The extruder is equipped with two fans – upper and lower. The main role of the extruder upper fan is to cool down the extruder, whereas the extruder lower fan cools down each layer of the print. Therefore, if your model warps, melts or you can notice burn marks on its surface, you should check the extruder fans for proper operation. The following manual presents how to replace both extruder fans.

1

M Series Printers Servicing

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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 the 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.

2

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.

3

Unplugging the Power Cable

Turn off the printer and unplug the power cable. Wait about 15 minutes and let the machine cool down.

4

Unplugging the Extruder Cable

Unplug the extruder cable.

THE MANUAL SHOWS THE EXTRUDER WITH THE TOP COVER V1. WE RECOMMEND REPLACING THE COVER V1 WITH THE COVER V2 FOR EXTRUDER CABLE PROTECTION REASONS. See the manual.
5

Extruder Upper Printed Cover Removal

Detach the extruder upper printed cover from the extruder.

6

Hotend Removal

With a 1.5mm Allen key loosen the two screws that secure the hotend and remove the hotend from the extruder.

7

Heater and Thermocouple Removal (from the Hotend)

With a 1.5mm Allen key loosen the two screws that secure the heater and thermocouple in the hotend. Then remove the heater and thermocouple.

8

Heater and Thermocouple Removal (from the Extruder)

Remove the heater and thermocouple from the extruder block and the heat shrink tubing.

9

Extruder Upper Fan Replacement

The following steps present the extruder upper fan replacement (Fan 1). It is placed on the heat sink next to the extruder alumium block. The fan grid is placed on the extruder upper fan.

Unplugging the Extruder Upper Fan Cable

Unplug the red connector from the extruder PCB. Remove the cable from the heat shrink tubing.

Unscrewing the Extruder Upper Fan

Unscrew the four screws that secure the extruder upper fan and remove them.

Extruder Upper Fan Removal

Remove the extruder upper fan grid and then remove the fan.

Extruder Upper Fan Assembly, part 1

Place the extruder upper fan on the heat sink next to the extruder alumium block. Next, place the grid on the fan.

Securing the Extruder Upper Fan

Secure the extruder upper fan with the four screws.

Extruder Upper Fan Assembly, part 2

Put the extruder upper fan cable through the heat shrink tubing and plug it in.

Carefully put the cable in the gap in the extruder aluminum block. Be careful not to damage the cable.
10

Extruder Lower Fan Replacement

The following steps present the extruder lower fan replacement (Fan 2). It is placed under the heat sink next to the extruder alumium block. The fan shroud is secured to the extruder lower fan.

Unplugging the Extruder Lower Fan Cable

Unplug the blue connector from the extruder PCB. Remove the cable from the heat shrink tubing.

Unscrewing the Extruder Lower Fan

Unscrew the three screws that secure the extruder lower fan.

Extruder Lower Fan Removal

Separate the extruder lower fan from the heat sink and remove the distance piece.

Unscrewing the Extruder Lower Fan Shroud

Unscrew one screw that secure the extruder lower fan shroud and separate it from the fan.

If the fan shroud in your printer is damaged or worn, download the model from the Zortrax Library and replace it during the extruder lower fan replacement.

Securing the Extruder Lower Fan Shroud

Put the shroud together with the new extruder lower fan and secure the shroud with one screw.

Extruder Lower Fan Assembly, part 1

Place the distance piece on the extruder lower fan. Install the fan under the heat sink.

Securing the Extruder Lower Fan

Secure the extruder lower fan with the three screws.

Extruder Lower Fan Assembly, part 2

Put the extruder lower fan cable through the heat shrink tubing and plug it in.

CAREFULLY PUT THE CABLE IN THE GAP IN THE EXTRUDER ALUMINIUM BLOCK. BE CAREFUL NOT TO DAMAGE THE CABLE.
11

Heater and Thermocouple Assembly (in the Extruder)

Put the heater and thermocouple cables through the heat shrink tubing.

CAREFULLY PUT THE CABLEs IN THE GAP IN THE EXTRUDER ALUMINUM BLOCK. BE CAREFUL NOT TO DAMAGE THE CABLE.
12

Heater and the Thermocouple Assembly (in the Hotend)

Insert the heater and thermocouple into the hotend and firmly tighten the two screws that secure them (using a 1.5mm Allen key).

Make sure that the screws don’t go through the insulation that covers the wires (this can happen if the heater goes too deep into the slot).

This picture shows the heater inserted correctly. This picture shows the heater pushed too far into the slot in the hotend.
13

Hotend Assembly

Insert the hotend into the extruder and tighten the two screws that secure it (using a 1.5mm Allen key).

14

Extruder Upper Printed Cover Assembly

Attach the extruder upper printed cover.

15

Plugging the Extruder Cable

Plug the extruder cable in.

16

Plugging the Power Cable

Plug the power cable in.

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