Open Hardware
Assembly Instructions

By purchasing a LulzBot TAZ Dual Extruder v3 Tool Head, you're ready to begin combining colors and textures with support material for unique prints that are sure to turn heads. Follow the steps below to install your LulzBot TAZ Dual Extruder v3 Tool Head on your TAZ 5 and explore the possibilities of printing with full geometric freedom.

Note: Be sure you are using the correct OHAI guide! The Dual Extruder v3 installation guide for TAZ 6 users can be found here

You will also need

• Metric hex drivers: 4 mm, 3 mm, 2.5 mm included with your LulzBot TAZ toolkit
• LulzBot TAZ Desktop 3D Printer
• USB cable, included with your LulzBot TAZ
• GNU/Linux, Mac OS X, or Windows-based computer
• Scissors or wire cutters for cutting zip ties
• 4x TAZ 5 low profile bed corners (print yourself)

5A
Completely power off your LulzBot 3D Printer and unplug the power supply before proceeding.

7A
Using a 2.5 mm hex driver and the screws removed in the previous step, replace the bed corner fingers with the 3D printed lower profile bed corner fingers.

The recessed side of the bed fingers should be facing up.

9A
Unscrew the cap on the second port on top of the electronics box on your LulzBot TAZ 5 3D Printer, then plug in the secondary extruder harness into the uncapped port.

9B
Route the new harness next to existing one on your printer, using wire ties to secure it in the same spots.

9C
Use a zip tie to secure the new secondary extruder harness into the empty harness holder on the top-left side of the x-carriage.

Note: Correct functionality can be tested by giving a command to Extruder 1 in Cura, and then watching to be sure Extruder 1 executes the command on the printer.

8A Use a 2.5 mm hex key to remove the screw in the bottom right of the tool head mount, as shown in image.

Note: Tool head mount does not need to be removed from the X-axis carriage, and is shown separately in the image for clarity.

8B Use a 2.5 mm hex key to replace screw with the M3x12 BHCS included with your V3 Dual tool head.

12A
Remove the protective foam from harness.

12B
Connect the primary extruder harness (existing harness) to the right-hand (E2) connection on tool head, taking care to note polarity. Make sure to match connections based on the the pins in the connectors.

Note: Older models may have guide pins in the extruder harness for connecting with a standard tool head. If the pins are not aligning correctly with the Dual Extruder v3 connections, as shown in image, one of the pins may need to be removed. Refer to this Molex Pin Replacement guide, steps 3 and 4, for instructions on removing pins.

12C
Connect the secondary extruder harness (new harness) to the left-hand (E1) connection on tool head, taking care to note polarity. Make sure to match connections based on the the pins in the connectors.

12D
Make sure the connectors are not against any moving parts and tuck into X-axis carriage notches. Verify the connectors are appropriately connected before proceeding.

14A
Select Settings dropdown > Printer > Add Printer.

14B
Select LulzBot TAZ 5 DualExtruder V3 and click Finish.

16A
To prevent damage to your 3D printer, power it off immediately if the tool head looks like it is on a course to lower into the print surface before triggering the Z end stop.

If the tool head looks like it will prematurely trigger the Z end stop too high above the print bed, adjust the thumb screw lower and restart this process.

The spring and washer can be removed if needed to achieve the proper Z height.

18A
In the top of the Cura LE window, click the Print Monitor tab, as shown in the image. Steps 18 and 19 are implemented through this tab's settings.

20A
Confirm Extruder 1 is selected in the Select extruder drop down menu, as shown in the image.

20B
Insert temperature as 205°C.

20C
Select Heat Extruder.

20D
Select Extruder 2.

20E
Insert temperature as 220°C.

20F
Select Heat extruder.

Note: If you scroll down, another option is available to assign to temperature values to each extruder, as shown in image. Enter in the same value for each each extruder as shown above, then select Heat extruder.

22A
To prevent the filament from stripping, it's important to calibrate both of the idlers before loading in the new filament.

22B
Locate the printed idler jig included with your LulzBot TAZ Dual Extruder v3 Tool Head.
Note: Idler jig is colored black in the kit, but is shown here in green for clarity and ease of visibility.

22C
Insert printed idler jig next to an idler, as shown in the image.

22D
Adjust each idler onto the printed jig one at a time. They should be tightened until the black head of the idler makes contact with the jig. Do not overtighten. The printed jig should be able to slide out easily.

24A
Clip end of filament with scissors to form a slanted point. This will improve the insertion effectiveness of the filament as it reaches the channel.

24B
Load Polylite PLA in Extruder 1 (left), and PolyDissolve S1 in Extruder 2 (right). Slightly pull back on the idler arm and insert the filament from a 45° angle.

24C
Once the filament stops, you may need to wiggle the filament until it slides in farther.

24D
Rotate the gears by hand to help pull the filament into the tool head. Clockwise for Extruder 1, counterclockwise for Extruder 2.

Note: If you're still experiencing difficulty loading the filament, slightly loosen the idler tension by half-turn increments to allow for more space on the filament path. It's possible for the filament to emerge from the back of the extruder during loading, simply remove and try loading again. Make sure the filament end is clipped at an angle to reach the channel.

24E
Purge factory filament by continuing to rotate gears by hand for both extruders, until extrusion transitions into the sample filament. Clockwise for Extruder 1, counterclockwise for Extruder 2.

26A
Wait until bed cools to recommended part removal temperature.

26B
Use blue handle knife to lift print off of bed.

You've now finished installation and are ready to explore new territories of 3D printing with your Dual Extruder v3!