How to replace a hotend heater (XL Single-Tool)

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Last updated 2 months ago

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Moderate

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Step 1 Introduction

⬢This guide will take you through the replacement of the hotend heater on the Original Prusa XL.

⬢This manual is for a single tool only.

⬢XL Heater 40 W is also available in our eshop.

Note that you have to be logged in to have access to the spare parts section.

Step 2 Tools necessary for this chapter

⬢For this chapter, please prepare:

⬢TX 6 Torx key

⬢TX 8 Torx key

⬢A cardboard box for use as a heatbed protection during the assembly. Hint: use the Prusament box.

⬢Small brass brush for cleaning the nozzle

Step 3 Filament unloading

⬢Manually move the X-axis assembly all the way to the front side of the printer.

⬢Move the extruder approximately to the center of the X-axis.

⬢If you have loaded the filament, unload it from the hotend. On the screen, navigate to Filament -> Unload Filament.

WARNING: The hotend and heatbed are very HOT. Do not touch these parts!!!

⬢Remove the filament from the hotend. It is not necessary to completely remove it from the printer. Just a few centimeters (inches) above the extruder.

Step 4 Cleaning the hotend

WARNING: The hotend and heatbed are very HOT. Do not touch these parts!!!

For the following steps, it is necessary to have the heaterblock and the hotend clean from the remains of the filament.

If you have a Prusa hotend sock on the hotend, remove it.

⬢On the printer screen, go to Control -> Temperature and set the nozzle temperature to 250°C.

⬢Wait at least 5 minutes. The remains of the filament must be warmed up slightly so that they can be removed more easily.

⬢Using the brass brush, carefully clean the heaterblock from the filament residue. Avoid contact of the brush with the hotend cables, as this could cause a short circuit.

⬢When the heaterblock is perfectly clean, cool down the printer. On the screen, navigate to Preheat -> Cooldown.

Wait until the hot parts are cooled down to ambient temperature. It takes approximately 10 minutes.

Step 5 Preparing the printer

Before you proceed, it is recommended to protect the heatbed.

⬢Make sure the heatbed is cooled down to ambient temperature. Place the empty cardboard box approximately to the front center part of the heatbed.

⬢From the rear side of the printer, turn the power switch OFF (symbol "O").

Step 6 Disconnecting the hotend

⬢Open the dwarf-cover-door to access the electronics board.

Each connector has a safety latch. It is necessary to press the latch before disconnecting. Otherwise, the connector may get damaged.

⬢Disconnect the hotend heater cable.

⬢Disconnect the hotend thermistor cable.

⬢Leave both cables free for now.

Step 7 Removing the hotend

If your x-carriage-cover has a hole in it, there is no need to remove the cover. Use the hole to release the hotend.

⬢Remove the x-carriage-cover from the X-carriage.

⬢Hold the hotend with your right hand.

⬢Using your left hand, insert the TX 8 Torx key all the way through the X-carriage until it reaches the grub screw in the extruder. Loosen the screw. Do not remove the screw, a few turns are enough!

⬢Carefully pull the hotend assembly out of the extruder.

⬢At the same time push the hotend cables behind the fan out of the extruder.

Step 8 Removing the heater

⬢Using a TX 6 Torx key, loosen and remove two grub screws.

⬢Pull out the heater out from the heaterblock.

Step 9 Installing the heater: parts preparation

⬢For the following step please prepare:

⬢New XL Heater 40 W (1x)

⬢New grub screws M3x4 (2x)

Step 10 Inserting the new heater

⬢Insert new grub screws and screw them using a TX 6 key. A few turns are enough for now.

⬢Insert the new heater all the way into the heaterblock.

⬢Make the heater aligned with the heaterblock's bottom side.

Make sure your heater is aligned with the bottom side of the heaterblock.

⬢Using a longer side of a TX 6 Torx key, gently tighten two grub screws while keeping the heater in position. Do not overtight.

Step 11 Inserting the hotend

⬢Push the hotend cable behind the heatsink fan up to the electronics.

⬢Locate the hole in the heatsink from the bottom of the extruder and insert the hotend nub into the heatsink.

⬢Push the hotend all assembly the way in.

⬢Rotate the heaterblock as in the picture. There must be approximately 35° - 40° angle to avoid damaging the hotend cables.

⬢Maintain the position and using the TX 8 Torx key tighten the grub screw to secure the hotend. Do not use extra force while tightening, it may damage the hotend nub.