1. Cleaning end effector.
    The end effector is printed with two "floors" towards the top of the interior where the hot end slides into it. Much of this material must to be removed with a sharp knife. Remove the floor material linking the hot end slot to the interior walls of the end effector. Clean the hot end slot with a small blade screwdriver ensuring that no protrusions exist on the walls of the slot. Shave off floor material that extends into the slot area from the top.
  2. Ream the Bowden sheath opening with a 3mm drill bit, working the bit like a file. Ensure that the Bowden sheath fits through the opening - it should be snug but not difficult to push through.
  3. Wires for the heating resistor and thermister pass through a hole located on the side opposite the opening for the fan. Floor material for the hot end retainer covers a large portion of the hole. Remove the floor material with a sharp knife and ream the hole with a 3mm drill bit, using the bit like a file. Note that a second hole is present within the wire passage hole. This small hole is provided for pushing the hot end out of the slot should maintenance be required. A 2.5mm allen key works perfectly as a pushing tool.
  4. Cleaned end effector.
    Clean out the Bowden sheath retainer recess (small hexagonal opening on the top interior of the hot end retainer) with a sharp knife and ensure that an M4 nut fits snugly in the recess.
  5. Thread the large conductor (heating resistor wire) through the large opening in the base of the effector and push it through the hole in the back of the effector so that it extends out the top of the effector. Remove any twist in the conductor. Pull the conductor from the top of the effector until the hot end is partially within the effector.
  6. Repeat the process with the smaller conductor (thermistor wire) being very careful to minimize straining the thermistor leads or solder joints.
  7. Work the two conductors until they are neatly straight and aligned with the exit hole in the effector.
  8. Carefully pull the conductors from the top of the effector while angling the slotted end of the hot end out the fan opening. Align the top of the hot end with the slot in the effector and simultaneously push the hot end into the slot while carefully pulling up slack in the conductors from the other side.
  9. If the M4 Bowden sheath retainer is not in the recess, replace it and thread the Bowden sheath into it through the opening in the top of the end effector. Pull the Bowden sheath and its retainer up and out of the hot end retainer cavity, make sure none of the sheath extends into the hot end retainer cavity as it will impede insertion of the hot end.
  10. Considerable force maybe required to fully insert the hot end - it is designed to be a tight fit to minimize play. It may be required to carefully lay the effector on the edge of the table, wire exit down, and carefully but firmly push the hot end into the slot with a suitable tool (one of the guide rods). Be careful to minimize strainging the conductors and assure that the Bowden sheath and retainer are pulled out of the way of the hot end!
  11. Check that the hot end is fully seated in the slot by first looking to see if it is tilted and if not then observing the small hole provided for the hot end retainer screw. The hole should be completely visible with the edge of the hot end tangentially neeting its inside edge. If the hot end refuses to fully seat in the slot, push the hot end out using a 2.5mm allen key in the hole provided (careful with conductors!), clean the slot again with a small blade screw driver and knife and try inserting the hot end again.
  12. Once the hot end is fully seated in the retainer, plastiform an M2 x 10mm screw through the top of the end effector. Tighten the screw fully so that its end extends past the top of the hot end.
  13. Only two M3 x 10mm screws are required to afix the fan to the end effector: Place the fan over the opening with the wires exiting the fan towards the top of the effector and the fan spider facing the interior of the effector. Align the fan's mounting holes with the holes in the fan opening and plastiform M3 x 10mm screws into oposite corners of the fan.
  14. Secure the fan, thermistor and heating resistor wires to the Bowden sheath with a small wire tie immediatly above the Bowden sheat opening.
  15. Set the assembled end effector aside.
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