Project Dashboard Maintenance and Repairs Replacing the LulzBot Mini Hexagon Hot End Workflow

1 Getting Started

WARNING:

At Aleph Objects, Inc. we respect your freedom to modify your LulzBot™ 3D printer. Any modifications or attempted repairs that cause damage are not covered under the Warranty.

Questions? Contact Technical Support by emailing Support@LulzBot.com, or by calling +1-970-377-1111.

2 Required Tools

  • Scissors
  • 1.5mm Driver
  • 2mm Driver
  • 2.5mm Driver
  • 3mm Driver
  • 4mm Driver
  • Dental Pick
  • Zip Ties
  • LulzBot v2 (Hexagon) Hot End
Required Tools

3 Power off your 3D Printer

Power down and unplug your printer.

Power Down

4 Remove Connector Cover

Using your 2.5mm driver, unscrew the two M3 screws that secure the connector cover on the X axis carriage.

Once removed, disconnect the 16 pin connector.

Removing Connector Cover
Disconnect 16 Pin Connector

5 Cut the Zip Ties

Cut the two zip ties holding the hot end harness to the X axis carriage.

Cut the Two Zip Ties

6 Remove Existing Tool Head

Remove the bottom screw first!

The tool head is attached with three screws. The print surface can be damaged if the tool head is allowed to fall onto the print surface.

With one hand, support the tool head.

Using the 4mm driver, unscrew the three M5 screws securing the tool head to the X axis carriage.

Remove the bottom screw first, followed by the remaining two screws.

Screw Locations
Remove Lower Screw First
Remove Upper Screw Second
Remove Final Screw

7 Remove Micro Blower Screw

Using your 1.5mm driver, remove the screw holding the micro blower in place and set the screw aside.

Screw Location

8 Remove Extruder Fan Screws

Using your 2.5mm driver, remove the two screws holding the extruder fan to the fan mount.

Screw Locations
Fan Removed

9 Remove Extruder Fan Mount Screws

Using your 2mm driver, remove the screws holding the fan mount to the tool head mount.

Remove Fan Mount Screws

10 Remove Hot End from Extruder

Using your 3mm driver, remove the two screws holding the hot end from the extruder assembly.

Screw locations
Toolhead Disassembled
Components Separated

11 Remove the New Heater Cartridge Pins

Using the dental pick included with your toolkit, gently push down on the clasp that holds the pin in place. This will allow you to remove the pins.

Release and remove the two large red wires.

The pick is sharp. Be careful.

Replacement LulzBot Hexagon Hot End
Pin Catch Location
Pins Removed

12 Raise Pin Catches

Using your dental pick, gently raise the catch that was depressed in the previous step.

The pick is sharp. Be careful.

Pin Catch Location
Raising Catch

13 Remove Cable Housing

Remove the cable housing for wire routing access.

Remove Cable Housing

14 Remove the Original Heater Cartridge Pins

Using the dental pick included with your toolkit, gently push down on the catch that holds the pin in place. This will allow you to remove the existing pins.

Release and remove the two larger red wires.

The pick is sharp. Be careful.

Release Pin Catch
Both Pins Removed

15 Route Heater Cartridge Wires

The LulzBot Hexagon Hot End comes with standard length wires.

You will be required to wrap the two heater cartridge wires around the existing wiring harness twice to reduce the wire length.

Wrap heater cartridge wires around other wires

16 Insert New Heater Cartridge Pins

Insert the two heater cartridge wire pins into the connector.

Be sure the raised catch latches in the connector.

Reminder: Polarity does not matter.

Insert Pin 1
Insert Pin 2

17 Remove the New Thermistor Pins

Using the dental pick included with your toolkit, gently push down on the catch that holds the pin in place. This will allow you to remove the existing pins.

Release and remove the two smaller wires.

The pick is sharp. Be careful.

Remove New Thermistor Pins
New Thermistor Pins Removed

18 Raise Thermistor Pin Catches

Using your dental pick, gently raise the catches that were depressed in the previous step.

The pick is sharp. Be careful.

Raising Thermistor Pin Catches

19 Release Original Thermistor Pins

Using the dental pick included with your toolkit, gently push down on the catch that holds the pin in place. This will allow you to remove the existing pins.

Release and remove the two smaller wires.

The pick is sharp. Be careful.

Releasing Pin 1
Releasing Pin 2
Thermistor Pins Removed

20 Route Thermistor Wires

The LulzBot Hexagon Hot End comes with standard length wires.

You will be required to wrap the two thermistor wires around the existing wiring harness twice to fit within the harness cover.

Wires Wrapped

21 Insert New Thermistor Pins

Insert the two thermistor wire pins into the connector.

Be sure the raised catch latches in the connector.

Reminder: Polarity does not matter.

Insert Pin 1
Insert Pin 2

22 Remove 5v Leveling Wire and Washer

Unscrew the 5v leveling wire from the side of the hot end heater block using your 2mm driver.

Be sure to save the washer and screw.

Unscrew Leveling Wire from Heater Block
Save the Locking Washer and Screw

23 Install 5v Leveling Wire

Install the 5v leveling wire and washer to the new hot end using your 2mm driver.

Route the wire behind the hot end, angled toward the hot end heat sinks.

Washer Alignment
Tighten the Screw Once Aligned

24 Assemble Tool Head

Install the 3mm screws from the underside of the extruder body with the 2.5mm driver.

Ensure that the Hexagon text is facing forward, with the thick red wires coming out of the right hand side of the block.

Alignmnet
Screw 1
Screw 2

25 Route Wires

Route all wires towards the back of the tool head to allow room for the extruder fan mount.

Keep the micro blower wires towards the front.

Route Wires

26 Install Extruder Fan Mount

Using your your 2mm driver, install the extruder fan mount to the side of the extruder.

Make sure that the wires are routed to the back.

Install Extruder Fan Mount

27 Install Extruder Fan

Use your 2.5mm driver and two M3 screws, secure the fan to the fan mount.

Installing Fan

28 Install Micro Blower

Use your 1.5mm driver to install the micro blower back onto the tool head.

Install Micro Blower

29 Replace Cable Housing

Replace the cable housing around the wiring harness and secure it using a zip tie.

Install Cable Housing

30 Tool Head Assembled

Your tool head should match the image.

Assembled Tool Head

31 Re-Mount Tool Head

Press the repaired toolhead onto the X axis carriage, aligning the tab with the cutout on the back of the new tool head.

Secure it to the X axis carriage by loosely screwing in the top two screws. Leave the top two screws loose.

Install the last screw into the bottom of the X axis carriage and fully tighten.

Tighten the top two screws.

Keep These Screws Loose Until Last
Tighten This Screw First

32 Plug In 16pin Harness Connector

Plug in the two 16 pin connectors, making sure to match them based on the pins in the connector.

Verify the connectors are appropriately aligned before proceeding

Connector Alignment

33 Mount Connector Cover

Cover the connector with the cover and attach it to the X axis carriage using two M3 screws and the 2.5 mm driver.

Ensure the wires are routed through the gap in the cover.

Install Wire Cover

34 Secure Wire Harness

  • Using two zip ties, secure the cabling harness to the extruder mount.
Securing Wire Harness

35 You're Done!

Verify everything is working properly:

  • Does your micro blower turn on when your 3D printer is powered on?

  • Do you get any errors when connecting through Cura?

  • Print your favorite test object to verify functionality.

  • Be sure to watch the bed probing sequence, to ensure everything is hooked up properly.

Questions? Contact Technical Support by emailing Support@LulzBot.com, or by calling 1-970-377-1111.

Replacement Complete
Done! Take me home