Original Prusa XL Single-Tool Upgrade

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Table of Contents

1. Introduction

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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

Step 6 - Front, left, right and rear side

Step 7 - Manipulating with the printer

Step 8 - Spare nozzles

Step 9 - Silicone sock

Step 10 - CAUTION: Lubricant Handling

Step 11 - View high resolution images

Step 12 - We are here for you!

Step 13 - How to successfully finish the assembly

Step 14 - Reward yourself

Step 15 - Prepare your desk

2. Printer preparing

Step 1 - Preparing the printer

Step 2 - Protecting the heatbed

Step 3 - Printer unpluging

Step 4 - Can I open the Haribo?

Step 5 - Let's get started

3. Nextruder disassembly

Step 1 - Tools necessary for this chapter

Step 2 - Wi-Fi antenna detaching

Step 3 - PTFE unpluging

Step 4 - Disconnecting the Nextruder cable

Step 5 - Detaching the dock

Step 6 - Detaching the Nextruder

Step 7 - Detaching the Nextruder

Step 8 - Still no sweets?

Step 9 - Good job!

4. Nextruder upgrade

Step 1 - Tools necessary for this chapter

Step 2 - Dock disassembly: parts preparation

Step 3 - Dock disassembly: cable bundle

Step 4 - Dock disassembly

Step 5 - New dock assembly: parts preparation

Step 6 - New dock assembly: inserting the nut

Step 7 - New dock assembly: metal dock

Step 8 - New dock assembly: upper screw

Step 9 - New dock assembly: lower screw

Step 10 - New dock assembly: cable support

Step 11 - New dock assembly: cable support

Step 12 - New dock aseembly: PTFE tube

Step 13 - New dock assembly: parts preparation

Step 14 - New dock assembly: cable bundle

Step 15 - New dock assembly: cable bundle securing

Step 16 - New dock assembly: nozzle seal

Step 17 - Nextruder disassembly: cable bundle

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Summary of Contents for Original Prusa XL Single-Tool

Page 1 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 18 - Nextruder disassembly: Nextruder body ..........Step 19 - Nextruder disassembly: heatsink screw ................... Step 20 - Grub screw relocate ........... Step 21 - Nextruder assembly: parts preparation ..............Step 22 - Tool-changer cable connecting .................. Step 23 - Fan-shield assembly ................
Page 3 ..................Step 7 - Wizard: Loosen pin ................Step 8 - Wizard: Loosen screws ................... Step 9 - Wizard: Lock the tool ............. Step 10 - Wizard: Tighten the upper screw .............. Step 11 - Wizard: Tighten the lower screw ..................
Page 5 1. Introduction Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 6 1. Introduction STEP 1 Preparing the upgrade kit Welcome to the tutorial on how to upgrade your Original Prusa XL Single-Tool to Original Prusa XL Dual-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 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 Single-Tool to Dual-Head Upgrade...
Page 8 Left side - can be recognized thanks to the safety sticker near its edge. Right side - opposite to the left side, there is no safety sticker on this side. Rear side - the remaining side, where is PSU. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 9 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 Single-Tool to Dual-Head Upgrade...
Page 10 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 in the printer's bearings, mainly in the linear rail channels. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 11 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 Single-Tool to Dual-Head Upgrade...
Page 12 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 Single-Tool to Dual-Head Upgrade...
Page 13 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 chapter 2. Printer preparing Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 14 2. Printer preparing Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 15 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 Single-Tool to Dual-Head Upgrade...
Page 16 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 Single-Tool to Dual-Head Upgrade...
Page 17 2. Printer preparing STEP 5 Let's get started Everything checked? So, let's start with disassembling the printer. Let's go to the next chapter: 3. Nextruder disassembly Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 18 3. Nextruder disassembly Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 19 Wi-Fi antenna on the back of the printer. Turn the printer, so the back side of the printer is facing you. Unscrew the Wi-Fi antenna from the antenna connector and place it nearby. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 20 Push the safety latch and disconnect the Nextruder cable from the connector "DWARF1". Attach the antenna-holder to the screws and push the cover to the left. Tighten the screws. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 21 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. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 22 If any gummy bears are missing, please go to your nearest candy store immediately. Eat ten gummy bears. Did you know that gummy bears were first created by a German candy maker named Hans Riegel in the 1920s. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 23 3. Nextruder disassembly STEP 9 Good job! Well done, the printer is ready for the assembly. Let's go to the next chapter: 4. Nextruder upgrade Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 24 4. Nextruder upgrade Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 25 T8 Torx key T10 Torx key (T10 Torx screwdriver) 2.5 mm Allen key Needle-nose pliers for cutting zip ties STEP 2 Dock disassembly: parts preparation For the following steps, please prepare: Old Nextruder assembly (1x) Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 26 The screw will fall out from the lower hole. Keep the screw for later use. Pull out the dock-cable-router-single-tool_adapter from the xl-dock-cable-router. Remove the M3x10 screw from the dock-cable-router-single-tool-adapter. Keep the screw for later use. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 27 New dock assembly: inserting the nut Insert the M3nS nut into the hole in the new xl-dock-cable-router. Take the new Xl-dock-cable-router from the upgrade. Push the nut into the xl-dock-cable- router using a 2.5mm Allen key. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 28 Double-check the screw. It's there? Proceed to the next step. STEP 8 New dock assembly: upper screw Insert the M3x12bT screw into the plastic cutout. Tighten the screw with a T10 Torx key. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 29 Tighten the screw with the T10 Torx key. STEP 10 New dock assembly: cable support From the back side of the xl-dock-cable-router: Locate two holes for the nuts. Insert two M3nN nuts into the holes. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 30 Push the PTFE tube through slowly and in a controlled, otherwise you may pinch or tangle it. Gently insert the PTFE tube into the cable bundle through the hole. The PTFE tube has to look like this. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 31 Slide the spring over the M3x30 screw, taking care not to let it fall off. STEP 14 New dock assembly: cable bundle Locate the cable bundle cutout on a side of the xl-dock-cable-router Insert the cable bundle into the cutout. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 32 Insert the nozzle seal (with the spring) into the hole. Secure the nozzle seal with a 2.5 mm Allen key. Do not over-tighten, a few turns are enough for now. Heigh calibration will be done later after finishing the dock assembly. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 33 From the right side of the Nextruder, using a T10 Torx screwdriver unscrew two M3x20rT screws. Do not throw them away! From the left side of the Nextruder, unscrew two screws using a 2.5 mm Allen key. Pull out the Nextruder body from the Nextruder. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 34 Using a T8 Torx key, relocate the grub screw from the upper hole to the lower hole. Tighten the screw gently! The grub screw is for the nozzle release. Make sure, that the Nozzle is not touching the fan-nozzle part. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 35 For the following steps, please prepare: Tool-changer (1x) Tool-changer cable (1x) XL-tc-hotend-fan-shield (1x) M3x30 screw (1x) M3x8rT screw (2x) M3x8bT screws (2x) STEP 22 Tool-changer cable connecting Connect the tool-changer cable with the tool-changer. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 36 The second photo shows a different angle. Locate the space between two M3nS spacers (long silver M3 nuts). Insert the tool-changer cable through two nuts to the back of the Nextruder. Be careful of cables! Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 37 Insert the M3x30 screw into the lower hole and tighten it using a 2.5 mm Allen key. STEP 26 Tool-changer connecting Open the plastic cover by pulling out the bottom corner. Open the plastic cover. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 38 Close the plastic cover. Do not pinch any cables! STEP 28 Haribo Eat ten gummy bears. Did you know that gummy bears were first created by a German candy maker named Hans Riegel in the 1920s. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 39 4. Nextruder upgrade STEP 29 Good job! Well done! Nextruder and the cable bundle are prepared for the next steps. Let's go to the next chapter: 5. ToolChanger assembly Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 40 5. ToolChanger assembly Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 41 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. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 42 Tool Changer Upper Lock (1x) Tool Changer Lower Lock (1x) Spring 3x9 (4x) TC push pin (4x) M3x12bT screw (4x) you removed in the previous chapter X-carriage-cover (1x) you removed in the previous chapter Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 43 M3x12bT screws from the front side. Ensure the correct orientation of the part. Attach the TC block upper assembly to the X-carriage from the top and secure it with two M3x12bT screws from the front side. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 44 Eat eight gummy bears. Did you know that in 2014, a gummy bear-inspired emoji was added to the Unicode Standard, allowing gummy bear enthusiasts to express their love for the candy in digital conversations. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 45 5. ToolChanger assembly STEP 9 Almost done That wasn't so hard. Anyway, good job! Let's go to the next chapter: 6. Nextruder & accessories assembly Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 46 6. Nextruder & accessories assembly Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 47 For the next steps, please prepare: T10 Torx key (T10 Torx screwdriver) 2.5 mm Allen key 3.0 mm Allen key STEP 2 Nextruder cable: parts preparation For the next steps, please prepare: Cable bunde (2x) Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 48 The dock is a press fit, so the screw needs to be tightened very hard. Attach all the remaining docks using the same procedure Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 49 STEP 6 Dock inspection: video The following instructions need to be done correctly and carefully. Achieve better understanding and successful assembly by watching the video alongside the guide. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 50 Version A: The Wi-Fi antenna holder is on the side. We haven't removed it. The antenna connector has to be assembled by you: Version B: The Wi-fi antenna is in the middle. Continue to the next step. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 51 Locate the Wi-Fi antenna connector in the middle of the printer. Screw the Wi-Fi antenna on the antenna connector. The antenna can be rotated around and bent in two directions. We recommend pointing the antenna straight upwards. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 52 Insert the second Nextruder PTFE tube all the way into the middle hole in the part. STEP 12 Spool holder: parts preparation For the following steps, please prepare: Spool-holder-slider (1x) Spool-holder-base(1x) M4x12 screw (1x) M4nEs nut (1x) Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 53 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 Single-Tool to Dual-Head Upgrade...
Page 54 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 16 Nextruder assembly: parts preparation For the next steps, please prepare: Nextruder (2x) Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 55 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 Single-Tool to Dual-Head Upgrade...
Page 56 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. Proceed to the next step. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 57 STEP 22 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 Single-Tool to Dual-Head Upgrade...
Page 58 - Spring 15x5 (1x) STEP 24 Almost done! Congratulation! Your Original Prusa XL is ready to be fired up! Compare the final look with the picture. Let's go to the next chapter: 7. First Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 59 7. First run Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 60 (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 Single-Tool to Dual-Head Upgrade...
Page 61 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 article. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 62 Dock calibration will guide you through how to properly calibrate the position of individual tool heads on the printer. 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 Single-Tool to Dual-Head Upgrade...
Page 63 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 Single-Tool to Dual-Head Upgrade...
Page 64 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 Single-Tool to Dual-Head Upgrade...
Page 65 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 Single-Tool to Dual-Head Upgrade...
Page 66 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 Single-Tool to Dual-Head Upgrade...
Page 67 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 Single-Tool to Dual-Head Upgrade...
Page 68 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 Single-Tool to Dual-Head Upgrade...
Page 69 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 Single-Tool to Dual-Head Upgrade...
Page 70 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 Single-Tool to Dual-Head Upgrade...
Page 71 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 Single-Tool to Dual-Head Upgrade...
Page 72 Did you know that Haribo gummy bears are one of the most important parts of the Original Prusa printers assembly instructions. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 73 Congratulations! You should be ready to print by now ;-) You can start by printing some of our test objects bundled on the included USB stick - you can check them out Printables. Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 74 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 Single-Tool to Dual-Head Upgrade...
Page 75 Manual changelog (Single-Tool to Dual-Head Upgrade) Original Prusa XL Single-Tool to Dual-Head Upgrade...
Page 76 Manual changelog (Single-Tool to Dual-Head Upgrade) STEP 1 Version history Versions of the Original Prusa XL Single-Tool to Dual-head upgrade manual: 01/2024 - Initial version 1.00 05/2024 - Updated to version 1.01 STEP 2 Changes to the manual (1) 05/2024 Added information about the new gray nozzle seal.
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