How to replace the Hotend assembly (XL multi-tool)

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Step 1 Introduction

⬢This guide will take you through the replacement of the hotend assembly on the Original Prusa XL multi-tool.

⬢To replace the Hotend assembly on the Original Prusa XL (single-tool) go to How to replace the Prusa Nozzle (XL single-tool)

The following instructions are compatible with all Prusa Nozzle diameters.

⬢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.

Step 2 Necessary tools

⬢For this guide, please prepare:

⬢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 Preparing the printer

⬢On the printer screen, navigate to Control ->Pick/Park Tool ->Pick tool, and select the tool that has the nozzle to be changed.

⬢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!!!

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 on the selected tool head.

⬢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 and the hotend from the filament residue. Avoid contact of the brush with the hotend cables, as this could cause a short circuit.

⬢When the heaterblock and the hotend are 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 Parking the tool

⬢On the printer screen, navigate to Control ->Pick/Park Tool ->Park Current Tool.

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

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

Step 6 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 7 Removing the Nextruder

⬢Remove the Nextruder, by pulling it outwards from the metal inserts.

Although a small resistance is expected, as the metal inserts are magnetic, use moderate force.

⬢Carefully place the Nextruder on the cardboard box.

Step 8 Disconnecting the hotend

⬢Loosen the M3x12 screw to open the dwarf-cover-door.

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

⬢Disconnect the hotend thermistor cable.

⬢Disconnect the hotend heater cable.

⬢Leave both cables free for now.

Step 9 Removing the hotend

⬢Insert the Torx TX 8 key all the way through the Tool Plate 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 10 Installing the XL Hotend: parts preparation

⬢For the following steps, please prepare:

⬢New XL Hotend assembly (1x)

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 assembly all the way in.

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

⬢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 tube.

Step 12 Connecting the hotend

⬢Connect the hotend heater to the upper slot on the electronics board.

⬢Connect the hotend thermistor to the lower slot on the electronics board.

⬢Tighten the M3x12 screw and close the dwarf-cover-door.

⬢Remove the cardboard box from the heatbed.

Step 13 Docking the Nextruder

⬢Take the Nextruder and place it carefully next to the dock.

⬢Place the two metal inserts through the white holes in the dock. The magnets will help you dock the Nextruder.

Check that the Nozzle seal lightly touches the nozzle.

Step 14 Nozzle seal height calibration

Starting from May 2024, you may receive a gray nozzle seal. The assembly and functionality remain identical to the red one.

⬢The following image was made with the Nextruder and dock removed from the printer for better visibility of how it should be set. Please do not remove the docks from the printer and set the seal height with the dock still connected to the printer.

⬢In the next step, we'll calibrate the height of the nozzle seal.

⬢Using the 2.5 mm Allen key, tighten or untighten the M3x30 screw to calibrate the height of the nozzle seal.

If you have an older version of the XL-dock-cable-router, follow the instructions for the new XL-dock-cable-router.

⬢Proceed to the next step.

Step 15 Nozzle seal height calibration

⬢If is the Nozzle seal too low or too high, we need to reposition its height.

⬢Using a 2.5 mm Allen key:

⬢Turn the M3x30 screw clockwise to set the Nozzle seal lower.

⬢Turn the M3x30 screw counterclockwise to set the Nozzle seal higher.

⬢The correct position of the nozzle seal is when it isn't bent and is touching the nozzle.

Step 16 Final check

⬢On the printer screen, navigate to Control -> Pick/Park Tool -> Pick tool, and pick the tool with the replaced hotend.

⬢Go to Preheat and select any of the material temperatures (e.g. ABS with 255°C on hotend).

⬢Go back to the main screen and watch on the bottom bar to see if the temperature rises.

⬢Before you proceed to the next step, 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 17 It's done

⬢That's it, good job! You just successfully installed the hotend on your multi-tool Original Prusa XL.

How to replace the Hotend assembly (XL multi-tool)

How to replace the Hotend assembly (XL multi-tool)

Step 1 Introduction

Step 2 Necessary tools

Step 3 Preparing the printer

Step 4 Cleaning the hotend

Step 5 Parking the tool

Step 6 Protecting the heatbed

Step 7 Removing the Nextruder

Step 8 Disconnecting the hotend

Step 9 Removing the hotend

Step 10 Installing the XL Hotend: parts preparation

Step 11 Inserting the hotend

Step 12 Connecting the hotend

Step 13 Docking the Nextruder

Step 14 Nozzle seal height calibration

Step 15 Nozzle seal height calibration

Step 16 Final check

Step 17 It's done

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