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Table of Contents
Related Manuals for Original Prusa XL
Summary of Contents for Original Prusa XL
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Page 1: Table Of Contents
Table of Contents 1. Introduction ........................................Step 1 - Preparing the upgrade kit ................Step 2 - Getting the necessary tools ................Step 3 - Getting the necessary tools ..................... Step 4 - Labels guide ....................... Step 5 - Cheatsheet ............... - Page 2 Step 15 - Connecting the side Wi-Fi antenna ............Step 16 - Connecting the Nextruder cables ................Step 17 - XL buddy box covering ..............Step 18 - Guiding the docks PTFE tubes ..............Step 19 - Guiding the docks PTFE tubes ........
- Page 3 Step 28 - Quick guide for your first prints ................... Step 29 - Printable 3D models ................Step 30 - Prusa knowledge base ..................... Step 31 - Join Printables! Manual changelog XL (dual-head to five-head upgrade) ..........................Step 1 - Version history...
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Page 5: Introduction
1. Introduction Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 6: Step 1 Preparing The Upgrade Kit
1. Introduction STEP 1 Preparing the upgrade kit Welcome to the tutorial on how to upgrade your Original Prusa XL Dual-Head to Original Prusa XL Five-Head. Please prepare the upgrade kit received from Prusa Research. For the assembly, prepare a clean workbench with a space of at least 1 m x 1 m (40 in x 40 in). -
Page 7: Step 3 Getting The Necessary Tools
All the boxes and bags including parts for the build are labeled. The amount of parts is written on the label. This number is included in the total number of each type of part. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 8: Step 5 Cheatsheet
STEP 6 Front, left, right and rear side IMPORTANT: The XL printer is large and it is almost impossible to have the entire body in every single picture. Throughout the manual, there will used terms to describe the side you will be working on: Front side - the location featuring the xLCD screen. -
Page 9: Step 7 Manipulating With The Printer
You'll find spare nozzles in the upgrades. You can replace the nozzle on your existing Nextruder with a new 0.4 mm diameter nozzle For replacing the Prusa nozzle, go How to replace the Prusa Nozzle (XL multi-tool) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 10: Step 9 Silicone Sock
When you browse the guide on help.prusa3d.com, you can view the original images in high resolution for clarity. Just hover your cursor over the image and click the Magnifier button ("View original") in the top left corner. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 11: Step 11 We Are Here For You
Lost in the instructions? Missing screw or cracked printed part? Let us know! You can contact us using following channels: Using comments under each step. Using our 24/7 live chat at shop.prusa3d.com Writing an email to info@prusa3d.com Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 12: Step 12 How To Successfully Finish The Assembly
Use a reasonable force, the printed parts are tough, but not unbreakable. If it doesn't fit, check your approach twice. Most important: Enjoy the build, have fun. Cooperate with your kids, friends or partners. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 13: Step 13 Prepare Your Desk
Prepare something to contain the plastic bags and the removed packing materials so you can recycle them afterwards. Make sure there are no important parts being discarded. OK, we are ready. Let's start! Go to thr next chapter 2. Printer preparing Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 14: Printer Preparing
2. Printer preparing Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 15: Step 1 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. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 16: Step 3 Printer Unpluging
PSU cable. STEP 4 Can I open the Haribo? Keep the Haribo bag closed for now! This dose of energy is primarily for printer assembly. Wait until you are prompted to open it. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 17: Step 5 Haribo
Did you know that gummy bears were first created by a German candy maker named Hans Riegel in the 1920s. STEP 6 Let's get started Everything checked? So, let's start with disassembling the printer. Let's go to the next chapter: 3. Nextruder detaching Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 18: Detaching The Nextruder
3. Detaching the Nextruder Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 19: Step 1 Tools Necessary For This Chapter
Turn the printer, so the back side of the printer is facing you. Locate the Wi-Fi antenna connector in the middle of the printer. Loosen the Wi-Fi antenna from the antenna connector and set it aside. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 20: Step 3 Ptfe Unpluging
Push the secure pin and disconnect the second Nextruder cable from the lower slot labeled DWARF 2. Attach the cover to the screws. Push it all the way to the left and tighten the screws. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 21: Step 5 Nextruder Cable Bunde Unpluging
M3x8r screws and take off the cable support. Gently undock the second Nextruder and put it aside. Repeat these steps for the first Nextruder. Good job! The docks look like this. We can continue. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 22: Step 7 Nextruder Nozzle Seal
STEP 8 Nextruder dock detaching Using a 2.5mm Allen key, untighten the screw inside the second Nextruder dock (middle hole). Remove the Nextruder dock. Repeat these steps for the first Nextruder dock. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 23: Step 9 Haribo
"little rubber bears" in German. STEP 10 Good job! Well done! The printer is ready for the third PSU assembly. Let's go to the next chapter 4. PSU & electronics assembly. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 24: Psu & Electronics Assembly
4. PSU & electronics assembly Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 25: Step 1 Tools Necessary For This Chapter
Using a T10 Torx key, loosen four screws securing the electronics cover. Remove the cover. Locate and unplug the Wi-Fi connector. If you have the Wi-Fi antenna on the side of the printer, unplug the connector too. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 26: Step 3 Back Antenna Disassembly
Using a T10 Torx key, remove two M3x4rT screws holding the rear-cable- management-base and remove it. Cut two zip ties. Be aware of cables! Good job. The back side of the printer is ready for the third PSU assembly. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 27: Step 5 Psu Assembly: Parts Preparation
Place the black cable on the right terminal and secure it with the terminal screw. From the side of the PSU, insert the Down-angled-ac-adapter as described in the picture. Turn the power switch ON (symbol "I"). Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 28: Step 7 Psu Assembly: Psu Preparing
3mm Allen key. STEP 8 PSU assembly: printer preparing Locate two holes on the back of the printer. Insert two M3x6 screws and secure them. A few turns are enough for now. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 29: Step 9 Attaching The Psu
On the bottom of the PSU, tighten two M3x6 screws using a 2.5mm Allen key. Pushing down the Down-angled-ac-adapter, secure its position. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 30: Step 11 - Psu Covers: Parts Preparations
Insert the M3x8 screw into the switch-cover. On the right side of the PSU, locate the hole in the back plate of the printer. Using a 2.5mm Allen key, secure the cover screw with the back of the printer. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 31: Step 13 Psu Covers: Lower Cover
Insert the prepared PSU cover under the PSU. Tighten both M3x10 screws using a 2.5mm Allen key. STEP 14 PSU power cable cover: parts preparation For the next step, please prepare: Cover PSU cable (1x) PSU-cable-cover (2x) M3x8 screw (4x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 32: Step 15 Psu Power Cable Cover: Lower Cover
STEP 16 PSU power cable cover: power cable Do not twist the cable. Insert the power cable through the upper hole. From the back side of the printer, gently pull the power cable out. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 33: Step 17 Psu Power Cable Cover: Middle Cover
PSU power cable cover: upper cover Insert two M3x8 screws into the back plate as described in the picture. Insert the PSU-cable-cover onto the screws. Tighten two M3x8 screws using a 2.5mm Allen key. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 34: Step 20 - Installing The Xl_Splitter
Using both hands, insert the XL-splitter into the slot in the XL-sandwich-board. Take the power cable and turn it around the left side of the XL-buddy-box. Place the black cable on the left terminal and secure it with the terminal screw. -
Page 35: Step 21 Filament Sensor Cable: Parts Preparation
Zip-ties (2x) STEP 22 Filament sensor cable: connecting the cable Locate the filament sensor cable connector on the left side of the XL-sandwich board. Plug one end of the filament sensor cable to the connector. Locate the perforations in the metal sheet for the zip-ties. -
Page 36: Step 23 Metal Plate Cable Covers: Parts Preparations
Adjusting the XL-buddy-box-cover CAUTION: Exercise caution as the sheets may have sharp edges. Take the XL-buddy-box-cover and locate a rectangular cutout on it. According to the second picture, bend the cutout "inside" the cover. The sheet must be bent to 90 °. -
Page 37: Step 25 Lower Metal Plate Cable Covers
Make sure that no cable is pinched in the plastic covers. Make sure that the metal cover does not pinch the motor cable. Secure the rear-cable-management-upper with four M3x4rT screws using a T10 Torx key. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 38: Step 27 Xl Buddy Cover
The electronics cover does not need to be tightened. Attach the XL buddy box cover to the screws on the electronics box. And slide it down to lock it on the screws. -
Page 39: Step 29 Well Done
4. PSU & electronics assembly STEP 29 Well done! Good job! The third PSU is attached. Let's go to the next chapter: 5. Extruder & accessories assembly Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 40: Nextruder & Accessories Assembly
5. Nextruder & accessories assembly Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 41: Step 1 Tools Necessary For This Chapter
2.5 mm Allen key 3.0 mm Allen key STEP 2 Filament sensor: parts preparation For the following steps, please prepare: Side filament sensor assembly - right (1x) M3x10 screw (1x) M3nEs nut (1x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 42: Step 3 Right Filament Sensor
Insert and tighten the M3x10 screw using a 2.5 mm Allen key. You should now have both Side Filament sensors attached. STEP 4 Nextruder cable: parts preparation For the Nextruder cable bundle assembly please prepare: Cable bunde (5x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 43: Step 5 Guiding The Nextruder Cable
Push the 2.5 mm Allen key all the way through the hole in the rear metal sheet until you reach the middle screw in the xl-dock-cable-router and tighten the screw. The dock is a press fit, the screw MUST be tightened firmly. -
Page 44: Step 7 - Version B: Attaching The Nextruder Docks
Place the xl-dock-cable-router on the bottom metal sheet below the aluminum extrusion. There is a protruding screw from the xl-dock-cable-router. Attach the screw to the first screw hole on the long metal profile. Through the hole in the rear metal sheet, check if the cable holder is lined up with the hole. -
Page 45: Step 9 - Dock Inspection: Video
The spring does not always have to be fitted on the nozzle seal. In this case, take the spring on the M3x30 screw in the nozzle seal. It is always included in the bag. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 46: Step 11 - Version A: Installing The Nextruder Nozzle Seal
STEP 12 Connecting the Nextruder cables Locate the xl-rear-cable-management-plug (cover) on the rear of the printer. 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. -
Page 47: Step 13 - Wi-Fi Antenna Holder Versions
Attach the antenna-holder on the screws and push the cover to the left and tighten the screws. Connect the antenna to the apporpiate slot on the XL Buddy board. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 48: Step 15 Connecting The Side Wi-Fi Antenna
STEP 16 Connecting the Nextruder cables Do not take the XL-splitter board out of the printer, the photo is only a tool for connecting the Nextruder cables. Connect the third, fourth and fifth (from the right) Nextruder to the splitter: Third Nextruder. -
Page 49: Step 17 - Xl Buddy Box Covering
STEP 17 XL buddy box covering Be carefull, do not pinch any cables! Put the XL-buddy-box-cover back on the printer. Check Nextruders cables, they have to be inside the cutout in the cover. With a T10 key tighten the four screws. -
Page 50: Step 18 - Guiding The Docks Ptfe Tubes
Installing the Wi-Fi antenna: parts preparation For the following steps, please prepare: Wi-Fi antenna (1x) The Original Prusa XL is shipped with two versions of the Wi-Fi antenna, each with a different shape. The functionality is the same. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 51: Step 21 Installing The Wi-Fi Antenna
We recommend pointing the antenna straight upwards. STEP 22 Spool holder: parts preparation For the following steps, please prepare: Spool-holder-slider (3x) Spool-holder-base (3x) M4x12 screw (3x) M4nEs nut (3x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 52: Step 23 Assembling The Spool Holder
Insert the M4x12 screw on the longer side of the 3mm Allen key. Insert the 3mm Allen key with the M4x12 screw through the assembled spool holder to the prepared hole in the spool-holder-base. The M4x12 screw has to protrude through the spool-holder-base. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 53: Step 25 Spool Holder: Left Side
Do not use the spool holder as a handle! Keep in mind that if you mount the Spool holder too high or too low, it may not fit the filament spool on it. There has to be enough space around it. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 54: Step 26 - Spool Holder: Right Side Assembly
Keep in mind that if you mount the Spool holder too high or too low, it may not fit the filament spool on it. There has to be enough space around it. STEP 27 Nextruder assembly: parts preparation For the next steps, please prepare: Nextruder (5x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 55: Step 28 How To Dock The Nextruder
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. Using a T10 key tighten the marked two screws. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 56: Step 30 Nextruder Cable Bundle Assembly
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. -
Page 57: Step 32 Nozzle Seal Height Calibration
STEP 33 Haribo time! Eat another eight gummy bears. Did you know that the bright colors of gummy bears are achieved through the use of food coloring, which adds to their visual appeal. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 58: Step 34 Remaining Fasteners
- M3x20rT (2x) - M4x12 (1x) STEP 35 Almost done! Congratulation! Your Original Prusa XL is ready to be fired up! Compare the final look with the picture. Now, let's go to the last chapter 6. First run. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 59: First Run
6. First run Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 60: Step 1 Before You Start With Multi-Tool
(for example, where other printers are printing). From the rear side of the printer, plug in the PSU cable. Turn the power switch ON (symbol "I"). Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 61: Step 3 Factory Reset
Prusa Nextruder sock (Optional) A silicone sock is supplied with each Nextruder package. If you want to install the sock, do it before the calibration. How to install the sock - check the article. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 62: Step 5 Wizard
For this procedure, please prepare: Universal wrench (1x) Mini wrench (1x) It is necessary to follow every step in the dock calibration properly! Do not rush, read every step twice, then proceed with the instruction. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 63: Step 8 Wizard: Loosen Screws
Using a Mini wrench, unscrew and remove both dock pins on Dock 1. STEP 8 Wizard: Loosen screws Follow the wizard instructions on the screen. Using a Uni wrench, loosen two screws. A few turns are enough. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 64: Step 9 Wizard: Lock The Tool
Using a Uni wrench, tighten the upper screw on a side of the dock. After confirming by the continue button on the LCD, the XY axis will leave the dock with the tool. Clear the space. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 65: Step 11 - Wizard: Tighten The Lower Screw
After clicking on the continue button on the LCD, the printer will put back the tool into the dock1 and do a few calibration moves. After the Dock1 calibration, proceed to the Dock2 calibration and repeat the steps. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 66: Step 13 Wizard: Dock Successfully Calibrated
Slightly tap the nozzle. No need to use extra force. In case the Loadcell does not detect enough touch, you will be prompted to repeat the step. Otherwise, you will see Loadcell test passed OK when it succeeds. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 67: Step 15 Wizard: Recalibrate Filament Sensors
It takes several seconds for the filament sensor to be calibrated. After the successful calibration, proceed on the screen by selecting Continue. Proceed to the next step. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 68: Step 17 Wizard: Recalibrate Filament Sensors
On the screen, select Finish and proceed with the calibration with all tool heads on your printer. STEP 18 Calibration pin: parts preparing For the next step, please prepare: Calibration pin (1x) Calibration-pin-key (1x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 69: Step 19 Calibration Pin: Parts Assembly
Wizard: Tool Offset Calibration During offset calibration, you will need to screw the calibration pin into the center of the heatbed. Click on Continue to start the Tool Offsets Calibration. Calibration pin (1x) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 70: Step 21 Wizard: Sheet Install
Follow the wizard instructions on the screen. Take off the steel sheet from the heatbed. Install the calibration pin into the middle of the heatbed. Turn the pin clockwise. Now, the printer will calibrate all five tool heads. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 71: Step 23 Wizard: Offset Calibration Done
Place the steel sheet on a heatbed. The printer will finish the calibration. Good job! The Offset calibration is done. STEP 24 Calibration pin Insert the calibration pin into the side filament sensor. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 72: Step 25 It's Done
Did you know that Haribo gummy bears are one of the most important parts of the Original Prusa printers assembly instructions. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 73: Step 27 Checking The Heatbed Installation (Semi-Assembled Printer)
Handbook, which is tailor-made for your printer and follow the instructions to set up the printer properly. The latest version is always available at this link. Read the chapters Disclaimer and Safety instructions. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 74: Step 29 Printable 3D Models
Looking for inspiration on new projects? Check our blog for weekly updates. If you need help with the build, check out our forum with a great community :-) All services share one account. Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 75: Manual Changelog Xl (Dual-Head To Five-Head Upgrade)
Manual changelog XL (dual-head to five-head upgrade) Original Prusa XL Dual-Head to Five-Head Upgrade... -
Page 76: Step 1 Version History
Manual changelog XL (dual-head to five-head upgrade) STEP 1 Version history Versions of the Original Prusa XL Double-head to Five-head upgrade manual: 01/2024 - Initial version 1.00... - Page 77 Notes:...
- Page 79 Notes:...
- Page 81 Notes:...
- Page 83 Notes:...