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Reassembling the extruder head after manually cleaning it

Now that you're an expert in de-clogging and cleaning the extruder head, let's put it back together

2.3.13 - STEP 13: Insert and trim a new section of AWG-13 PTFE/Teflon sleeving

You'll need to replace the the PTFE/Teflon sleeve with a fresh one:

And once the new section of PTFE/Teflon sleeving is inserted, it should look like this:

2.3.14 - STEP 14: Evaluate the aperture of the brass extruder nozzle, and clean debris

The next thing you'll need to do is to clean off any debris from the threaded portion of the extruder tube. In addition it's always a good idea to clean off any significant debris from the brass extruder nozzle, and see if it might need to soak in some acetone for a while prior to being joined back to the extruder tube.

In most clog conditions, you'll be able to re-use the brass extruder nozzle straight away, but for sever clog situations, you may wish to soak the nozzle in acetone for a few hours (or even overnight) to soften any molten filament remains. This is why it's not a bad idea to have a few spare extruder nozzles (contact AIO for pricing and availability), as having spares will enable you to get back to production more quickly.

If you didn't laugh too hard at the suggestion of getting a 0.013“ guitar string, then this is time to carefully poke it through the brass nozzle aperture to completely clean any remaining debris:

2.3.15 - STEP 15: Thread and tighten the brass extruder nozzle

Now you'll want to manually thread the brass extruder nozzle on to the stainless steel extruder tube and rotate it until it reached the top of its possible travel. Finger tighten it so that no threads are exposed and then using the appropriate tools, further tighten the brass nozzle. Do not over-tighten!

Make sure that no threads are showing:

2.3.16 - STEP 16: Loosen the M3 x 4mm grub screw in the heat sink and align it with the extruder nozzle

2.3.16 - STEP 16: Loosen the M3 x 4mm grub screw in the heat sink and align it with the extruder nozzle

2.3.17 - STEP 17: Lock the heat sink into place at the top of its travel on the extruder tube

2.3.18 - STEP 18: Manually thread the hexagonal thermocouple and rotate the extruder tube sub-assembly against it

After putting the extruder tube sub-assembly together (comprised of the stainless steel extruder tube, the aluminum heat sink, and the brass extruder nozzle), the next very important step is to thread the hexagonal thermocouple back into the brass nozzle so that you can hold it stationary and then rotate the extruder tube sub-assembly against/around it.

This is essentially the reverse of the step in the dis-assembly process, and requires the exact same attention to making sure to handle the hexagonal thermocouple, and especially its wires carefully so that they do not get twisted.

Now we're in the home stretch…

2.3.19 - STEP 19: Re-insert the heater element and secure it with the M3 x 4mm grub screw

The heater element should slide back in easily, however if it there is baked-on filament debris on it, then you may need to carefully scrape the debris off, or possibly use some fine sandpaper or 00 or 000 steel wool, but it's pretty rare that you'll need to do that.

The important thing is to pay attention to is actually how the heater element is seated; it needs to be essentially flush with the side of the brass extruder nozzle on the side where the hexagonal thermocouple is mounted:

2.3.20 - STEP 20: Replace and tighten the second the M3 x 4mm grub screw that secures the nozzle to the extruder tube

Okay, we're in the “home stretch” now, and the rest of this is really very easy (not that much of it is all that challenging, once you know what everything is…)

2.3.21 - STEP 21: Snap the extruder tube sub-assembly into its locked position in the rear plastic housing

2.3.22 - STEP 22: Mount the front plastic housing onto the rear plastic housing, seat the fastening clips, and screw the shell together

2.3.23 - STEP 23: Admire your superb work and congratulate yourself on a job well done!

The first time you go through this process, it may seem complex and tedious, but after you've done it once or twice, you 'll probably be able to do it in under 10 minutes, and it will become quite simple

2.3.24 - STEP 24: Re-install the extruder head into the Zeus and use the Zeus software to check the nozzle height

reassembling_extruder_after_manual_clean.txt · Last modified: 2016/04/05 04:50 by roger