How to replace the CoreXY plastic parts

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Last updated a month ago

Difficulty

Very difficult

Steps

140

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Step 1 Introduction

⬢This guide will take you through the installation of CoreXY plastic parts on the Original Prusa XL.

⬢All necessary parts are available in our eshop prusa3d.com.

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

⬢This manual is compatible with the Original Prusa XL Enclosure.

This manual is compatible with all Original Prusa XL printers.

Step 2 Tools necessary for this manual

⬢For the following manual, please prepare:

⬢Torx T10 screwdriver

⬢2.5mm Allen key

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

⬢4.0 mm Allen key

Step 3 Additional tools

Tools that are not included but can make assembly easier, especially when installing add-ons.

⬢Additional tools:

⬢Side cutters for cutting zip ties and side panels cutouts

Step 4 Manipulating with the printer

Never manipulate the printer by using the spoolholders or the upper metal flanges. You can damage the LED lights hidden inside.

⬢When assembling, handle the base using the extrusions.

Step 5 Protecting the heatbed

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.

Step 6 Printer unpluging

⬢Turn the power switch OFF (symbol "O").

⬢From the rear side of the printer, unplug the PSU cable.

Step 7 Removing the Wi-Fi antenna

⬢For the rear version:

⬢Unscrew the antenna from the antenna connector.

⬢For the side version:

⬢Unscrew the antenna from the antenna connector.

Step 8 Optional: Cables disconnecting

The next steps are for users who have an Original Prusa XL Enclosure add-on, otherwise skip to the Belt releasing

⬢Disconnect the FAN and LED cables from the board by pressing the safety latch.

⬢Unplug the PE faston from the connection box.

Step 9 Optional: Front side releasing

⬢From the front side of the enclosure:

⬢Open the lid.

⬢Remove the M4x8r screw using a 2.5mm Allen key. Don't throw the parts away!

Step 10 Optional: Rear side releasing

⬢From the rear side of the printer:

⬢Remove the M4x8r screw using a 2.5mm Allen key. Don't throw the parts away!

Step 11 Optional: Enclosure removing

⬢Grasp the Enclosure on the front where is the support plate.

⬢Grasp the Enclosure on the back of where is the filtration cover.

⬢1. Push the enclosure to the back of the printer.

⬢2. Remove the Enclosure from the printer and place it on a flat surface.

Step 12 Belt releasing

⬢On the front side of the printer:

⬢Using a 2.5mm Allen key, release the M3 screw holding the left CoreXY tensioner. Do not remove the screw completely.

⬢Using a 2.5mm Allen key, release the M3 screw holding the right CoreXY tensioner. Do not remove the screw completely.

⬢Gently tension the belt with your finger. If the belt has a similar degree of looseness as shown in the picture, proceed to the next step.

Step 13 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 14 X-carraige cover removing

⬢Remove the X-carriage cover. Don't throw the part away!

The cover snaps onto the X-carriage. It is easily removable by hand.

Step 15 Single-tool Nextruder

This step is for single-tool owners only. Otherwise, ship to the next step.

⬢Remove two M3x12bT screws using a T10 Torx screwdriver. Don't throw the screws away!

⬢Hold the extruder and remove the remaining two M3x12bT screws from the top screw holes. Don't throw the screws away!

⬢Remove the single-tool Nextruder from the X-carriage. Place the Nextruder on the box covering the heatbed.

Step 16 Belt clamps removing

The color of the belt-clamps may be different depending on if you have an Original Prusa XL Enclosure. The procedure is the same, please continue.

⬢Using the T10 Torx screwdriver, remove two M3x12rT screws holding the lower belt-clamp. Remove the belt-clamp. Do not throw the parts away!

⬢Using the T10 Torx screwdriver, remove two M3x12rT screws holding the upper belt-clamp. Remove the belt-clamp. Do not throw the parts away!

⬢With the belt-clamps removed, proceed to the next step.

Step 17 Belts removing

⬢Grasp the bottom belt on the left side of the CoreXY and pull the belt out of the printer.

⬢Grasp the upper belt on the right side of the CoreXY and pull the belt out of the printer.

⬢Throw old belts away!

Step 18 X-axis: parts preparation

⬢For the next step, please prepare:

⬢Zip-tie (2x)

Step 19 X-axis securing

⬢Single-tool:

⬢Secure the X-axis with zip-ties to prevent falling from the linear rail during the disassembly in the next steps.

⬢Multi-tool:

⬢Secure the X-axis with zip-ties to prevent falling from the linear rail during the disassembly in the next steps.

Step 20 Front left releasing

⬢On the front side of the printer:

If you don't have the Original Prusa XL Enclosure, remove two M3x6bT screws. Don't throw the parts away! Continue to the next step.

⬢Remove the M3x10rT screw and remove the front left bracket. Don't throw the parts away!

⬢Remove the M3x6rT screw. Don't throw the parts away!

Step 21 Front right releasing

If you don't have the Original Prusa XL Enclosure, remove two M3x6bT screws. Don't throw the parts away! Continue to the next step.

⬢Remove the M3x10rT screw and remove the front right bracket. Don't throw the parts away!

⬢Remove the M3x6rT screw. Don't throw the parts away!

Step 22 Rear right releasing

⬢On the rear side of the printer:

If you don't have the Original Prusa XL Enclosure, remove three M3x6bT screws. Don't throw the parts away! Continue to the next step.

⬢Remove two M3x10rT screws using a T10 Torx screwdriver. Don't throw the parts away!

⬢Leave the connection box hanging freely on the cables.

⬢Remove the remaining M3x10rT screw using a T10 Torx screwdriver. Don't throw the parts away!

⬢Remove the fixing bracket rear left. Don't throw the parts away!

Step 23 Rear left releasing

If you don't have the Original Prusa XL Enclosure, remove three M3x6bT screws. Don't throw the parts away! Continue to the next step.

⬢Remove two M3x8bT screws using a T10 Torx screwdriver. Don't throw the parts away!

⬢Remove the fixing bracket rear left. Don't throw the parts away!

⬢Remove the M3x6bT using a T10 Torx screwdriver. Don't throw the parts away!

Step 24 CoreXY cover removing

⬢On the right inner side of the CoreXY cover, unplug the PE connector.

⬢Leave the PE connector free.

⬢Gently pull the CoreXY cover from the printer towards you. Do not throw the part away!

Step 25 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 26 Anthenna cable disconnecting

⬢Locate and unplug the Wi-Fi connector.

If you have the Wi-Fi antenna on the side of the printer, unplug the connector too.

Step 27 Back antenna removing

This step is only for the printer, which has a Wi-Fi antenna on the back of the printer.

Be careful, do not damage the Wi-Fi antenna cable.

⬢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.

Step 28 Nextruder disconnecting

⬢In case you have a side antenna, 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.

⬢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 29 Back cover releasing

⬢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!

Step 30 Optional: Cable cover cap removing

This step is only for users who have an Original XL Enclosure. Otherwise, continue to the next step.

⬢Using a T10 Torx screwdriver, remove two M3x6rT screws.

Watch out for cables!

⬢Gently remove cable-cover-cap-right.

Step 31 Back cover removing

Watch out for cables!

⬢Carefully remove the rear cable management upper from the printer.

Step 32 Back right cables releasing

Watch out for the cables!

⬢Cut off two zip-ties holding the cables.

⬢Cut off two zip-ties holding the LED cable.

Step 33 Back left cables releasing

Watch out for the cables!

⬢Cut off two zip-ties holding the cables.

⬢Cut off two zip-ties holding the LED cable.

⬢For XL Enclosure owners only. Otherwise, ship to the next step.

⬢Cut off one zip-tie holding the cables on the XL Enclosure board cover.

Step 34 Optional: Left XY motor & LED cable disconnecting

These steps are for Original XL Enclosure owners. Otherwise, continue to the step Side antenna removing

⬢By pressing the safety latch, unplug the LED cable from the connection box.

⬢By pressing the safety latch, unplug the XY motor cable.

Step 35 Optional: Right XY motor & LED cable disconnecting

⬢By pressing the safety latch, unplug the XY motor cable.

⬢By pressing the safety latch, unplug the LED cable from the connector.

Step 36 Left XY motor & LED cable disconnecting

⬢By pressing the safety latch, unplug the XY motor cable.

⬢By pressing the safety latch, unplug the LED cable.

Step 37 Right XY motor & LED cable disconnecting

⬢By pressing the safety latch, unplug the XY motor cable.

⬢By pressing the safety latch, unplug the LED cable.

Step 38 Side antenna removing

These steps are for side antenna owners only. Otherwise, continue to the next step.

⬢Remove two M3x10 screws using a 2.5 Allen key. Don't throw the screws away.

⬢Gently pull out the antenna cable from the black cotton sleeve. Put the antenna aside.

Step 39 CoreXY right metal cover remove

⬢From the right side of the printer:

⬢Using the T10 Torx screwdriver, remove two M3x6bT screws. Don't throw the parts away!

⬢Push the cover from the inner side.

⬢Remove the CoreXY cover. Don't throw the parts away!

Step 40 CoreXY-back-right disassembly

⬢Gently remove the LED strip cable from the CoreXY back.

⬢Remove the LED strip panel from the printer. Don't throw the part away!

⬢Using the 2.5mm Allen key, remove four M3x10 screws.

⬢Remove the XY motor.

Step 41 CoreXY left metal cover remove

⬢From the left side of the printer:

⬢Using the T10 Torx screwdriver, remove two M3x6bT screws. Don't throw the parts away!

⬢Push the cover from the inner side and remove the CoreXY cover. Don't throw the parts away!

Step 42 CoreXY-back-left disassembly

⬢Gently remove the LED strip cable from the CoreXY back. Remove the LED strip panel from the printer. Don't throw the part away!

⬢Using the 2.5mm Allen key, remove four M3x10 screws.

⬢Remove the XY motor.

Step 43 CoreXY-tensioner removing

⬢From the front side of the printer:

⬢Untighten the screw and remove the right CoreXY-tensioner. Do not remove the screw.

⬢Untighten the screw and remove the left CoreXY-tensioner. Do not remove the screw.

Step 44 CoreXY-tensioner disassembling

⬢Remove each single pulley with a pin from the CoreXY-tensioners. Throw the old plastic parts into the bin.

⬢From each single pulley, remove the two O-rings. Throw the old O-rings into the bin.

Leave the pins in the single pulleys, we'll reassemble them in the next steps.

Step 45 CoreXY-tensioner: parts preparing

⬢For the next steps, please prepare:

⬢CoreXY-tensioner (2x)

⬢M3nN nut (2x)

⬢O-ring (4x)

Step 46 Single pulley reassembly

⬢Place an O-ring on each end of the pin.

⬢Push the O-rings towards the centre to keep the pulley in the centre.

⬢Prepare both pulleys.

Step 47 CoreXY-tensioner preparing

⬢Insert one M3nN nut into each CoreXY-tensioner.

⬢Insert each prepared single pulley into the CoreXY-tensioners.

Step 48 CoreXY-tensioner securing

⬢Insert the prepared CoreXY-tensioner into the CoreXY-front-left and secure it with the screw. A few turns are enough for now!

⬢Insert the prepared CoreXY-tensioner into the CoreXY-front-right and secure it with the screw. A few turns are enough for now!

Step 49 Y-carriage-left-top disassembly

⬢Using a 2,5mm Allen key, remove four M3x30 screws. Don't throw the screws away!

⬢Remove the Y-carriage-left-top. Throw the old plastic part into the bin.

⬢Remove two single pulleys with the pins from the Y-carriage-left-base. Put them aside, we'll reassemble them later.

Step 50 Y-carriage-right-top disassembly

⬢Using a 2,5mm Allen key, remove four M3x30 screws. Don't throw the screws away!

⬢Remove the Y-carriage-right-top. Throw the old plastic part into the bin.

⬢Remove two single pulleys with the pins from the Y-carriage-right-base. Put them aside, we'll reassemble them later.

⬢Remove the X-axis with a secured tool-changer (x-carriage). Put the part aside.

Step 51 Y-carriage base disassembly

⬢Remove three M3x10 from the Y-carriage-right-base. Don't trow the screws away!

⬢Remove the Y-carriage-right-base. Throw the old plastic part into the bin.

⬢Remove three M3x10 from the Y-carriage-left-base. Don't trow the screws away!

⬢Remove the Y-carriage-left-base. Throw the old plastic part into the bin.

Step 52 Single pulley reassembly: parts preparation

⬢For the next steps, please prepare:

⬢O-ring (8x)

⬢Assembled Single pulley (4x) removed in previous steps

Step 53 Single pulley reassembly

⬢Remove the old O-rings from each of the individual belt pulleys. Throw the old O-rings into the bin.

⬢Place a new O-ring on each end of the pin.

⬢Push the O-rings towards the centre to keep the pulley in the centre.

⬢Prepare all four single pulleys.

Step 54 X-axis: parts preparation

⬢For the next steps, please prepare:

⬢X-axis (1x) removed in the previous steps

⬢M3nN nut (8x)

⬢M3x10 screw (6x) removed in the previous steps

The printed parts of the Y-carriage are marked with printed letters. Look at the third picture.

⬢Y-carriage-right-base (1x) marked RB

⬢Y-carriage-left-base (1x) marked LB