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Prusa Research Original Prusa XL Enclosure Manual

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  • Page 1: Table Of Contents

    Table of Contents 1. Introduction ........................................Step 1 - Preparing the Enclosure kit ..................Step 2 - Printer compatibility ..............Step 3 - Tools necessary for this guide ............... Step 4 - Front, left, right and rear side ..............Step 5 - CAUTION: Lubricant Handling ..............
  • Page 2 ................Step 35 - LED strip cable securing ................ Step 36 - Enclosure cables securing ............Step 37 - Door frame top: parts preparation ............... Step 38 - Door frame top orientation ................Step 39 - Door frame top assembly ..........
  • Page 3 ............Step 26 - Fixing bracket front right securing ............... Step 27 - Fixing bracket rear left securing ................Step 28 - Connection box securing ............Step 29 - Fixing bracket rear right securing ............Step 30 - Removing the rear Wi-Fi antenna ....................
  • Page 4 ..............Step 17 - Idler attaching: three screws ................. Step 18 - Idler-swivel attaching .................. Step 19 - Fan shroud removing ..............Step 20 - Fan shroud: parts preparation ................... Step 21 - Fan shroud securing ..................Step 22 - Nextruder docking .................
  • Page 5 ....................Step 1 - Version history...

  • Page 7: Introduction

    1. Introduction Original Prusa XL Enclosure...

  • Page 8: Step 1 Preparing The Enclosure Kit

    STEP 1 Preparing the Enclosure kit Welcome to the manual on how to assembly the Original Prusa XL Enclosure. Please prepare the Original XL Enclosure 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 9: Step 3 Tools Necessary For This Guide

    Left side - identifiable by the safety sticker positioned along its edge. Right side - in contrast to the left side, lacks a safety sticker. Rear side - the remaining section housing the PSU (Power Supply Unit). Original Prusa XL Enclosure...

  • Page 10: Step 5 Caution: Lubricant Handling

    Lubricant accumulates in the printer's bearings, mainly in the linear rail channels. STEP 6 Manipulating with the printer Never manipulate the printer by using the spoolholders or the upper metal flanges. You can damage the LED lights hidden inside. When assembling, handle the base using the extrusions. Original Prusa XL Enclosure...

  • Page 11: Step 7 Manipulating With The Enclosure

    For the most common screws and nuts you can also use the enclosed letter, which contains Prusa Cheatsheet on the other side. You can download it from our site help.prusa3d.com/cheatsheet. Print it at 100 %, don't rescale it, otherwise, it won't work. Original Prusa XL Enclosure...

  • Page 12: Step 9 View High Resolution Images

    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 prusa3d.com Writing an email to info@prusa3d.com Original Prusa XL Enclosure...

  • Page 13: Step 11 - Prepare Your Desk

    Leave the Z-axis at least 10cm above the bottom panel. 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. Original Prusa XL Enclosure...

  • Page 14: Step 13 Printer Unpluging

    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. Original Prusa XL Enclosure...

  • Page 15: Enclosure Assembly

    2. Enclosure assembly Original Prusa XL Enclosure...

  • Page 16: Step 1 Tools Necessary For This Chapter

    STEP 1 Tools necessary for this chapter For this chapter, please prepare: 2.5mm Allen key STEP 2 Left frame: parts preparation For the next steps, please prepare: Frame left (1x) Side panel (1x) Nylon rivet (16x) Original Prusa XL Enclosure...

  • Page 17: Step 3 Left Panel Installing

    Align the hole in the side frame and the hole in the side panel. Insert the rivet through both the side frame and the panel. Push on the nylon rivet to secure the back panel in the frame. Original Prusa XL Enclosure...

  • Page 18: Step 5 Left Panel Securing

    Double check that all the nylon rivets are fully inserted and secured in the holes. From the inside. From the outside. STEP 6 Right frame: parts preparation For the next steps, please prepare: Frame right (1x) Side panel (1x) Nylon rivet (16x) Original Prusa XL Enclosure...

  • Page 19: Step 7 Right Panel Installing

    Insert the nylon rivet from the outside through the right frame and side panel. Secure the side panel with remaining 15 nylon rivets. Double check that all the nylon rivets are fully inserted and secured in the holes. View from the inside. View from the outside. Original Prusa XL Enclosure...

  • Page 20: Step 9 Magnetic Bumpers: Parts Preparation

    From the inside of the side frame, insert the M4x16r screw into the threaded hole and tighten fully. Slide the protective bumper onto the screw from the outside of the side frame. Insert the magnetic bumper onto the screw and tighten it. Original Prusa XL Enclosure...

  • Page 21: Step 12 Back Frame: Parts Preparation

    Put the left frame next to the back panel. Fit the perforation of the left frame into the cut-out on the back panel, and slide both pieces together as illustrated in the image to secure them. Original Prusa XL Enclosure...

  • Page 22: Step 14 Left Frame Securing

    Put the right frame next to the back panel. Fit the perforation of the right frame into the cut-out on the back panel, and slide both pieces together as illustrated in the image to secure them. Original Prusa XL Enclosure...

  • Page 23: Step 16 Right Frame Securing

    Carefully turn the assembly and secure the panels with three M4x5r screws from the back side of the panels using a 2.5mm Allen key. STEP 17 Frame support: parts preparation For the next steps, please prepare: Frame support (1x) M4x5r screw (6x) Original Prusa XL Enclosure...

  • Page 24: Step 18 Frame Support Securing

    Secure the left side with three M4x5r screws using a 2.5mm Allen key. Secure the right side with three M4x5r screws using a 2.5mm Allen key. STEP 19 Top panel: parts preparation For the next steps, please prepare: Top panel (1x) Nylon rivet (13x) Original Prusa XL Enclosure...

  • Page 25: Step 20 Top Panel Installing

    Place the top panel, so the top edge is under the top frame of the back panel. STEP 21 Top panel securing While holding the top panel, insert the nylon rivets from the outside through the holes to secure the top panel in its position. Original Prusa XL Enclosure...

  • Page 26: Step 22 Filter And Fan Holder: Parts Preparation

    M4x12b screw (2x) Zip-tie (1x) STEP 23 Filter and fan holder assembly Place the fan holder with metal cutouts towards you. Place the blower onto the filter-and-fan-holder. Secure the blower with two M4x12b using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 27: Step 24 Filter And Fan Holder Installing

    Insert the whole blower cable through the hole in the back panel. Take the zip-tie and insert it through the metal cut-out in the filter and fan holder. Secure the blower cable with the zip-tie. Do not overtighten the zip-tie! Cut the end of the zip-tie. Original Prusa XL Enclosure...

  • Page 28: Step 26 Hepa Filter: Parts Preparation

    Insert the HEPA filter between the fan holder and the back panel, ensuring that the darker side of the filter (the side without the company text) is facing towards you. Push the HEPA filter all the way in. Original Prusa XL Enclosure...

  • Page 29: Step 28 Filtration Cover: Parts Preparations

    Filtration cover (1x) M4x5r screw (4x) Zip-tie (2x) STEP 29 Filtration cover installing Attach the filtration cover to the fan holder assembly. Note the logo orientation! Secure the cover with four M4x5r screws using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 30: Step 30 Fan Cable Securing

    From November 2024, you may receive a new LED Stick Board, which can be supplemented with an additional LED strip. For the next steps, please prepare: LED diffuser (1x) LED Stick Board (1x) LED Stick Bracket (3x) M3x18 screw (3x) M3n nut (3x) Original Prusa XL Enclosure...

  • Page 31: Step 32 Led Strip Assembly

    LED strip installing Attach the assembled LED panel on the inner side of the right frame as shown. Secure the LED panel from the outside of the right frame with three M3x18 screws using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 32: Step 34 Led Strip Cable: Parts Preparation

    Insert three zip-ties through the perforations and secure the cable. Do not overtighten the zip-ties. Cut the ends of the zip-ties. Insert five zip-ties through the perforations and secure the cable. Do not overtighten the zip-ties. Cut the ends of the zip-ties. Original Prusa XL Enclosure...

  • Page 33: Step 36 Enclosure Cables Securing

    Insert the ends of the cables through the cut-out in the metal. STEP 37 Door frame top: parts preparation For the next step, please prepare: Front panel (1x) Door frame support (1x) Door frame top (1x) M4x8r screw (5x) Original Prusa XL Enclosure...

  • Page 34: Step 38 Door Frame Top Orientation

    Do not overtighten the screws as this may cause the panel to crack! Secure the support and the top with a M4x8r screw using a 2.5mm Allen key. Secure the support and the top with remaining M4x8r screws using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 35: Step 40 Door Frame Left & Right: Parts Preparation

    M4x8r screw (12x) STEP 41 Nut cover assembly Prepare one M4 nut cover. Prepare one M4n nut. Insert the M4n nut into the M4n nut cover. Repeat this process for all remaining M4n nuts and M4n nut covers. Original Prusa XL Enclosure...

  • Page 36: Step 42 Door Frame Right Installing

    Insert the M4x8r screw into the hole. Do not overtighten the screws as this may cause the panel to crack! From the inside of the front panel, insert the M4n nut onto the screw. Secure the screw using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 37: Step 44 Door Frame Right Securing: Long Side

    Door frame left installing Attach the door frame left onto the front panel. Do not overtighten the screws as this may cause the panel to crack! Secure the panel with an M4x8r screw using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 38: Step 46 Door Frame Left Securing: Short Side

    From the inside of the front panel, insert the M4n nut onto the screw. Secure the screw using a 2.5mm Allen key. STEP 47 Door frame left securing: long side Insert four M4x8r screws into the holes and secure them with the M4n nuts using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 39: Step 48 Door Frame Bottom: Parts Preparation

    Attach the door frame bottom onto the front panel. Do not overtighten the screws as this may cause the panel to crack! Insert four M4x8r screws into the frame and secure them with M4 nuts using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 40: Step 51 Right Magnetic Bumper Installing

    Insert the M4x5r screws into the hole. From the bottom side of the front panel, insert the magnetic bumper onto the screw and tighten it. Hint: Use a 2.5mm Allen key for tightening the M4 screw. Original Prusa XL Enclosure...

  • Page 41: Step 52 Left Magnetic Bumper Installing

    Foam seal: parts preparations For the next steps, please prepare: Front door - left seal 1 (1x) Front door - left seal 2 (1x) Front door - right seal 2 (1x) Front door - right seal 1 (1x) Original Prusa XL Enclosure...

  • Page 42: Step 54 Left Foam Seal Installing

    Remove the protective film from the front door right seal 2. Align the flat end with the door frame left edge and apply the front door right seal 2 to the panel. Look at the picture. Original Prusa XL Enclosure...

  • Page 43: Step 56 Hinges: Parts Preparation

    Note the orientation of the screw holes. Secure the hinge with two M4x12b screws using a 2.5mm Allen key. Attach the second hinge on the frontpanel and secure it with two M4x12b screws using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 44: Step 58 Temperature Sensor: Parts Preparation

    2. Enclosure assembly STEP 58 Temperature sensor: parts preparation For the next steps, please prepare: Temperature sensor (1x) STEP 59 Temperature sensor installing Pull out the protective battery foil. Insert the temperature sensor CORRECTLY into the front panel. Original Prusa XL Enclosure...

  • Page 45: Step 60 Opening Cover Attaching

    On the right side of the lid, insert and secure two M4x12b screws using a 2.5mm Allen key. On the left side of the lid, insert and secure two M4x12b screws using a 2.5mm Allen key. Original Prusa XL Enclosure...
  • Page 46 2. Enclosure assembly STEP 62 Good job! Well done! The Enclosure is assembled. Please proceed to the next chapter. Original Prusa XL Enclosure...

  • Page 47: Printer Upgrade

    3. Printer upgrade Original Prusa XL Enclosure...

  • Page 48: Step 1 Tools Necessary For This Chapter

    For this chapter, please prepare: T10 Torx key (screwdriver) 2.5mm Allen key STEP 2 XL base covers removing From the front face of the printer: Pull out the right extrusion cover. Pull out the left extrusion cover. Original Prusa XL Enclosure...

  • Page 49: Step 3 Xl Base Nuts: Parts Preparation

    How to insert the nuts Fit the M3nE nut and push it into the profile in the direction of the pins. Turn the M3nE nut into the profile to secure it. Good job, the nut is secured. Original Prusa XL Enclosure...

  • Page 50: Step 6 Lower Bellows Holder: Parts Preparation

    Insert the nuts approximately as shown in the photo. STEP 6 Lower bellows holder: parts preparation For the next steps, please prepare: Lower bellows holder (1x) Bellows magnet holder (2x) Bellows magnet spacer (2x) Magnets (2x) M3x6 screw (4x) M3x8bT screw (4x) Original Prusa XL Enclosure...

  • Page 51: Step 7 Few Tips Before We Start

    Take bellows magnet spacer and place in on the bellows magnet holder. Insert the bellows magnet spacer with bellows magnet holder under the cutout in the lower bellows holder. Secure the assembly with two M3x8bT using a T10 Torx screwdriver. Original Prusa XL Enclosure...

  • Page 52: Step 9 Left Bellows Magnet Spacer

    Take a magnet and carefully and slowly place it in the left cut-out. The polarity of the magnet is not important. Take a magnet and carefully and slowly place it in the right cut-out. The polarity of the magnet is not important. Original Prusa XL Enclosure...

  • Page 53: Step 11 - Lower Bellows Holder Securing: Left Side

    Allen key. Insert the M3x6 screw into the right rear hole and tighten the screw using a 2.5 mm Allen key. The bellows will be attached to the printer at the end of the assembly manual. Original Prusa XL Enclosure...

  • Page 54: Step 13 Corexy Inserts: Parts Preparation

    STEP 14 CoreXY inserts From the bottom side of the CoreXY: Insert two M3nEs inserts into the left extrusion. Insert two M3nEs inserts into the right extrusion. Insert the nuts approximately as shown in the photo. Original Prusa XL Enclosure...

  • Page 55: Step 15 Upper Magnet Cover: Parts Preparation

    For the next steps, please prepare: Upper magnet cover (2x) Upper magnet holder (2x) Magnets (4x) M3x8bT screw (8x) Lockwasher (4x) STEP 16 Few tips before we start Keep the magnets apart at a sufficient distance. They can break each other! Original Prusa XL Enclosure...

  • Page 56: Step 17 Upper Magnet Cover Assembly

    Carefully and slowly insert the magnets into the cut-out in the upper magnet covers. The polarity of the magnet is not important. There are two magnets on each upper magnet holder. Check that the assembly looks as shown. Original Prusa XL Enclosure...

  • Page 57: Step 19 Upper Magnet Cover Securing: Right Side

    Hint: You can align the M3nEs nuts with the M3 hole in the upper magnet cover using the square holes and an Allen wrench. Insert two M3x8bT screws and secure them with the T10 Torx screwdriver. Original Prusa XL Enclosure...

  • Page 58: Step 21 Connection Box: Parts Preparation

    Connection box assembly Ensure that the longer metal section is facing away from you. Insert the XL Enclosure splitter as shown in the picture (PRUSA logo facing you). Secure the XL Enclosure splitter with two M3x6 screws. Original Prusa XL Enclosure...

  • Page 59: Step 23 Fixing Brackets: Parts Preparation

    Attach the fixing bracket front left onto the metal cover. Ensure the front left fixing bracket is correctly positioned: The fixing bracket front left slips under LED cover lip. This is wrong, please align the fixing bracket front left correctly. Original Prusa XL Enclosure...

  • Page 60: Step 26 Fixing Bracket Front Right Securing

    Ensure the front left fixing bracket is correctly positioned: The fixing bracket front left slips under LED cover lip. This is wrong, please align the fixing bracket front left correctly. Insert the M3x10rT screw and secure it with the T10 Torx screwsdriver. Original Prusa XL Enclosure...

  • Page 61: Step 27 Fixing Bracket Rear Left Securing

    Attach the fixing bracket rear left. Secure the fixing bracket rear left with the M3x10rT screw. STEP 28 Connection box securing Attach the XL enclosure board assembly. Secure the XL enclosure board assembly with two M3x10rT screws. Original Prusa XL Enclosure...

  • Page 62: Step 29 Fixing Bracket Rear Right Securing

    STEP 30 Removing the rear Wi-Fi antenna This step only applies to printers that have the Wi-Fi antenna on the back of the printer. Otherwise, skip to the next step. Unscrew the antenna from the antenna connector. Original Prusa XL Enclosure...

  • Page 63: Step 31 Xl Buddy Box

    This step applies only if your printer has a side antenna. If not, proceed to the next step. 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. Nextruder unpluging Now proceed to the Original Prusa XL Enclosure...

  • Page 64: Step 33 Rear Antenna: Connector Removing

    Single-tool: There is only one cable. By pressing the security latch, remove the DWARF1 cable and proceed to the next step. Dual-Head & Five-Head: There are two cables. By pressing the security latch, remove the DWARF1 and DWARF2 connectors from the board. Original Prusa XL Enclosure...

  • Page 65: Step 35 Back Cover Removing

    Watch out for the cables! On the right side, cut off two zip-ties. Locate the right PE screw on the board. Remove the M3x5 screw and leave the cable there. Do not throw away the screw! Original Prusa XL Enclosure...

  • Page 66: Step 37 Fan & Pe Cable: Parts Preparation

    Attach the PE cable with the M3x5 screw through the free PE cable (which we released in the previous step). Secure both cables using a 2.5mm Allen key. Adjust the cable routing as shown in the picture. Original Prusa XL Enclosure...

  • Page 67: Step 39 Pe Cable Connecting

    Connect the fan cable to the right connector on the FDM XL Enclosure splitter. Adjust the cable routing as shown in the picture. Connect the second end to the FAN1 connector on the XL sandwich board. Original Prusa XL Enclosure...

  • Page 68: Step 41 Installing Led Cable

    Connect the black LED cable to the middle connector on the FDM XL Enclosure splitter. Lead the cable behind the Nextruders cables. Connect the second end to the LED Light 2 connector on the XL sandwich board. Original Prusa XL Enclosure...

  • Page 69: Step 43 Enclosure Cables Securing

    Cut off the end of the cable tie. STEP 44 Securing the cables Insert the zip-tie through the metal cut-out and secure all cables. Do not overtighten the zip-tie. Cut the ends of the zip-ties. Original Prusa XL Enclosure...

  • Page 70: Step 45 Back Cover: Parts Preparation

    Don't pinch any cables! Attach the rear cable management upper to the printer. Double-check the cables, there are a lot of them. Secure the left side with two M3x4rT screws. Secure the right side with two M3x4rT screws. Original Prusa XL Enclosure...

  • Page 71: Step 47 Antenna Cover Attaching

    The next line is only for printers with more than 2 Nextruders. Otherwise go to the next step. Connect the third, fourth and fifth (from the right) Nextruder to the splitter: Third Nextruder. Fourth Nextruder. Fifth Nextruder. XL splitter with connected Nextruders has to look like this. Original Prusa XL Enclosure...

  • Page 72: Step 49 Xl Buddy Box Covering

    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 Enclosure...

  • Page 73: Step 51 Lower Belt Release

    Loosen the M3 screw holding the right CoreXY tensioner, approximately 4 full turns. Do not remove the screw completely. Gently stretch the belt with your finger. If the belt feels loose as shown in the picture, proceed to the next step. Remove the x-carriage-cover. Original Prusa XL Enclosure...

  • Page 74: Step 53 Belt Clamp: Parts Preparation

    Take the new (PCCF) belt-clamp and attach the belts. The belts must touch in the middle. Check that the belt is not twisted! Attach the belt-clamp with the belts to the x-carriage. Check that the belt is not twisted! Original Prusa XL Enclosure...

  • Page 75: Step 55 Lower Belt Securing

    Take the new (PCCF) belt-clamp and attach the belts. The belts must touch in the middle. Check that the belt is not twisted! Attach the belt-clamp with the belts to the x-carriage. Check that the belt is not twisted! Original Prusa XL Enclosure...

  • Page 76: Step 57 Upper Belt Securing

    Make sure that the belts touch each other in the belt clamps. Snap the x-carriage-cover back onto the X-carriage. You must feel a slight "click" to ensure the cover fits on the part. STEP 58 Belt tightening Tighten the belts on both sides, approximately 4 full turns. Original Prusa XL Enclosure...

  • Page 77: Step 59 Belt Tensioning: Video

    We have our own belt tuner. The application determines the belt tension by measuring the frequency of the vibration generated by strumming it. Follow the instructions in the video below to adjust the belt. STEP 60 Bellows: parts preparation: For the next step, please prepare: Bellows (1x) Original Prusa XL Enclosure...

  • Page 78: Step 61 Bellows Installation

    Well done, the printer has been upgraded. Now go to the Nextruder upgrade and select the type of printer you have: Original Prusa XL Single-Tool Nextruder upgrade Original Prusa XL Dual-Head (also for Five-head) Nextruder upgrade Original Prusa XL Enclosure...

  • Page 79: Nextruder Upgrade (Multi-Tool)

    4. Nextruder upgrade (Multi-Tool) Original Prusa XL Enclosure...

  • Page 80: Step 1 Tools Necessary For This Chapter

    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 first Nextruder. Leave the cable hanging. Original Prusa XL Enclosure...

  • Page 81: Step 3 Nextruder Undocking

    Release an M3 screw with a 2.5 mm Allen key. A few turns are enough. Open the cover by swiveling the cover 90 degrees. 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. Original Prusa XL Enclosure...

  • Page 82: Step 5 Pg Case Releasing: Four 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. Original Prusa XL Enclosure...

  • Page 83: Step 7 Idler Releasing

    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. Original Prusa XL Enclosure...

  • Page 84: Step 9 Nextruder Idler: Parts Preparation

    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. Original Prusa XL Enclosure...

  • Page 85: Step 11 - 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. Original Prusa XL Enclosure...

  • Page 86: Step 13 Idler-Swivel: Parts Preparation

    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. Original Prusa XL Enclosure...

  • Page 87: Step 15 Assembling The Idler-Nut

    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. Original Prusa XL Enclosure...

  • Page 88: Step 17 Idler Attaching: Three Screws

    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 cover. Tighten a M3 screw using a 2.5 mm Allen key. Original Prusa XL Enclosure...

  • Page 89: Step 19 Fan Shroud Removing

    T10 Torx screwdriver. Don't throw the screws away! Remove the PETG fan-shroud. Throw it into the bin (trash can). STEP 20 Fan shroud: parts preparation For the next steps, please prepare: PCCF fan shroud (1x) Original Prusa XL Enclosure...

  • Page 90: Step 21 Fan Shroud Securing

    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 22 Nextruder docking Take the Nextruder and place it carefully next to the dock. Carefully dock the Nextruder. Original Prusa XL Enclosure...

  • Page 91: Step 23 Nextruder Connecting

    STEP 24 Good job Well done. The first Nextruder is finished. All of your Nextruders have to be upgraded to the PCCF parts! After the upgrade, proceed to the next chapter. Original Prusa XL Enclosure...

  • Page 92: Nextruder Upgrade (Single-Tool)

    5. Nextruder upgrade (Single-Tool) Original Prusa XL Enclosure...

  • Page 93: Step 1 Tools Necessary For This Chapter

    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. Original Prusa XL Enclosure...

  • Page 94: Step 4 Nextruder Cable Bundle Releasing

    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. Original Prusa XL Enclosure...

  • Page 95: Step 5 Idler-Swivel Releasing

    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. Original Prusa XL Enclosure...

  • Page 96: Step 7 Pg Case Releasing: Three Screws

    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! Original Prusa XL Enclosure...

  • Page 97: Step 9 Idler Disassembly

    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 Original Prusa XL Enclosure...

  • Page 98: Step 11 - Assembling The Extruder Idler

    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! Original Prusa XL Enclosure...

  • Page 99: 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 Original Prusa XL Enclosure...

  • Page 100: Step 15 Assembling The Idler-Swivel

    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. Original Prusa XL Enclosure...

  • Page 101: Step 17 Idler Attaching: Four Screws

    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. Original Prusa XL Enclosure...

  • Page 102: Step 19 Idler-Swivel Attaching

    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. Original Prusa XL Enclosure...

  • Page 103: Step 21 Fan Shroud Removing

    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) Original Prusa XL Enclosure...

  • Page 104: Step 23 Fan Shroud Securing

    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. Original Prusa XL Enclosure...

  • Page 105: Step 25 Nextruder Releasing

    STEP 26 Nextruder detaching Insert and secure two M3x12bT screws using a T10 Torx screwdriver. Snap the x-carriage-cover back onto the X-carriage. You must feel a slight "click" to ensure the cover fits on the part. Original Prusa XL Enclosure...

  • Page 106: Step 27 Good Job

    5. Nextruder upgrade (Single-Tool) STEP 27 Good job Well done. The Nextruder is finished, proceed to the next chapter. Original Prusa XL Enclosure...

  • Page 107: Enclosure Secure

    6. Enclosure secure Original Prusa XL Enclosure...

  • Page 108: Step 1 Tools Necessary For This Chapter

    2.5mm Allen key STEP 2 Enclosure preparing On the assembled Enclosure, open the lid. Grasp the Enclosure on the front where is the support plate. Grasp the Enclosure on the back of where is the filtration cover. Original Prusa XL Enclosure...

  • Page 109: Step 3 Enclosure Attaching

    2. Push the enclosure to the front of the printer. 3. Push the enclosure to the back of the printer. Align the holes for the screws. STEP 4 Enclosure securing: parts preparation For the next steps, please prepare: M4x8r screw (4x) Original Prusa XL Enclosure...

  • Page 110: Step 5 Front Side Securing

    From the rear side of the printer: Secure the left bottom corner with an M4x8r screw to the fixing-bracket-back-right using a 2.5mm Allen key. Secure the left bottom corner with an M4x8r screw to the fixing-bracket-back-left using a 2.5mm Allen key. Original Prusa XL Enclosure...

  • Page 111: Step 7 Enclosure Cables Connecting

    FDM XL Enclosure splitter. STEP 8 Enclosure PE cable: parts preparation For the next steps, please prepare: PE cable (1x) M4x5r screw (1x) Zip-tie (1x) Original Prusa XL Enclosure...

  • Page 112: Step 9 Pe Cable Securing

    Secure the PE cable by tightening the M4x5r screw using a 2.5mm Allen key. Attach the PE faston to the XL Enclosure board cover. STEP 10 Cables securing Secure all cables together with a zip-tie. Do not overtighten the zip- tie. Cut the end of the zip-tie. Original Prusa XL Enclosure...

  • Page 113: Step 11 - Installing The Wi-Fi Antenna: Parts Preparation

    This step is only for the printer, which has a Wi-Fi antenna on the back of the printer. Secure the Wi-Fi antenna to the connector in the middle of the printer and adjust it to point straight upwards for optimal signal strength. Original Prusa XL Enclosure...

  • Page 114: Step 13 Serial Number Sticker: Parts Preparation

    For the next step, please prepare: Serial number sticker (1x) STEP 14 Serial number sticker Peel off a piece of the protective layer from the serial number sticker. Stick the sticker on the lower left rear corner of the XL Enclosure. Original Prusa XL Enclosure...

  • Page 115: Step 15 First Run

    Upgrade to the latest firmware. On the screen, go to Control -> Enclosure and turn it on. Adjust belt tension on your XL STEP 16 Good job! Well done, your Original Prusa XL is now ready to print something great! Original Prusa XL Enclosure...

  • Page 116: Manual Changelog Xl Enclosure Kit

    Manual changelog XL Enclosure kit Original Prusa XL Enclosure...
  • Page 117 Manual changelog XL Enclosure kit STEP 1 Version history Versions of the Original Prusa XL Enclosure manual: 05/2024 - Initial version 1.00...
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