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    How to replace the main cable connector cover (XL)

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    How to replace the main cable connector cover (XL)

    How to replace the main cable connector cover (XL)
    Relevant for:
    XL
    Last updated in an hour
    How to replace the main cable connector cover (XL)
     Difficulty
    Moderate
     Steps
    38
     Available languages

    Step 1 Introduction

    Introduction
    Introduction
    Introduction
    ⬢This guide will take you through the installation of the Main cable connector cover on the Original Prusa XL.
    The following instructions are compatible with all Original Prusa XL versions.
    ⬢All necessary parts are available in our eshop prusa3d.com.
    ⬢This manual is compatible with the Original Prusa XL Enclosure.
    We will demonstrate replacing the Main cable connector cover on a printer without the XL Enclosure for better visibility. There is no need to remove the XL Enclosure.

    Step 2 Tools necessary for this manual

    Tools necessary for this manual
    Tools necessary for this manual
    Tools necessary for this manual
    ⬢For the following manual, please prepare:
    ⬢Torx T10 screwdriver
    ⬢2.5 mm Allen key
    ⬢A cardboard box for use as heatbed protection during the assembly. We will use the Nextruder box as an example.

    Step 3 Unloading the filament

    Unloading the filament
    Unloading the filament
    Unloading the filament
    Unloading the filament
    ⬢If you have loaded the filament, unload it from the hotend. On the screen, navigate to Filament -> Unload Filament.
    ⬢Remove the filament from the hotend. It is is necessary to completely remove it from the printer.
    WARNING: The hotend and heatbed are very HOT. Do not touch these parts!!!
    ⬢Move the Z-axis down. On the screen, navigate to Control -> Move axis -> Move Z.
    ⬢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 4 Unpluging the printer

    Unpluging the printer
    Unpluging the printer
    ⬢Turn the power switch OFF (symbol "O").
    ⬢From the rear side of the printer, unplug the PSU cable.

    Step 5 Protecting the heatbed

    Protecting the heatbed
    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 Multi-tool & Single-tool

    Multi-tool & Single-tool
    Multi-tool & Single-tool
    Multi-tool & Single-tool
    The following instructions are divided according to your printer variant. 
    ⬢Choose the appropriate steps:
    ⬢Multi-tool: please proceed to the next step
    ⬢Single-tool: please proceed to the Single-tool: releasing the Nextruder
    The manual was created on the Multi-Tool Nextruder. The process is the same, only the pictures are different.

    Step 7 Multi-tool: disconnecting the Nextruder

    Multi-tool: disconnecting the Nextruder
    Multi-tool: disconnecting the Nextruder
    Multi-tool: disconnecting the Nextruder
    Multi-tool: disconnecting the Nextruder
    ⬢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 fitting, press the blue collet and unplug the PTFE tube from the Nextruder. Leave the PTFE hanging freely.
    ⬢Locate the Nextruder cable, press the secure pin and unplug the cable from the second Nextruder. Leave the cable hanging.

    Step 8 Multi-tool: Disassembling the Nextruder cable

    Multi-tool: Disassembling the Nextruder cable
    Multi-tool: Disassembling the Nextruder cable
    Multi-tool: Disassembling the Nextruder cable
    Multi-tool: Disassembling the Nextruder cable
    ⬢Put the Nextruder cable on the box.
    ⬢Using a 2.5 mm Allen key, remove the M3x16 screw from the xl-dwarf-cover-connector.
    ⬢Gently remove the Nextruder cable from the xl-dwarf-cover-connector. Throw the xl-dwarf-cover-connector away.

    Step 10 Multi-tool: Preparing the XL dwarf cover connector

    Multi-tool: Preparing the XL dwarf cover connector
    Multi-tool: Preparing the XL dwarf cover connector
    Multi-tool: Preparing the XL dwarf cover connector
    Multi-tool: Preparing the XL dwarf cover connector
    ⬢Take the XL-dwarf-cover-connector.
    Proceed carefully, do not break the XL-dwarf-cover-connector!
    ⬢Use both hands to gently open the XL-dwarf-cover-connector. 5.0 mm is enough.
    ⬢Insert the M3nN nut into the prepared hexagon hole in the XL-dwarf-cover-connector.

    Step 11 Multi-tool: Reassembling the Nextruder cable

    Multi-tool: Reassembling the Nextruder cable
    Multi-tool: Reassembling the Nextruder cable
    Multi-tool: Reassembling the Nextruder cable
    Multi-tool: Reassembling the Nextruder cable
    ⬢Insert the Nextruder cable into the prepared XL-dwarf-cover-connector.
    ⬢Insert the XL-dwarf-cover-connector into the XL-dwarf-cover-connector-jig.
    Do not pinch any cables!
    The Nextruder cable needs to be longer than the front of the XL-dwarf-cover-connector-jig.
    ⬢Insert the M3x10 screw and secure it with a 2.5 mm Allen key.
    ⬢Good job. The connector is ready.

    Step 13 Multi-tool: Disassembling the Nextruder

    Multi-tool: Disassembling the Nextruder
    Multi-tool: Disassembling the Nextruder
    Multi-tool: Disassembling the Nextruder
    Multi-tool: Disassembling the Nextruder
    The next steps are compatible with both Single-tool and Multi-tool Nextruders.
    ⬢Using a 2.5 mm Allen key, remove the M3x16 screw. Don't throw the part away!
    ⬢Remove the XL-dwarf-cover-door. Don't throw the part away!
    ⬢Turn the Nextruder so that the back is facing upwards.
    ⬢Using a T10 Torx screwdriver, remove two M3x6bT screws. Don't throw the parts away!
    ⬢Remove the XL-dwarf-cover-back. Don't throw the part away!
    ⬢Slide out the XL-dwarf-cover-base from the dwarf board. Throw the XL-dwarf-cover-base away.

    Step 16 Multi-tool: Securing the XL dwarf cover base

    Multi-tool: Securing the XL dwarf cover base
    Multi-tool: Securing the XL dwarf cover base
    Multi-tool: Securing the XL dwarf cover base
    Multi-tool: Securing the XL dwarf cover base
    ⬢Note the rail that fits perfectly on the dwarf board.
    ⬢Push the XL-dwarf-cover-base to the dwarf board and slide it in place.
    ⬢Place the XL-dwarf-cover-back.
    ⬢Insert two M3x6bT screws and secure them with a T10 Torx screwdriver.

    Step 18 Multi-tool: XL dwarf cover door securing

    Multi-tool: XL dwarf cover door securing
    Multi-tool: XL dwarf cover door securing
    Multi-tool: XL dwarf cover door securing
    ⬢Turn the Nextruder on its back.
    ⬢Attach the XL-dwarf-cover-door.
    ⬢Insert M3x16 and secure it gently using a 2.5 mm Allen key.
    ⬢Good job. The Nextruder is prepared.

    Step 19 Multi-tool: docking the Nextruder

    Multi-tool: docking the Nextruder
    Multi-tool: docking the Nextruder
    Multi-tool: docking the Nextruder
    Multi-tool: docking the Nextruder
    ⬢Place the two metal inserts through the white holes in the dock. The magnets will help you dock the Nextruder.
    Check that the cable bundle is not twisted!
    ⬢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.
    ⬢Tighten two M3x8rT screws. using a T10 Torx screwdriver.

    Step 20 Multi-tool: securing the cable bundle

    Multi-tool: securing the cable bundle
    Multi-tool: securing the cable bundle
    Multi-tool: securing the cable bundle
    Multi-tool: securing the cable bundle
    ⬢Insert the PTFE tube into the fitting on the Nextruder. Push it all the way in.
    ⬢Attach the Nextruder cable to the top of the Nextruder.
    ⬢Insert two M3x10 screws and secure them using a 2.5 mm Allen key.
    ⬢Well done! The first Nextruder is ready. Repeat the Multi-tool steps on each Nextruder you have.

    Step 21 Single-tool: releasing the Nextruder

    Single-tool: releasing the Nextruder
    Single-tool: releasing the Nextruder
    Single-tool: releasing the Nextruder
    ⬢Turn the printer, so the front side is facing you.
    ⬢Snap off the x-carriage-cover back from the X-carriage. Do not throw it away, we'll use it later!
    ⬢Using a T10 Torx key, remove two M3x12bT screws.

    Step 22 Single-tool: detaching the Nextruder

    Single-tool: detaching the Nextruder
    Single-tool: detaching the Nextruder
    Single-tool: detaching the Nextruder
    ⬢Hold the Nextruder during disassembly.
    ⬢Untighten two M3x12bT screws using a T10 Torx key.
    ⬢Detach the Nextruder and place it nearby, we will rebuilt it in the next steps.
    ⬢Place the Nextruder with the cable bundle on the box.

    Step 23 Single-tool: releasing the cable bundle

    Single-tool: releasing the cable bundle
    Single-tool: releasing the cable bundle
    Single-tool: releasing the cable bundle
    Single-tool: releasing the cable bundle
    ⬢From the front side of the Nextruder, using a T10 Torx screwdriver untighten two screws to release the cable support.
    ⬢Press the fitting and pull out the PTFE tube.
    ⬢Press the secure pin and remove the Nextruder cable.
    ⬢Put the Nextruder aside, we will work on it later.

    Step 24 Single-tool: Disassembling the Nextruder cable

    Single-tool: Disassembling the Nextruder cable
    Single-tool: Disassembling the Nextruder cable
    Single-tool: Disassembling the Nextruder cable
    Single-tool: Disassembling the Nextruder cable
    ⬢Put the Nextruder cable on the box.
    ⬢Using a 2.5 mm Allen key, remove the M3x16 screw from the xl-dwarf-cover-connector.
    ⬢Gently remove the Nextruder cable from the xl-dwarf-cover-connector. Throw the xl-dwarf-cover-connector away.

    Step 26 Single-tool: Preparing the XL dwarf cover connector

    Single-tool: Preparing the XL dwarf cover connector
    Single-tool: Preparing the XL dwarf cover connector
    Single-tool: Preparing the XL dwarf cover connector
    Single-tool: Preparing the XL dwarf cover connector
    ⬢Take the XL-dwarf-cover-connector.
    ⬢Using both hands, gently open the XL-dwarf-cover connector. Open it just enough—5.0 mm is sufficient.
    Proceed carefully, do not break the XL-dwarf-cover-connector!
    ⬢Insert the M3nN nut into the prepared hexagon hole in the XL-dwarf-cover-connector.

    Step 27 Single-tool: Reassembling the Nextruder cable

    Single-tool: Reassembling the Nextruder cable
    Single-tool: Reassembling the Nextruder cable
    Single-tool: Reassembling the Nextruder cable
    Single-tool: Reassembling the Nextruder cable
    ⬢Insert the Nextruder cable into the prepared XL-dwarf-cover-connector.
    ⬢Insert the XL-dwarf-cover-connector into the XL-dwarf-cover-connector-jig.
    Do not pinch any cables!
    The Nextruder cable needs to be longer than the front of the XL-dwarf-cover-connector-jig.
    ⬢Insert the M3x10 screw and secure it with a 2.5 mm Allen key.
    ⬢Good job. The connector is ready.

    Step 28 Single-tool: Disassembling the Nextruder

    Single-tool: Disassembling the Nextruder
    Single-tool: Disassembling the Nextruder
    Single-tool: Disassembling the Nextruder
    Single-tool: Disassembling the Nextruder
    The next steps are compatible with both Single-tool and Multi-tool Nextruders.
    ⬢Using a 2.5 mm Allen key, remove the M3x16 screw. Don't throw the part away!
    ⬢Remove the XL-dwarf-cover-door. Don't throw the part away!
    ⬢Turn the Nextruder so that the back is facing upwards.
    ⬢Using a T10 Torx screwdriver, remove two M3x6bT screws. Don't throw the parts away!
    ⬢Remove the XL-dwarf-cover-back. Don't throw the part away!
    ⬢Slide out the XL-dwarf-cover-base from the dwarf board. Throw the XL-dwarf-cover-base away.

    Step 31 Single-tool: Securing the XL dwarf cover base

    Single-tool: Securing the XL dwarf cover base
    Single-tool: Securing the XL dwarf cover base
    Single-tool: Securing the XL dwarf cover base
    Single-tool: Securing the XL dwarf cover base
    ⬢Note the rail that fits perfectly on the dwarf board.
    ⬢Push the XL-dwarf-cover-base to the dwarf board and slide it in place.
    ⬢Place the XL-dwarf-cover-back.
    ⬢Insert two M3x6bT screws and secure them with a T10 Torx screwdriver.

    Step 33 Single-tool: XL dwarf cover door securing

    Single-tool: XL dwarf cover door securing
    Single-tool: XL dwarf cover door securing
    Single-tool: XL dwarf cover door securing
    ⬢Turn the Nextruder on its back.
    ⬢Attach the XL-dwarf-cover-door.
    ⬢Insert M3x16 and secure it gently using a 2.5 mm Allen key.
    ⬢Good job. The Nextruder is prepared.

    Step 35 Single-tool: securing the cable bundle

    Single-tool: securing the cable bundle
    Single-tool: securing the cable bundle
    Single-tool: securing the cable bundle
    ⬢Insert the PTFE tube into the fitting on the Nextruder. Push it all the way in.
    ⬢Hook up the keyhole openings in the flexible plate of the cable bundle and tighten two M3x8rT screws using a T10 Torx screwdriver.

    Step 37 Single-tool: installing the Nextruder

    Single-tool: installing the Nextruder
    Single-tool: installing the Nextruder
    Single-tool: installing the Nextruder
    Single-tool: installing the Nextruder
    ⬢From the back of the X-carriage, attach the extruder assembly to the X-carriage. See the correct orientation of the extruder.
    ⬢Insert and fully tighten all four M3x12bT screws diagonally to secure the extruder assembly.
    ⬢Attach the bottom part of the x-carriage-cover back onto the X-carriage, then snap the upper part onto the X-carriage. You must feel a slight "click" to ensure the cover fits on the part.

    Step 38 Good job

    Good job
    Good job
    ⬢Well done! The XL-dwarf-cover-connector is replaced.
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