3. Printer upgrade

Relevant for:

Last updated a month ago

Difficulty

Moderate

Steps

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Step 1 Tools necessary for this chapter

⬢For this chapter, please prepare:

⬢T10 Torx key (screwdriver)

⬢2.5mm Allen key

Step 2 XL base covers removing

⬢From the front face of the printer:

⬢Pull out the right extrusion cover.

⬢Pull out the left extrusion cover.

Step 3 XL Base nuts: parts preparation

⬢For the next steps, please prepare:

⬢M3nEs nut (4x)

Step 4 How to insert the nuts

⬢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.

Step 5 XL base nuts inserting

⬢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.

Step 6 Lower bellows holder: parts preparation

⬢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)

Step 7 Few tips before we start

⬢Keep the magnets apart at a sufficient distance. They can break each other!

Step 8 Right bellows magnet spacer

⬢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.

Step 9 Left bellows magnet spacer

⬢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.

Step 10 Lower magnets

⬢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.

Step 11 Lower bellows holder securing: left side

⬢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.

Step 12 Lower bellows holder securing: right side

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.

Step 13 CoreXY inserts: parts preparation

⬢For the next steps, please prepare:

⬢M3nEs nut (4x)

Step 14 CoreXY inserts

⬢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.

Step 15 Upper magnet cover: parts preparation

⬢For the next steps, please prepare:

⬢Upper magnet cover (2x)

⬢Upper magnet holder (2x)

⬢Magnets (4x)

⬢M3x8bT screw (8x)

⬢Lockwasher (4x)

Step 16 Few tips before we start

⬢Keep the magnets apart at a sufficient distance. They can break each other!

Step 17 Upper magnet cover assembly

⬢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.

Step 18 Upper magnets attaching

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.

Step 19 Upper magnet cover securing: right side

⬢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.

Step 20 Upper magnet cover securing: left side

⬢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.

Step 21 Connection box: parts preparation

⬢For the next steps, please prepare:

⬢XL Enclosure board cover (1x)

⬢XL Enclosure splitter (1x)

⬢M3x6 screw (2x)

Step 22 Connection box assembly

⬢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.

Step 23 Fixing brackets: parts preparation

⬢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)

Step 24 Fixing bracket front left attaching

⬢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.

Step 25 Fixing bracket front left securing

⬢Insert the M3x10rT screw and secure it with the T10 Torx screwsdriver.

Step 26 Fixing bracket front right securing

⬢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.

Step 27 Fixing bracket rear left securing

⬢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.

Step 28 Connection box securing

⬢Attach the XL enclosure board assembly.

⬢Secure the XL enclosure board assembly with two M3x10rT screws.

Step 29 Fixing bracket rear right securing

⬢Remove two M3x8bT screws.

⬢Attach the fixing bracket rear left.

⬢Secure the fixing bracket rear left with two M3x10rT screws.

Step 30 Removing the rear Wi-Fi antenna

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.

Step 31 XL buddy box

⬢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.

Step 32 Side antenna: cover removing

⬢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

Step 33 Rear antenna: connector removing

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.

Step 34 Nextruder unplugging

⬢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.

Step 35 Back cover removing

⬢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.

Step 36 Back cables releasing

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!

Step 37 Fan & PE cable: parts preparation

⬢For the next steps, please prepare:

⬢PE cable (the longest one) - 350mm (1x)

⬢Fan cable (4 wires)- 450mm (1x)

⬢LED cable (5 wires) - 420mm (1x)

⬢M3x5 screw (1x) you removed in the previous steps

⬢Zip-tie (4x)

Step 38 PE cable securing

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.

Step 39 PE cable connecting

⬢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.

Step 40 Fan cable connecting

⬢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.

Step 41 Installing LED cable

⬢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.

Step 42 Installing LED cable

⬢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.

Step 43 Enclosure cables securing

⬢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.

Step 44 Securing the cables

⬢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.

Step 45 Back cover: parts preparation

⬢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

Step 46 Back cover attaching

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.

Step 47 Antenna cover attaching

⬢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.

Step 48 Antenna & Nextruder connecting

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.

Step 49 XL buddy box covering

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.

Step 50 CAUTION: Lubricant Handling

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.

Step 51 Lower belt release

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.