Open Hardware
Assembly Instructions

Obtain a completed Frame Assembly [AS-PR0165]

Place the completed frame on the granite block and verify that it sits flat and and doesn’t teeter, like a chair with one short leg.

Line up the square along both ends, perpendicular to the length of the frame, as pictured.
Examine the relationship between frame and square. If at any point the gap meets or exceeds 2mm, the frame must be rejected for re-squaring.

If the frame has passed inspection, place it on your workbench with the back of the machine facing you.

Push the axis to the middle of travel (mid-frame) by applying even downward force on the X-Ends.
Rotate the frame so the back is facing you.
Orient the X Carriage Assembly [AS-PR0166] upright as pictured.
Straighten the X Axis drive belt attached to the X Carriage Assembly and route the end through the X-Idler End, beginning above the bearings with the teeth of the belt facing down.
Ensure there are no twists in the belt
Continue routing the X Axis drive belt back through the X-Carriage Assembly below the tensioner and behind the Interface Board Mount.

Route the drive belt around the X Motor pulley, beginning from below the pulley with teeth facing up.

Route the belt through the clamp feature of the X-Carriage as pictured.
Place one X Belt Clamp w/ Insert [PP-GP0380] into the feature as pictured and thread one M3x16 SHCS [HD-BT0185] with washer [HD-WA0038] into the insert from above.
Using a pair of pliers, remove slack from the drive belt by pulling on the end.
Do not tension the belt at this point, only remove the slack
Torque the X-Belt Clamp fastener to 5in*lbs

Raise the axis by hand back to the mid-travel position and rotate so the front of the unit is facing you.

The X-Axis bushings have compression features that allow the printed part to be tightened on the bushings to prevent unwanted motion.
Tighten the lower X-Axis compression bushing by tightening the flat head fastener on the bottom front of the carriage.
Tighten until you can no longer tilt the bushings on the rod, but ensure the bearing can still slide freely left to right.
Do the same for the upper X-Axis compression bushing by tightening the flat head fastener towards the top front of the carriage.

Now we will set the alignment between the upper/lower X Axis bushings.
Push the X-Double Bearing as far to the left as possible in relation to the X-Carriage during the following steps Slide the X Carriage to the left end of travel against the X-Motor End and tighten the left button head fastener on the front of the carriage.
Torque to 5in*lbs
Slide the X Carriage to the right end of travel against the X-Idler End and tighten the right button head fastener on the front of the carriage.
Torque to 5in*lbs

Finally, tighten the bottom rear fastener on the X-Carriage to 5in\lbs

Apply one Caution Hot Sticker [DC-LB0154] to the X-Carraige Cover as pictured.

Pick up and rotate the assembly clockwise 90 degrees, set it down.
Ensure all four feet of the frame and both feet on the bottom of the Control Box are resting flat on the workbench.
The Control Box should neither be too high or too low in relation to the frame assembly. Use the granite block if you are not confident in the flatness of your workbench.
Tighten all four fasteners securing the Control Box Mounts to the frame using a long shank ball-tipped 3mm hex driver. Tighten securely

Obtain two Cable Clips [PP-GP0390]

Place one Cable Clip [PP-GP0390] on the top rear frame extrusion, with the open side facing up, against the frame corner nearest the Control Box Assembly.
Place another Cable Clip [PP-GP0390] on the top rear frame extrusion, with the open side facing up, 150mm from the Cable Clip that was just placed. Use the pictured jig to ensure proper spacing.

Place the Extruder Harness through both Cable Clips.

Attach the Extruder Harness to the X-Carriage as pictured using four Zip Ties [HD-MS0058]
Note position of zip-tie latch
Cut excess zip tie flush with latch

Obtain three Cable Clips [PP-GP0390]
Place one Cable Clip [PP-GP0390] on the bottom rear frame extrusion, open side facing up, mid-way between the left rear bottom frame corner and the left rear Y-Chassis Mount.
Place another Cable Clip [PP-GP0390] on the bottom rear frame extrusion, open side facing up, mid-way between both rear Y-Chassis Mounts.
Place the last Cable Clip [PP-GP0390] on the bottom rear frame extrusion, open side facing up, 20mm from the right side of the right rear Y-Chassis Mount.

Place the Z-Right cable (longest of the 3 exiting near the bottom of the interconnect housing) in all 3 Cable Clips.
Place the Y-Motor cable (mid length of the 3 exiting near the bottom of the interconnect housing) in the first two Cable Clips.

Connect the JST of the X-Harness (2nd harness from the top of the Interconnect Housing) to the X-Motor.
Remove the highlighted fastener, slide the terminal ring onto the fastener, and re-install the fastener into the same position it was removed from, tightening securely.
Connect the 2 purple quick connects to the outer tabs of the switch on the X-Motor End.

Use two zip-ties [HD-MS0058] to secure the X Harness to the bottom of the X-Motor End, as pictured.
Cut excess of zip-ties flush with the latch.

Place the Y-Axis rear spacer (printed jig) on the top rear of the left Y-Axis frame extrusion between the Y-Corner and the Y-Table Mount, as pictured.
Slide the Y-Axis frame forward so that the spacer jig cannot be wiggled back and forth. Tighten the fastener securing the left table mounts to the y-axis frame.
Torque to 5in*lbs

Place the pre-cut Y-Frame square at the location shown.
Move the right Y-Axis frame forward or back slightly until it is square; you should not be able to wiggle the square and there should be no gaps. Tighten the right chassis mount and table mount fasteners.
Torque to 5in*lbs
Double check with the square to ensure proper alignment.

Due to similar appearance, you must first verify that you have the correct extruder to mount.

The Workhorse Edition Tool Head has used two different nozzle types. The hardened steel nozzle and the plated copper nozzle. These can be differentiated by their color.
Hardened steel nozzles will be darker and dull in appearance, see images.

The sticker on the blower shroud should read "HE 0.5mm"

Printers with a serial number earlier than KT-PR0051NA-2705 will have used the hardened steel, and all subsequent printers will have the the plated copper nozzles installed.

The WE Tool Head also includes a black Idler Tube Clamp, verify that it is present and installed correctly.

Move each axis through the entire range of motion while observing where the belt rides in each idler. The belt should not rub on any printed or machined parts.

The position of the Z axis belt in the idlers can be adjusted by use of the 2 set screws in the Z-Top plates behind and in front of the Z belt tension screw. If the belt is riding towards the front, tighten the set screw in front of the Z belt tension screw. If riding towards the rear, tighten the rear set screw.

X belt position can be slightly corrected by tightening one of the X belt tensioner screws tighter than the other and thus securing the belt at an angle; If riding towards the front, tighten the rear tensioner screw further than the front. If riding towards the rear, tighten the front tensioner screw further than the rear.