OHAI: Open Hardware Assembly Instructions

1 Gather parts for the final assembly

Components:
- Frame Assembly XZ
- Y axis assembly
- Motor extension -1
- Motor extension -2
- Motor extension -3
- Motor extension -4
- Extruder extension
- X switch extension
- Y switch extension
- Z switch extension
- Heat bed extension
- Strain relief plate
- Strain relief outer
- Corrugated tubing 100mm
- Rubber feet
- Small Zip ties
- M3 x 6 set screw
- M3 x 12 SHCS
- M3 Washer
- Thumb screws
- Heat Bed
Tools:
- 1.5mm Allen Driver
- 2.5mm Allen Driver
- 4mm Allen Driver
- Phillips screw driver
- Flat head screw driver
- Side cutters
- Zip tie gun
- TL-FX0006 Fixture
- TL-FX0018 Fixture
- TL-FX0017 Fixture

1.5mm allen driver

2.5mm Allen Driver

4mm Allen Driver

Phillips head screw driver

Flat head screw driver

Side cutters

Zip tie gun

TL-FX0006 Fixture

TL-FX0018

TL-FX0017

2 Add feet to Frame assembly

Install 4x rubber feet to bottom of frame.
Take note of location, do not cover bottom of vertical extrusion.

Rubber feet shown with Frame

Right side with feet

Left side with feet

All four feet shown

3 Plug in Z left motor

Route Z left motor wire through relief position #5.
Plug into the board in location shown.

Route Z left motor wire through relief #5

Plug motor into RAMBo board in this location

4 Install the Z switch

Install switch as shown and secure with a M3 x 6 set screw.
Route wires through relief #6 and plug in as shown.

Limit switch parts

Install switch into Z motor mount left

Secure with set screw

Route through relief position #6

Plug in as shown

5 Add the Z right motor extension

Connect the Z motor extension to the right Z motor.
Route the extension through relief position #8.
Plug in as shown and put ground lug on post.
Zip tie at the 3 locations indicated while removing slack.

Z motor right extension parts

Plug extension into Motor

Route through relief position #8

Zip tie in 3 places as shown

Plug in where shown

6 Add the X switch and extension

Route switch extension wires though X end motor mount.
Plug switch extension wires onto limit switch.
Secure with set screw.
Plug in X-motor wire.
Zip tie one end of the extension to the motor mount as shown. Zip tie the other end to the plug.
Route wires through relief position # 1
Plug in wires as shown and put ground lug onto post.

Parts

Orientation of limit switch wires

Orientation of limit switch

Tighten set screw

Zip tie through hole in motor mount

Zip tie other end on motor wire

Route through relief position #1

Plug in as shown and put ground lug on post

7 Add the Extruder extension

Fasten end of wires to cutout in print carriage
Route wires on inside of extrusion
Route through strain relief #4
Plug in as shown and put ground lug on post
Zip tie as shown

Parts

Plug in and zip tie to extruder carriage

Feed through relief #4

Plug in as shown

Add first zip tie (around X motor extension also)

Add second zip tie

Add third zip tie

Add fourth zip tie

8 Install the Y axis assembly

Loosen Y table mounts and Y mount chassis to allow for adjustment
Install thumbscrews
Square frame using fixtures
Tighten Y table mounts, Y mount chassis and thumbscrews (Don't over-tighten thumbscrews as they are disassembled for shipping)
Make sure Y axis is sitting flush on frame with no gaps in between extrusions

Y axis

Align Y axis mounts

Install thumb screws

Square frame using fixtures

Y axis is sitting on frame with no gaps

9 Add feet to the Y axis assembly

Install feet onto the bottom of the Y axis.

Parts

Feet on Y end Motor

Feet on Y end Idler

10 Add the Y motor and Switch extension

Route wires though relief #2.
Plug in as shown and put ground lug on post.
Plug in extensions to Y motor and Y switch.
Zip tie at 2 locations shown.
Install M3 nuts on ground posts.

Parts

Route through relief #2

Plug wires into board

Wire routing

Plug together and zip tie

M3 nuts installed on ground posts

11 Add the bed extension

Zip tie to Y plate as shown.
Route wires through frame connector and then through relief #3.
Plug in wires as shown.
Zip tie wires to frame connector as shown.

Parts

Zip tie to Y plate

Route through frame connector and relief #3

Plug bed in

Zip tie wires to frame connector

12 Add the strain relief

Using 3 M3 x 12 bolts and M3 washers install relief shield as shown.

Parts

Bottom of electronics case

Prep relief shield

Installing relief shield

Fully installed

13 Install the LCD extension

Note: The number 2 LCD wire connects to 2 plugs, the number 1 wire connects to just 1 plug.
With the number 2 LCD wire on top, feed both wires through the electronics case and around the back side of the closest extrusion.
Looking from the back of the printer, plug the number 2 wire into the furthest right plug on the back of the LCD. Plug the number 1 wire into the other plug.
Keeping the wires as straight as possible, add 3 zip ties as shown. Leave some slack for the LCD plugs at top of wire.
Connect the wires to the RAMBo in the positions shown. Note: The arrow on each plug indicates the upper left hand pin position.

LCD harness parts

Feed through the case

Gently pull through

Plug in and zip tie as shown

Enough slack for LCD plugs

Plug in as shown

14 Add the power through case assembly

Install the power plug into the electronics case using 4 4-40 x .25 Flat head screws. The single large key slot in the plug should be towards the top of the printer.
Insert the 6 pin power connector into the plug on the top right of the RAMBo board.
Run the power wires from the 6 pin connector through the square hole in the top of the electronics case. Connect the two wires to the 'OFF' side of the power switch.
Run the wires from the power plug through the square hole and connect them to the 'ON' side of the power switch.
Snap the power switch into position on the electronics case. Note: Make sure the 'OFF' position of the switch is towards the front of the printer.
Make sure the switch is in the 'OFF' position.