The extruder aluminum block is one of the most important parts of the extruder as it holds the hotend which melts the materials and provides the proper temperature of the material during the whole printing process. However, if you encounter problems with material loading but the hotend and the nozzle are not clogged, you should inspect the extruder aluminum block. Sometimes it is possible that the material gets blocked within the material duct inside the extruder block. If the duct cannot be unblocked mechanically, for example, with a needle or an Allen key, replace the extruder aluminum block. This manual shows the correct replacement procedure.
M Series Printers Servicing
The Zortrax M Series includes two printer models right now: the M200 and the M300. These printers are similar in terms of design and technology. The most important difference is their size: the M200 has a 200x200x180mm workspace, whereas M300 has an increased 300x300x300mm workspace.
Therefore, maintenance and repair work can be carried out in the same manner with both models. The following manual shows M200 repair work. For the M300, these procedures look 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.
Unplugging the Extruder Cable
Unplug the extruder cable.
Extruder Upper Printed Cover Removal
Detach the extruder upper printed cover from the extruder.
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.
Unscrewing the Axis Block Covers, part 2
Unscrew the other screw that secures the axis block cover on each block.
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.
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.
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.
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.
Securing the Axis Block Covers, part 2
Tighten the other screws on each axis block.
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.
Extruder Aluminum Cover Assembly
Reattach the extruder aluminum cover to the extruder and secure it with the screws.
Extruder Lower Printed Cover Assembly
Attach the extruder lower printed cover to the extruder.
Extruder PCB Assembly
Place the extruder PCB in its place and secure it with the two screws.
Plugging all Cables into the Extruder PCB
Plug all the cables in. Remember to arrange the cables so that they don’t get damaged, e.g. by wrapping against each other.
Extruder Upper Printed Cover Assembly
Attach the extruder upper printed cover to the lower cover.
Plugging the Extruder Cable
Plug the extruder cable in.
Plugging the Power Cable
Plug the power cable in.