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Extruder Aluminum Block Replacement

The extruder aluminum block is one of the main parts of the extruder. It holds most of the components which are necessary for the printing process, including the hotend, extruder motor, or fans. It is sometimes possible that the material gets blocked within the material duct inside the extruder aluminum block. If you encounter problems during material loading or extrusion, at first you should check whether the hotend or nozzle are not clogged. If problems still exist, inspect the extruder block. Remove material residues that have accumulated in the duct with a needle or an Allen key. If the duct cannot be unblocked mechanically, replace the extruder aluminum block. This manual shows the correct replacement procedure.

The following manual shows the M200 repair work. For the M300, these procedures are the same.

Unloading the Material

From the menu choose “Material” and then “Unload the material” option. The extruder should start to heat up automatically. Once the extruder is hot, the motor will start to unload the material.

Unplugging the Power Cable

Turn off the printer and unplug the power cable.

Material Guide Removal

Detach the material guide from the extruder cover. Next, separate the guide from the extruder cable.

Unplugging the Extruder Cable

Detach the extruder upper printed cover and unplug the extruder cable.

Unplugging all Cables from the Extruder PCB

Unplug all the cables from the extruder PCB.

Unscrewing the Extruder PCB

Unscrew the two screws that secure the extruder PCB using a 2mm Allen key. Remove the PCB from the extruder.

Extruder Lower Printed Cover Removal

Remove the extruder lower printed cover.

Extruder Aluminum Cover Removal

Unscrew the screws that secure the extruder aluminum cover on both sides of the extruder. Separate the cover from the extruder motor.

Extruder Motor Removal

Unscrew the four screws that secure the extruder motor. Separate the motor from the extruder block.

Unscrewing the Axis Block Covers, part 1

Unscrew one of the screws that secures the axis block cover on each block.

The axis blocks in the M300 look different than in the M200 but they can be unscrewed in the same way.

Unscrewing the Axis Block Covers, part 2

Unscrew the other screw that secures the axis block cover on each block.

Extruder Removal

Remove the extruder along with its guide rails.

Extruder Guide Rails Removal

Loosen the two screws on the axis block cover and separate the cover from the extruder guide rail. Next, remove the rail from the extruder.

Loosen the two screws placed under the other axis block cover and separate the cover from the extruder guide rail. Remove the rail from the extruder.

Hotend Removal

Unscrew the two screws that secure the hotend in the extruder. Remove the hotend from the extruder and remove the heater, thermocouple and fans cables from the extruder block.

Extruder Lower Fan Removal

Unscrew the three screws that secure the extruder lower fan, separate the fan from the heat sink and remove the distance piece.

Extruder Upper Fan Removal

Unscrew the four screws that secure the heat sink with the extruder upper fan. Separate the heat sink from the extruder block.

Extruder Bearing Removal

Unscrew one screw that secures the extruder bearing. Remove the bearing using tweezers.

Extruder Linear Bearings Removal

Loosen the two screws that secure the extruder linear bearing and remove the bearing from the extruder aluminum block.

Remove the remaining bearings likewise. There are four linear bearings altogether.

Extruder Bearing Assembly

Insert the extruder bearing into the new extruder aluminum block and secure it with the screw.

Extruder Upper Fan Assembly

Join the extruder aluminum block with the extruder upper fan heat sink and tighten the four screws.

Extruder Lower Fan Assembly

Place the extruder lower fan in its place and tighten the three screws. Remember to place the distance piece.

Hotend Assembly

Insert the hotend into the extruder and tighten the two screws.

Extruder Linear Bearings Assembly

Insert the extruder linear bearing into the extruder and secure it with the two screws.

Install the remaining bearings likewise. There are four linear bearings altogether.

Extruder Guide Rails Assembly

Insert the extruder guide rails into the extruder and place the axis block covers on both rails. Be careful not to damage the linear bearings – insert the guide rails at a straight angle.

Do not tighten the screws on the axis block covers yet.

Extruder Installation

Install the extruder with its guide rails in the printer.

Securing the Axis Block Covers, part 1

Tighten the screws that secure the axis block cover on each block.

Do not tighten the screws fully yet. They need to be tightened once the assembly is finished.

Securing the Axis Block Covers, part 2

Tighten the other screws on each axis block.

Do not tighten the screws fully yet. They need to be tightened once the assembly is finished.

Tightening the Screws on the Axis Block Covers, part 1

Finish tightening the screws on the axis block covers.

Tightening the Screws on the Axis Block Cover, part 2

Secure the axis block covers to the extruder guide rails by tightening the screws shown in the video.

Extruder Motor Assembly

Reattach the extruder motor to the extruder block and secure the motor with the screws. Press the motor to the right side so that the bearing rack is as close as possible to the bearing. Tighten the screws crosswise in the following order: 1-4, 2-3.