OHAI: Open Hardware Assembly Instructions

1 Getting Started

The LulzBot TAZ SideKick Filament Runout Sensor will catch the moment your print runs out of filament during a 3D print. This option will stop your print automatically until you can return to add more filament.

We recommend removing the Y-Axis to provide better accessibility during the installation, however you are able to install the Filament Runout Sensor with the Y-Axis installed. You may need to move the bed plate around in order to route the sensor wire through the printer.

The items required for the installation of the TAZ SideKick Filament Runout Sensor:

SideKick Filament Runout Sensor
8" Wire Tie
2X LCD Cable Clips
2.5mm Hex Wrench
Side Cutters or Scissors
Small Pliers (Tweezers can be used but it may be difficult)

Required items

2 Remove Feed Tube Holder

Before starting, power off and unplug your TAZ SideKick.

Now start by sliding the feed tube holder to the end of the feed tube holder mount.

Then pinch the middle of the mount so that there is little to no gap at the end of the mount.

Now twist the feed tube holder so that the top side slides over the top tab on the feed tube holder mount, then you are able to completely slide the feed tube holder off of the feed tube holder mount.

Using the slide cutters or scissors, cut the cable tie that is holding the feed tube in place. We will be using the feed tube for the filament runout sensor.

Then slide the feed tube inside the filament sensor and secure using the 8" cable tie provided in the SideKick Filament Runout Sensor kit.

While pinching the mount together twist and slide the feed tube holder off

Use slide cutters or scissors to remove cable tie

Remove the feed tube from the feed tube holder

Slide feed tube inside filament runout sensor and secure with the provided cable tie

3 Attach Runout Sensor to Frame

Take the runout sensor and slide it onto the feed tube holder mount making sure the feed tube is on the top side.

Then press the wire into the extrusion, then check by the runout sensor to make sure the wire is not pinched by the plastic.

Now secure the wire to the extrusion with the provided LCD Cable Clips.

Slide the runout sensor onto the feed tube holder mount, make sure feed tube is on top

Press the wire into the extrusion and check wire for any pinching

Start by pressing on one side of the LCD cable clip to the extrusion

Continue to press on the LCD cable clip until the other side snap into place

Repeat for the second LCD cable clip

4 Route Sensor Wires through Printer

Take the wire connector and feed it in between the extrusion and the left Z axis motor.

Then route the wire under the wire harness that goes into the power supply as shown in Reference#1, you may need to move the LZ motor harness around in order to route the runout sensor wire under the power supply harness.

The TAZ SideKick 747 printer will have a larger gap then the TAZ SideKick 289 printer.

Now take the wire and slide it between the Y-Axis frame mount and the power plug housing, making sure the wire is secured by the power supply harness and is tucked away from any moving component.

Remove the Y and LZ motor harnesses from the cable clips and then place the runout sensor wire inside the cable clips.

Once the runout sensor wire is secured in the cable clips place the LZ motor harness back in the cable clips, followed by the Y motor harness.

Route the runout sensor wire between the LZ motor and the extrusion

Reference#1 Gently pull up on the LZ motor harness so that you can slide the runout sensor wire under the power supply harness

Slide the runout sensor wire between the Y-Axis frame mount and the power plug housing

Remove the Y motor harness from the cable clips

Remove the LZ motor harness from the cable clips

Place the runout sensor wires inside both cable clips

Replace the LZ motor harness inside both cable clips

Replace the Y motor harness inside the first cable clip

5 Connect Sensor Wires to the Control Board

Use the 2.5mm hex driver and remove the two bolts that are holding the control box cover in place, keep track of these two bolts because you will need them to close the box.

Using a small pliers or tweezers gently twist up on the breakaway tab on the control box. Make sure to GENTLY twist to prevent breaking off more of the wall

Then push the extruder harness into the board so you are able to connect the runout sensor wire to the board.

Now take the connector at the end of the runout sensor wire and have the mostly flat side face the control box fans then connect the wire to the top right port.

Use the 2.5mm hex driver to replace the two bolts that close the control box.

Using the 2.5mm hex driver remove the top bolt on the control box cover

Repeat for the bottom bolt set both bolts off to the side because they are needed later on

Locate the break away tab on the control box near the square grommet

Using a small pliers, gently twist up on the tab to break it off

Make sure the whole tab snapped off, if there is a sharp edge left, gently remove with pliers

Push the extruder harness into the control box so that you are able to move it around inside the box

Gently push the extruder harness out of the way so you can see the top right wire port

Making sure the mostly flat side of the runout sensor wire is facing the control box fans, connect the runout sensor to the board

Make sure the runout sensor wire is seated where the tab was removed.

Then shut the control box cover and secure the cover to the box using the 2.5mm hex driver

Secure the top side of the cover using the 2.5mm hex driver

Verify that the runout sensor wire is not pinched by the cover

6 Finishing Up