Project Dashboard LulzBot Mini 2 Z-Axis Left Assembly Workflow

1 Gather Components

Materials required for AS-PR0099:
1x- [DC-LB0154] Caution Hot Sticker
1x- [EL-HR0130] Mini X Extruder Harnesses Assembly - Rev IR
2x- [EL-MT0029] NEMA 17 Stepper Motor, Moons
1x- [EL-SW0022] SWITCH BASIC SPDT 3A .110QC 125V
1x- [HD-BL0033] Timing belt, 372 teeth
2x- [HD-BT0012] M3 Set Screw
4x- [HD-BT0039] M3x12 SHCS
4x- [HD-BT0107] M2x10 SHCS
4x- [HD-BT0128] M3x6 FHCS
4x- [HD-BT0146] M3x12 BHCS
2x- [HD-MS0033] GT2, 16 Teeth, timing pulley
4x- [HD-MS0058] Wire Tie, 8" Black
4x- [HD-MS0230] M2x6 SHCS
2x- [HD-RD0035] 8mm Smooth rod, 315mm
8x- [HD-WA0012] M2 Washer
8x- [HD-WA0038] M3 Washer
1x- [PP-GP0130] X-End Motor Assembly, Mini 2
1x- [PP-GP0309] Z-Upper Left Assembly, Mini 2
1x- [PP-GP0307] Belt Tensioning Collar
2x- [PP-GP0308] Z Belt Clamp
1x- [PP-GP0332] Bump Stop
1x- [PP-GP0310] Z-Lower Left, Mini 2

Materials required for AS-PR0099

2 Z Left Motor and Z Lower Assembly

Attach a Pulley [HD-MS0033] to a Motor [EL-MT0029] offset the pulley from the face of the motor 13mm. Use the printed jig to ensure consistency. Verify that the flat portion of the motor shaft lines up with the flat portion of the jig.

Ensure one of the pulley set screws is aligned with the flat segment of the motor shaft, secure pulley in place with the two set screws already installed in the pulley, tighten to 3 in*lbs.

Align the Z-Motor with the Z-Lower Left (orientation is critical) the motor connector is to be facing toward the right of the Z lower left part.

Attach the motor to the Z lower left using 4x- M3x12 BHCS [HD-BT0146] with 4x- M3 washers [HD-WA0038] , tighten screws to 5 in*lbs.

Tighten first set screw on flat portion of motor shaft
Tighten both set screws to 3 in*lbs
Align Z-Left Motor with Z-Lower Left Note: orientation is critical; take note of motor connector's position
Secure Z-Lower Left to Z-Left Motor

3 Attach Bump Stop and Z-Belt

Align and install the Bump Stop [PP-GP0332] with the mount located in the middle of the X-End Motor assembly [PP-GP0130] as pictured. The Bump Stop should be oriented with the flat side facing away from the belt path. Secure the Bump Stop with 2x- M2x10 SHCS [HD-BT0107] with M2 washers [HD-WA0012], tighten screws until the Bump Stop no longer moves freely.

Cut a belt [HD-BL0033] straight with the the teeth of the belt and insert one end into the top slot of the BLANK. [reference#1] then continue pushing the belt until the end come out of the front slot.

Once the belt is routed through the top and front slot on BLANK slide the Belt Tensioning Collar [PP-GP0107] over the belt.
Make sure to pinch the two sides of the belt together to lock the teeth and prevent slipping
See attached picture [reference#2]

Place 2x M3 Nyloc Nuts in the two hex holes on the X-End Motor assembly

Then Using 2x SHCS M3x30 [HD-BT0042] with 2x M3 Washers [HD-WA0038] attach the BLANK to the X-End Motor assembly. [reference#3]
Note: Stop once the bolts are fully through the nyloc nuts

Install Bump Stop
Bump Stop Orientation
Cut the belt
[reference#1] Route the belt through the top and front slots on BLANK
[reference#2] Then slide Z-belt clamp over the belt locking the teeth together
Fold the tail end of the belt through the second hole on the belt tensioner collar
Place the nyloc nuts in the slots on the X-end motor assembly
[reference#3] Attach the BLANK to the X-end motor assembly

4 Attach EL-HR0130 X Extruder Harness

Attach both cable chains to the X-End Motor assembly using 2x M3x6 FHCS [HD-BT0128] for each chain. The three wire segment on the motor side of the X-End Motor assembly and the five wire segment on the bushing side.

Next align and install the Z-Max End Stop switch [EL-SW0022] with the switch mount located above the motor mount. Secure the switch with 2x M2x10 SHCS [HD-BT0107] and M2 washers [HD-WA0012], tighten screws to 3 in*lbs.

The Cable Tie placement guild show where to start the cable tie and where the final position of the head of the cable tie should be. Start by feeding the tail of the cable tie through the circled hole and make sure the head of the cable tie is by the corresponding arrow. The placement order for the cable ties is RED, YELLOW, then GREEN

Follow the RED Circle and Arrow

Using 1x Cable Tie [HD-MS0058] secure the two lower wires. The cable tie head must be by the RED arrow.
Then pass the X-Motor Cable underneath the three extruder harness cables
See attached picture [reference#4]

Then bend the two outside tabs on the Switch and connect the white and yellow wire (Yellow wire goes to the tab by the button on the switch

Follow the YELLOW Circle and Arrow

Using 1x cable tie [HD-MS0058], secure the five wires to the cable mount area nearest the Motor mount. The cable tie head must be by the YELLOW arrow See attached picture [reference#5]
Make sure the X Motor wire is crossed under the other wires

Follow the GREEN Circle and Arrow

Then with a cable tie [HD-MS0058], following the GREEN circle and arrow secure the three wires to the cable mount area above the cable tie securing the two wires. The cable tie head must be by the GREEN arrow See attached picture [reference#6]

[reference#7] Shows where the cable ties head should be located

With a cable tie [HD-MS0058] secure the Z-Max Endstop wires along the edge of the x end motor as pictured. [reference#8]
Be sure the cable tie is under the quick connect terminals on the endstop side and the wire is on the *FRONT of the printed part.

Cut all cable ties flush, assembly should look exactly as pictured.
Note: The X motor cable's heatshrink should be aligned with the back of the X-End Motor assembly as pictured.

Install the three wire segment on the motor side of the X-end motor assembly
Install the five wire segment on the bushing side
Mount the endstop switch
Cable tie placement guild
[reference#4] Wrap a cable tie around the bottom two wires start the cable tie on the backside in the bottom hole
Bend the outer tabs on the switch to roughly 90 degrees then connect the wires
[reference#5] Wrap a cable tie around all five wires make sure the head of the cable ties is on the opposite side of the wires
[reference#6] Wrap cable tie around the top 3 wires and back to the latch through the top hole
[reference#7] Cables tied
Cut all cable ties flush, product should look as pictured below

5 X-Axis motor prep and installation

Attach a pulley [HD-MS0033] to a motor [EL-MT0029] , offset the pulley 6mm from the face of the motor, ensure one of the pulley set screws is aligned with the flat segment of the motor shaft, secure pulley in place with two set screws already installed in the pulley, tighten screws securely.

Bend the terminals of the Z-Max Endstop Switch outward to make space for the X-Motor, as pictured.

Attach the motor (with the connector oriented down toward the bottom of the X-End Motor assembly) to the X-End Motor assembly with 4x- M3x12 SHCS [HD-BT0039] with M3 washers [HD-WA0038], tighten screws in 8 in*lbs.

Remove the lower right phillips head screw from the back of the motor just installed [reference#9], install the screw into the ring terminal from the X Motor cable, re-install the screw until the head is again recessed and tight.

Connect the JST connector to the motor as pictured.

Align first set screw with flat side of motor shaft
Tighten both set screws securely
Bend the EndStop terminals outwards to make room for the X-Axis Motor
Attach X-Motor to X-End Motor printed part
[reference#9] Remove this screw for ground terminal ring install
Place terminal ring on screw and tighten the screw securely in the same hole
Connect the JST connector to the motor

6 X-End Motor to Z-Lower Left & Z-Upper Left Install

Using an 8mm part reaming tool, ream the 8mm smooth rod hole on the Z-Lower printed part [PP-GP0310] that has the M3 insert.

Do NOT ream the slot; this can damage the dowels and the reaming tool, keep the tool straight and to not remove too much material which would result in a loose fitting rod.

Do Not touch the reaming tool to the motor

Install two Smooth Rods [HD-RD0035] into the Z-Lower [PP-GP0310]

Install the X-End Motor assembly (with cables, switches, and motor attached) onto the Z Lower Left and Smooth Rods assembly as pictured.

Using an 8mm part reaming tool, ream the two 8mm smooth rod holes on the Z-Upper Left printed part [PP-GP0309].

Note:Take care to keep the tool straight and to not remove too much material which would result in a loose fitting rod.

Install the Z-Upper Left [PP-GP0309] to the end of the smooth rods opposite the Z-Lower Left assembly as pictured.

Install two M3x6 Set Screws [HD-BT0012] to the Z-Lower Right near the smooth rods, do not tighten.

Ream smooth rod hole with 8mm part reaming tool
Install Smooth Rods to Z-Lower
Install X-End Motor Assembly (with cables, switches, and motor attached)
Install Z-Upper Left
Install set screw, do not tighten
Install set screw in Z-Upper

7 Belt Routing & Upper Clamp install

Route the belt (attached to the X-End Motor assembly during step 3) down around the Z-Left Motor and up through the hole in the X-End Motor printed part (behind the X-Min Bump Stop).
Continue through the bearing in the Z-Upper so that the belt makes a loop back to the X-End Motor printed part.

Ensure the belt has not been twisted during this process.

Slide one Belt Tensioning Collar [PP-GP0307] onto the belt with the narrow end of the collar facing the Z-Upper.

Slip the belt through the upper slot in the Z-Belt clamp feature, see [reference#10]

The belt should be left loose at this time, secure it in place with one Z-Belt Clamp [PP-GP0308] and two M2x6 SHCS [HD-MS0230] with M2 washers [HD-WA0012]
See attached picture [reference#11]

Route around Z-Left Motor pulley and up through printed part (behind the bump stop circled)
Continue through Z-Upper
Install Belt Tensioning Collar
[reference#10] Slide the belt through the highlighted slot
Belt through slot in [reference#10]
[reference#11] Z-Belt secured with Z-Belt Clamp & two M2x6 SHCS w/ washers

8 Apply Caution Label

Apply 1x- [DC-LB0154] Caution Hot Sticker to the rear of the X-Motor as shown

Caution Hot Label Applied

9 Checklist

Look over the Mini 2 Z-Axis Left Assembly Checklist and make sure every step was followed.

Checklist for the Z-Axis Left Assembly
Done! Take me home