing bracket front left slips under LED cover lip.
⬢This is wrong, please align the fixing bracket front left correctly.
⬢Insert the M3x10rT screw and secure it with the T10 Torx screwsdriver.
⬢On the upper right side CoreXY:
⬢Using a T10 Torx screwdriver, remove the M3x8bT screw.
⬢Attach the fixing bracket front right onto the metal cover. Bracket slips under LED cover lip.
⬢Ensure the front left fixing bracket is correctly positioned:
⬢The fixing bracket front left slips under LED cover lip.
⬢This is wrong, please align the fixing bracket front left correctly.
⬢Insert the M3x10rT screw and secure it with the T10 Torx screwsdriver.
⬢Turn the printer so the rear side is facing you.
⬢Remove three M3x8bT screws.
⬢Attach the fixing bracket rear left.
⬢Secure the fixing bracket rear left with the M3x10rT screw.
⬢Attach the XL enclosure board assembly.
⬢Secure the XL enclosure board assembly with two M3x10rT screws.
⬢Remove two M3x8bT screws.
⬢Attach the fixing bracket rear right.
⬢Secure the fixing bracket rear right with two M3x10rT screws.
This step only applies to printers that have the Wi-Fi antenna on the back of the printer. Otherwise, skip to the next step.
⬢Unscrew the antenna from the antenna connector.
⬢Release (a few turns are enough) four M3 screws on the XL buddy box.
⬢Slide up and remove the XL buddy cover.
The next line is only for five-head printers. Otherwise, skip to the next step.
⬢By pressing the security latch, unplug the DWARF3, DWARF4 and DWARF5 from the board.
⬢This step applies only if your printer has a side antenna. If not, proceed to the next step.
⬢Loosen two screws on the cover slightly. No need to remove them completely. Push the cover to the right and remove it from the printer.
⬢Now proceed to the Nextruder unpluging
If you have the antenna on the side of the printer -> remove the cover and proceed to the next step.
⬢Gently unplug the antenna connector from the board.
⬢Release (a few turns are enough) two M3 screws on antenna-holder.
⬢Push the cover to the right.
⬢Carefully remove the antenna-holder with the cable from the printer.
⬢In this step, select the appropriate option based on your XL printer variant:
⬢Single-tool: There is only one cable. By pressing the security latch, remove the DWARF1 cable and proceed to the next step.
⬢Dual-Head & Five-Head: There are two cables. By pressing the security latch, remove the DWARF1 and DWARF2 connectors from the board.
⬢From the left side of the rear cable management upper, remove two M3x4rT screws. Do not throw them away!
⬢From the right side of the rear cable management upper, remove two M3x4rT screws. Do not throw them away!
Watch out for cables!
⬢Carefully remove the rear cable management cover from the printer by pulling it toward you.
Watch out for the cables!
⬢On the right side, cut off two zip-ties.
⬢Locate the right PE screw on the board.
⬢Remove the M3x5 screw and leave the cable there. Do not throw away the screw!
⬢For the next steps, please prepare:
⬢PE cable (the longest one) - 350 mm (1x)
⬢Fan cable (4 wires)- 450 mm (1x)
⬢LED cable (5 wires) - 400 mm (1x)
⬢M3x5 screw (1x) you removed in the previous steps
⬢Zip-tie (4x)
Note the correct orientation of the PE cable connector.
⬢Insert the M3x5 screw through the red end of the PE cable.
⬢Attach the PE cable with the M3x5 screw through the free PE cable (which we released in the previous step). Secure both cables using a 2.5mm Allen key.
⬢Adjust the cable routing as shown in the picture.
⬢Adjust the cable routing as shown in the picture.
⬢Slide the connector onto the metal sheet protrusion.
Fully secure the PE cable to the XL Enclosure board cover.
⬢Connect the fan cable to the right connector on the FDM XL Enclosure splitter.
⬢Adjust the cable routing as shown in the picture.
⬢Connect the second end to the FAN1 connector on the XL sandwich board.
⬢By pressing safety latch, disconnect the LED cable from the XL sandwich.
⬢Connect the LED cable to the left connector on the FDM XL Enclosure splitter.
⬢Connect the black LED cable to the middle connector on the FDM XL Enclosure splitter.
⬢Lead the cable behind the Nextruders cables.
⬢Connect the second end to the LED Light 2 connector on the XL sandwich board.
⬢Locate the metal perforation on the XL enclosure board assembly.
Watch out for the cables!
⬢Secure the cables carefully to the XL enclosure board cover. Do not overtighten the zip-tie. Cut the end of the zip-tie.
⬢Attach the cables to the black sleeve with a zip-tie and secure carefully. Do not overtighten the zip-tie. Cut off the end of the cable tie.
⬢Insert the zip-tie through the metal cut-out and secure all cables. Do not overtighten the zip-tie. Cut the ends of the zip-ties.
⬢For the next steps, please prepare:
⬢Rear cable management upper (1x) you removed in the previous steps
⬢M3x4rT screws (4x) you removed in the previous steps
Don't pinch any cables!
⬢Attach the rear cable management upper to the printer.
Double-check the cables, there are a lot of them.
⬢Secure the left side with two M3x4rT screws.
⬢Secure the right side with two M3x4rT screws.
⬢Connect the first dock (from the right side) cable to the upper slot labeled DWARF 1.
⬢Connect the second dock (from the right side) cable to the lower slot labeled DWARF 2.
If you have the antenna on the side of the printer -> attach the cover, secure the screw and proceed to the next step.
⬢Push the antenna cable through the opening in the cable cover (metal sheet) and guide it behind the cover to the electronics box.
⬢Attach the antenna-holder on the screws and push the cover to the left. Tighten the screws.
If you have the antenna on the side of the printer -> skip to the black line.
⬢Connect the antenna cable to the antenna connector on the board.
The next line is only for printers with more than 2 Nextruders. Otherwise go to the next step.
⬢Connect the third, fourth and fifth (from the right) Nextruder to the splitter:
⬢Third Nextruder.
⬢Fourth Nextruder.
⬢Fifth Nextruder.
⬢XL splitter with connected Nextruders has to look like this.
Be carefull, do not pinch any cables!
⬢Put the XL buddy box cover back on the printer.
⬢Check Nextruders cables, they have to be inside the cutout in the cover.
⬢With a T10 key tighten the four screws.
CAUTION: Avoid direct skin contact with the lubricant used for the linear rails in this printer. If a contact occurs, wash your hands immediately. Especially before eating, drinking, or touching your face.
⬢Lubricant accumulates mainly in the linear rail channels on the linear sides.
The belt clamps must be replaced as the original parts are not suitable for the higher temperatures they will experience inside the Enclosure. The new parts are high temperature rated.
You don't need to change the belt clamp if you have an Original Prusa XL shipped from June 2024.
You can skip to the Bellows: parts preparation
⬢Turn the printer, so the front side is facing you.
⬢
Loosen the M3 screw holding the left CoreXY tensioner, approximately 4 full turns. Do not remove the screw completely.
⬢Gently stretch the belt with your finger. If the belt feels loose as shown in the picture, proceed to the next step.
⬢Loosen the M3 screw holding the right CoreXY tensioner, approximately 4 full turns. Do not remove the screw completely.
⬢Gently stretch the belt with your finger. If the belt feels loose as shown in the picture, proceed to the next step.
⬢Remove the x-carriage-cover.
⬢For the next steps, please prepare:
⬢Belt clamp (2x)
Do not confuse PETG belt-clamp with PCCF belt-clamp. It is important to install a new belt-clamp shipped in the Enclosure package.
⬢Remove two M3x12rT screws and remove the PETG belt-clamp. Do not throw the screws away.
⬢Take the new (PCCF) belt-clamp and attach the belts. The belts must touch in the middle.
Check that the belt is not twisted!
⬢Attach the belt-clamp with the belts to the x-carriage.
Check that the belt is not twisted!
⬢Secure the belt-clamp with two M3x12rT screws (which you removed in the previous step) with a T10 Torx screwdriver.
⬢Remove two M3x12rT screws and remove the PETG belt-clamp. Do not throw the screws away.
⬢Take the new (PCCF) belt-clamp and attach the belts. The belts must touch in the middle.
Check that the belt is not twisted!
⬢Attach the belt-clamp with the belts to the x-carriage.
Check that the belt is not twisted!
⬢Secure the belt-clamp with two M3x12rT screws (which you removed in the previous step) with a T10 Torx screwdriver.
Make sure that the belts touch each other in the belt clamps.
⬢Snap the x-carriage-cover back onto the X-carriage. You must feel a slight "click" to ensure the cover fits on the part.
⬢Tighten the belts on both sides, approximately 4 full turns.
⬢On the Original Prusa XL, adjusting the belt to the optimal tension is crucial to achieving good quality on the prints. A loose belt can cause Layer shifting, Ghosting, or other print abnormalities, like getting an irregular shape instead of a perfect circle. An over-tightened belt can cause an irregular movement in the X and Y axes.
⬢We have our own belt tuner. The application determines the belt tension by measuring the frequency of the vibration generated by strumming it. Follow the instructions in the video below to adjust the belt.
⬢For the next step, please prepare:
⬢Bellows (1x)
⬢Attach the bellows on the lower belows holder with handles facing up.
⬢Well done, the printer has been upgraded. Now go to the Nextruder upgrade and select the type of printer you have:
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