Ultimaker EXTRUSION UPGRADE User manual

Installing the Extrusion Upgrade kit
The Extrusion Upgrade kit allows you to turn your
Ultimaker 2 or Ultimaker 2 Extended into an Ultimaker
2+ or Ultimaker 2 Extended+. This guide shows how
to install the upgrade kit step by step. In addition to
reading our detailed support text guide there are
an installation guide video and installation manual
available.
Your upgrade kit consists of several parts.
Check if all the parts are included before continuing.
Removing the cable cover
1. Pre-assembled print head
2. Nozzle kit
3. Short spool holder
4. Print head shafts (X and Y)
5. Hex wrench 2 mm
6. Pre-assembled feeder
7. Calibration card
8. Build plate clamps
9. Geared feeder mounting plate
10. M3 ring (2x)
11. M3 x 10 mm screw (6x)
12. “+” stickers
13. Print head alignment tool (2x)
14. Axles protect tools
15. Print head axis (dis)assemble tool (2x)
16. Grease
Remove the two screws (M3 x 8 mm) with
which the cable cover in the back left corner is
attached to the frame. One screw is attached to
the left side of the frame and the other one to
the back side.
Note: Ensure that the build plate is at the bottom
position.
• Remove the cable cover.
• Raise the build plate gently by holding it
with both hands as close as possible to the
back of the build plate.
• Place the Ultimaker on its right side as seen
from the front.
ACADEMY

Installing the Extrusion Upgrade kit
Loosening the electronics
Disconnecting the cables
Important: While removing the cables, do not pull on the wires.
Always pull on the plugs.
• Take the main board carefully. Ensure that the wires are still
connected when you hold the main board.
• Remove the wires from the green terminal HEATER 1 by
 pressingthetopoftheterminalwiththeatscrewdriver.
Note: When placing the machine upright, take care of where your
main board is, so you do not break it.
Note: If you have an older model of the main board on your
Ultimaker, you need to loosen the screws instead of pressing to
remove the wires.
• Disconnect the hot end fan from the middle of the board.
• Disconnect the feeder motor from E1 on the main board.
• There’s a ferrite core around the motor cables. Open it so you
can remove the feeder motor wire completely. (It’s possible that
your Ultimaker is older and doesn’t have the ferrite core).
• Disconnect the PT100 sensor from TEMP1 on the main board.
• Disconnect the print head fans from FAN PWM on the
main board.
• Pull the braided sleeve with cables and the feeder motor wire
out through the hole in the bottom left corner and the hole in the
back plate.
• Place the Ultimaker back upright and move the build plate down
for easier access during the next steps.
• Remove the two screws (M3 x 12 mm) and locknuts from the
electronics cover and set them aside. Use a socket wrench or pliers
to hold the locknut, while unscrewing the screws from the inside.
• Remove the cover and place it aside.
• Unscrew the four screws (M3 x 25 mm) from the main board and set
the screws and spacers aside.
ACADEMY

Installing the Extrusion Upgrade kit
Replacing the feeder
Note: Do not trap any of the wires
next to the feeder motor. Ensure
that the wires run between the
motor and the frame.
• Attach the feeder motor
to the body with the feeder
mounting plate, using the
four new screws
(M3 x 10 mm) and the
washers from the old feeder.
• Place the feeder on the
back with the small lever on
the bottom and use the two
supplied screws
(M3 x 10 mm) with M3 rings
around it to attach it.
ACADEMY
• Remove the four screws (M3 x 25 mm) from the feeder. While
removing the screws, hold the feeder motor at the inside of the
machine to prevent the motor from falling down.
• Keep the screws and washers and set the feeder and motor
aside. You do not need the feeder and feeder motor anymore.
• Take the new feeder motor and apply some grease
(Magnalube) to the small gear. Make sure the entire gear is
covered with a thin layer of grease.
• Place the feeder motor with the wires down on the inside of
your Ultimaker and place the geared feeder mounting plate
with the hole at the bottom over the four screw holes on the
outside.

Installing the Extrusion Upgrade kit ACADEMY
Replacing the build plate clamps
• Remove the glass plate.
• Place the 2 mm hex wrench on the screw in the front left corner
of the build plate. Hold the corresponding build plate screw at the
bottom of the build plate with your hand.
• Turn the build plate screw with the hex wrench to loosen the
parts completely.
• Remove the build plate clamp.
• Place the new build plate clamp between the spring and the build plate.
• Place the build plate screw with the washer around it against the bottom of the
build plate and hold it there.
• Insert the screw from the top and use the hex wrench to tighten it.
Note: Tighten the screw until there is quite
some tension on the spring, so that the
vibrations of the build plate are reduced. But
make sure there is at least 2 mm distance
between the screw terminal of the heated
bed and the base plate.
• Repeat these steps for the
build plate clamp at the
front right of the build plate.
• Place the glass plate back
on the build plate and
close the build plate clamps.

Installing the Extrusion Upgrade kit ACADEMY
Removing the print head
• Slide a print head axis (dis)assemble tool on either side
of the left sliding block until it clicks into the axle.
• Pop up the print head shaft until it comes out of the
sliding block at this side.
• Do the same on the right side.
• Repeat the steps 2 and 3 on the front and back, using
the print head axis (dis)assemble tools upside down.
• Turn all sliding blocks away from the print head.
• Move the print head so the shafts move out of the
sliding blocks and lift upwards. Set the print head
aside, you do not need anymore.

Installing the Extrusion Upgrade kit ACADEMY
Installing the new print head
• Guide the two new print head axles through the new
print head. The long axle is the X-axle and the short
axle is the Y-axle.
• Place the print head in its original position and ensure
that each axle is between the belts. The X-axle runs
from left to right and the Y-axle runs from front to
back.
• Align the axles to each sliding block.
• Place the print head axis (dis)assemble tools on either
side of the sliding blocks.
• Click the X-axle in the left sliding block and push down
until it snaps into place. Support the sliding block as
much as possible when you snap the axle into place.
• Repeat the steps for the other side of the X-axle and
the front and back of the Y-axle.
Note: Ensure that the axles are put in centrally
with equal space on each side and that there is
at least 1 mm distance between the axle and
the frame. Double-check that the left side of the
X-axle is activating the Y limit switch.
Note: Ensure that all sliding blocks are upright.

Installing the Extrusion Upgrade kit ACADEMY
The bowden tube
Guiding the cables
• Connect the end of the bowden tube to the feeder.
• Place the clamp clip around the tube coupling collet to secure the bowden tube.
• Place the Ultimaker on its right side.
• Feed the braided sleeve through the
hole at the back and the hole at the
bottom. Ensure that the whole braided
sleeve is through the hole, as it was
before you took it out.

Installing the Extrusion Upgrade kit ACADEMY
Connecting the cables
• Connect the blue-orange wire to the hot end fan connector on the middle of the board.
• Connect the PT100 sensor to TEMP1 on the main board.
• Connect the yellow-green wire to the Fan PWM.
• Connect the feeder motor to E1.
• Guide the motor wires of the Y motor and feeder motor through the ferrite core and close
the ferrite core.
• Connect the wires of the heater cartridge to the green terminal HEATER 1. Press at the top
 oftheterminalwiththeatscrewdriverandinsertthewires.Gentlypullattheheaterwires
to ensure they are stuck in place.
Note: If you have an older model of the electronics on your Ultimaker, you need to tighten
the screws instead of pressing to connect the wires.

Installing the Extrusion Upgrade kit ACADEMY
Attaching the main board
Attaching the cable cover
• Put the main board back in place and secure
it with the four screws (M3 x 25 mm) and
spacers you set aside when disassembling
the electronics.
Note: Be careful that no wires are trapped
between the main board and frame. Push
towards the back panel before completely
tightening the screws.
• Place the electronics cover back and secure
it with the two screws (M3 x 12 mm) and
locknuts you set aside when disassembling
the electronics.
• Put the Ultimaker upright and move the build
plate down.
• Place the cable cover and secure it with the
two screws (M3 x 8 mm) you set aside when
disassembling the electronics.
Note: Ensure that no cables are
trapped when you place the cable
cover.

Installing the Extrusion Upgrade kit ACADEMY
Firmware and
bed leveling
Toprinttherstprintwiththenewpartsinyour
Ultimaker,youneedtoupdateyourrmware.
• Connect the Ultimaker to your computer with
the USB cable.
• Connect the power supply and turn on the
Ultimaker.
• Start Cura and select the Ultimaker 2+ or
Ultimaker 2 Extended+ in the “Machine” menu
(depending on which Ultimaker you have).
• Goto“Machine”>“Installdefaultrmware”
Cura will now automatically upload the
 correctrmwaretoyourUltimaker.
• The new nozzle in your Ultimaker is at
a different height than the stock nozzle. It is
now necessary to re-level the buildplate
before continuing printing.

Installing the Extrusion Upgrade kit ACADEMY
Aligning the axles
Before you start, ensure that you have the print head align tools and
2mm hex wrench.
• Loosen the 2 pulleys on the back X axle.
• Place the print head align tools on each side of the back X axle.
• Move the print head to the back until the grub screws of the left
(double) pulley is visible and click the print head shaft in the align
tools.
• Push the left pulley towards the frame and tighten the grub screw
with the hex wrench.
• Remove the print head align tools from the shaft.
• Move the print head until the right front grub screw is visible and
click the align tools onto the print head shaft.
• Push the right pulley towards the frame and tighten the grub
screw.
• Repeat these steps for the 2 pulleys on the left Y axle.
Note: It is recommended
to lubricate the axles with
sewing machine oil. One drop
oneachaxleissufcient.

Installing the Extrusion Upgrade kit ACADEMY
Completing the upgrade
Now the work is done, it’s time to seal your upgrade with the spool holder and two
small + stickers.
Attach the new (smaller) spool holder to the back of your Ultimaker and place the
+ stickers their place. Stick the biggest + sticker behind the name of your Ultimaker
onthefrontpanelandthesmallestonthebackplatecover.Itisthesubtlenishing
touch that shows that your Ultimaker is upgraded with latest parts and is ready for
making prints of the highest quality.