5. Nextruder upgrade (Single-Tool)

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Last updated 7 days ago

Difficulty

Moderate

Steps

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Step 1 Tools necessary for this chapter

⬢For this chapter, please prepare:

⬢T10 Torx key (screwdriver)

⬢1.5mm Allen key

⬢2.5mm Allen key

Step 2 Nextruder detaching

You don't need to upgrade the Single-Tool Nextruder if you have an Original Prusa XL from June 2024. You can go to this Section.

⬢Pull out the x-carriage-cover from the X-carriage.

⬢Remove two lower M3x12bT screws from the X-carriage using a T10 Torx screwdriver.

Step 3 Nextruder releasing

Grasp the Nextruder with your hand to prevent it from falling.

⬢Remove two upper M3x12bT screws using a T10 Torx screwdriver.

⬢Pull out the Nextruder from the X-carriage.

⬢Place the Nextruder on the box on the heatbed.

Step 4 Nextruder cable bundle releasing

⬢From the front side of the Nextruder, using a T10 screwdriver, loosen (a few turns are enough) two M3x8r screws and take off the cable support.

⬢Locate the FESTO fitting, push the blue collet down and remove the PTFE tube from the second Nextruder. Leave the PTFE hanging freely.

Starting from September 2024, you may receive a new black Fitting M5-4. The assembly and functionality remain identical to the blue one.

⬢Locate the Nextruder cable, press the secure pin and unplug the cable from the second Nextruder. Leave the cable hanging.

⬢Place the Nextruder nearby.

Step 5 Idler-swivel releasing

⬢Open the cover.

⬢Release the two M3x30 screws and remove the idler-swivel from the Nextruder. Leave the screws in the heatsink.

⬢Place the idler-swivel nearby, we'll disassemble it later.

Step 6 PG case releasing: four screws

If your Nextruder has four screw cover, proceed to the next line. If your Nextruder has three screw cover, please proceed to the next step.

⬢Remove the M3x25 screw using the 2.5mm Allen key. Don't throw the screw away!

⬢Remove the idler from the Nextruder and place it nearby.

Step 7 PG case releasing: three screws

⬢Unscrew and remove two M3x25 screws. Do not throw them away! Loosen the last screw, do not remove it!

⬢Loosen the last screw, do not remove it!

⬢Open the cover by turning it slightly to the side.

Step 8 Idler releasing

⬢Using a 1.5mm Allen key, remove the grub screw. Do not throw it away!

⬢Remove the idler from the Nextruder.

⬢Good job, now we have the idler and idler-swivel. Let's upgrade them!

Step 9 Idler disassembly

⬢Release and remove the M3x5 screw from the idler using a 2.5mm Allen key. Do not throw it away!

⬢Remove the tubular spacer from the idler. Do not throw it away!

⬢Remove the bearing from the idler, it's not connected with the pin. Do not throw them away!

⬢Remove the pins from the idler. Do not throw them away!

⬢Throw the old Idler-levers to the bin.

Step 10 Nextruder idler: parts preparation

⬢For the next steps, please prepare:

⬢Idler-lever-a (1x)

⬢Idler-lever-b (1x)

⬢Bearing 693 2RS (2x) you removed in the previous steps

⬢Pin 2.9x8.5 (2x) you removed in the previous steps

⬢M3x6 screw (1x) you removed in the previous steps

⬢Tubular spacer 13.2x3.8x0.35 (1x) you removed in the previous steps

Step 11 Assembling the extruder idler

The next assembly steps for the idler and idler swivel are copy and paste. Continue with these steps, the assembly is the same - just with the PCCF parts.

⬢Insert the pins 2.9x8.5 into each hole in the Idler-lever-a as seen in the picture.

⬢Attach both bearings onto the pins into the Idler-lever-a.

⬢Close it up with the Idler-lever-b part and secure it with the M3x6 screw. Do not overtighten the screw. Both bearings must be able to rotate without significant resistance.

⬢From the same side, push the tubular spacer into the assembly. The "bottom" of the tubular spacer must be flush with the bottom part of the Idler assembly.

⬢Good job, now the idler-swivel.

Step 12 Idler-swivel disassembly

⬢Release and remove the M3nN nut. Do not throw it away!

⬢Remove the M3x20rT screw. Do not throw it away!

⬢Remove the idler-nut. Throw it into the bin!

Step 13 Idler-swivel disassembly

⬢Release and remove the M3nN nut. Do not throw it away!

⬢Remove the idler-swivel from the screw. Throw it into the bin!

⬢Remove the M3x20rT and spacer from the second idler-swivel. Do not throw them away!

⬢Throw the second idler-swivel into the bin.

Step 14 Idler-swivel: parts preparation

⬢For the following steps, please prepare:

⬢Idler-swivel (2x)

⬢Idler-nut (1x)

⬢M3x20rT screw (2x) you removed in the previous steps

⬢M3nN nut (2x) you removed in the previous steps

⬢Spacer 6x3.1x8 (1x) you removed in the previous steps

Step 15 Assembling the Idler-swivel

⬢Push the M3x20rT screw all the way through one of the idler-swivel.

⬢Slide the spacer onto the screw.

⬢Place the second idler-swivel from the opposite side on the screw.

⬢From the other side, attach the M3nN nut onto the screw. Hold the nut using the universal wrench and tighten the screw. Tighten just lightly! The spacer must rotate freely.

Step 16 Assembling the Idler-nut

⬢Insert the idler-nut into the idler-swivel assembly. Make sure that both parts are oriented correctly according to the picture.

⬢Secure both parts together by inserting the M3x20rT screw from the same side, like the first screw.

⬢Secure the screw with M3nN nut. Do not overtighten the nut. It must be possible to move with the Idler-swivel on the Idler-nut.

Step 17 Idler attaching: four screws

If your Nextruder has four screw cover, proceed to the next line. If your Nextruder has three screw cover, please proceed to the next step.

⬢Insert the assembled idler to its place.

⬢Secure the idler with the M3x25 screw using a 2.5mm Allen key. Do not overtighten the screw! The screw protrudes from the PG-ring after tightening.

Step 18 Idler attaching: three screws

⬢Insert the assembled idler to its place.

⬢Secure the idler with the M3 grub screw using a 1.5mm Allen key. Do not overtighten the screw! The screw protrudes from the PG-ring after tightening.

⬢Turn the PG-cover back.

⬢Insert two M3x25 and secure all three screws using a 2.5mm Allen key.

Step 19 Idler-swivel attaching

⬢Fit the assembled idler-swivel with two M3x30 screws.

⬢Tighten both M3x30 screws. Stop tightening as soon as the screw tips reach the front face of the idler nut.

⬢Close the extruder idler to the extruder.

⬢Close the idler-swivel and lock it over the extruder idler assembly.

Step 20 Nextruder cover closing

⬢Close the cover.

Step 21 Fan shroud removing

The next steps apply only, if your Nextruder has a PETG fan-shroud. If not, please proceed to the Nextruder connecting

⬢Remove two M3x13rT screws using a T10 Torx screwdriver. Don't throw the screws away!

⬢Remove the PETG fan-shroud. Throw it into the bin (trash can).

Step 22 Fan shroud: parts preparation

⬢For the next steps, please prepare:

⬢PCCF fan shroud (1x)

Step 23 Fan shroud securing

⬢Attach the new PCCF fan-shroud onto the Nextruder.

⬢Insert and secure two M3x14rT screws using a T10 Torx screwdriver.

⬢Good job, the Nextruder is upgraded. We can attach it to the printer.

Step 24 Nextruder connecting

Check that the cable bundle is not twisted!

⬢Attach the cable connector into the top of the Nextruder.

⬢Insert the semi-transparent PTFE tube into the fitting on the Nextruder. Push it all the way in.

Starting from September 2024, you may receive a new black Fitting M5-4. The assembly and functionality remain identical to the blue one.

⬢Hook up the keyhole openings in the flexible plate of the cable bundle onto the screw heads and push it up to correct the position and tighten the marked two screws.