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Ultimaker ORIGINAL+ Assembly Manual Download Page 39

39

Z STAGE

4

Assembly of the Z stage consists of several parts. You will start by preparing the 
aluminium base plate and heated bed, that together form the Z stage. After this, the 
Z stage cap will be assembled and the Z stage can be installed in the Ultimaker.

Summary of Contents for ORIGINAL+

Page 1: ...ASSEMBLY MANUAL Original manual V3 0 2016 Ultimaker ULTIMAKER ORIGINAL...

Page 2: ...s damage or expense arising out of or in any way connected with the assembly handling storage use or disposal of the product The information in this document was obtained from sources which we believe...

Page 3: ...31 Placing the X and Y axles 34 4 Z STAGE 39 Assembling the Z stage 40 Installing the Z stage 49 4 PRINT HEAD 54 Print head assembly 55 Placing the print head in the frame 63 Aligning the print head...

Page 4: ...accidents and injuries will be prevented and that you will obtain great quality prints Every effort has been made to make this manual as accurate and complete as possible The information is believed...

Page 5: ...umbers and names that are part of the Ultimaker Original kit Check if all parts are included before you start assembling Assembling the Ultimaker Original takes about 8 16 hours and requires the follo...

Page 6: ...k WHAT S IN THE BOX Short timing belt Long timing belt 2 4 1085 1086 Ball bearing 8 mm Sintered bushing Linear bearing Small ball bearing Square flanged linear bearing 10 4 2 1 2 1021 1056 1065 1142 1...

Page 7: ...Short cable duct Long cable duct you will only need 1 4 2 3 1010 1131 1132 Cable management pack Feeder quick fit coupling Clamp clip Knurled wheel Cap nut M8 Washer M8 Nut M8 Feeder spring 1 1 1 1 2...

Page 8: ...coupler PEEK isolator Tube coupling collet Clamp clip 1 1 1 1 1 1 1 1 1048 1049 1053 1054 1055 1067 1069 1071 Hot end pack Injection molded set Motor spacer Heated bed cable clip 1 1 1 1030 1241 1243...

Page 9: ...1201 1202 1203 1204 1205 1206 1207 1208 1209 1211 1214 1217 Glass retainer clip Knurled nut Washer M6 M3x4 bolt Countersunk bolt M3x8 Countersunk bolt M3x20 Self tapping bolt Spacer 8 mm Metal cable...

Page 10: ...troller window 1129 1146 1522 UltiController pack LAYER 3 Y linear shaft X linear shaft Z linear shaft Print head shaft X Y Z motor with trapezoidal lead screw Trapezoidal lead nut 2 2 2 2 1 1 1011 10...

Page 11: ...11 Jumper on main board Main board 2 1 4 2 1 1315 1546 Electronics pack Feeder motor X Y motor 1 2 1017 1082 Motors Power adapter 1 1238 Power adapter...

Page 12: ...te Heated bed Warning sticker Front plate Back plate Left plate Right plate Top plate Bottom plate Parts plate Aluminium base plate 1 1 1 1 1 1 1 1 1 1 1 1154 1155 1294 1673 1674 1675 1676 1677 1678 1...

Page 13: ...E 2 In this chapter the assembly of the frame of the Ultimaker Original is described You will start preparing the panels then you will assemble the frame and as a last step attach various parts to the...

Page 14: ...1021 1023 1025 1026 1 STICKERS Each Ultimaker Original kit has its own unique serial number You find your Ultimaker Original s serial number on the box and on a sticker in the kit Start by placing the...

Page 15: ...2 Every panel has 2 corresponding holes 1 Take a panel place the ball bearings on the corresponding holes and push them in Make sure that they are inserted deep enough and do not stick out Fig 3 Use a...

Page 16: ...k panels the limit switches and the bolts and washers Fig 4 The orientation of the limit switches is engraved on the panels except for the front panel Blue wired limit switch To mount the blue wired l...

Page 17: ...ch with two M3x12 bolts Fig 7 Black wired limit switch To attach the black wired limit switch perform the following actions 1 Take the back panel 2 Place the black wired limit switch with the lever po...

Page 18: ...he electronics You need the bottom panel and the Velcro parts 1 Move 4 pieces black Velcro parts through the four sets of slots of the bottom panel Fig 10 2 The Velcro parts should stick out at the en...

Page 19: ...nels because they are weak in this configuration However when the frame is finished the structure is very strong PARTS NEEDED ASSEMBLING THE FRAME Front panel Back panel Left panel Right panel Top pan...

Page 20: ...back panel Fig 13 3 Put the bottom panel with the markings downwards into the back panel Fig 14 4 Put the front panel in the top and the bottom panel Fig 15 Make sure that the wires of the limit swit...

Page 21: ...side 2 Place a short cable duct on the right side of the back panel Fig 17 3 Fold the short cable duct Fig 18 4 Place a small piece of tape on the cable duct to keep it folded Make sure the tape will...

Page 22: ...and 23 3 Place a long cable duct on the left side of the front panel fold and tape it like the other cable ducts Fig 24 and 25 4 Place the left panel Fig 26 5 Loosely secure the left panel with twelv...

Page 23: ...5 mm Short timing belt Motor spacer 2 2 2 2 1082 1084 1085 1241 Motor pack Pulley pack Wooden part 3B Wooden part 11A Washer M3 M3x12 bolt M3x16 bolt M3x25 bolt Hex nut Set screw Lock nut Metal cable...

Page 24: ...tainless steel set screws Fig 28 2 Place the pulley 5 mm internal diameter on the X and Y motors Make sure to keep the top of the pulley flush with the top of the motor axle Fig 29 3 Take the eight M3...

Page 25: ...wnwards Fig 33 and 34 When placing the motor make sure that the wires of the black limit switch are in between the motor spacer and the frame 7 Hook the cables behind the hook of the motor spacers tow...

Page 26: ...ch wooden part 3B with two M3x16 bolts and two lock nuts Fig 37 4 Take the metal cable clamp and attach it to the left panel using one M3x12 bolt and one lock nut This clamp will be used to keep the h...

Page 27: ...e X and Y axles can be put in the frame Therefore you will first assemble the sliding blocks and attach the wooden caps to the frame When this is done the X and Y axles can be placed in the frame with...

Page 28: ...en parts marked BACK A B C 2x D E Wooden parts marked LEFT A B C 2x D E Wooden parts marked RIGHT A B C 2x D E Small wooden parts marked C 4 mm 5 5 5 5 4 Laser pack Sintered bushing M3x10 bolt M3x30 b...

Page 29: ...facing the same direction Use the part C with the hole in it 2 Take the sintered bushing and push it through part A Fig 40 This might take some force Use a redundant piece of wood to push the sintered...

Page 30: ...fit 3 Place the claw marked FRONT into the front sliding block and secure the sliding block with 3 M3x30 bolts and 3 hex nuts Don t put a bolt on the place where the claw will be closed Fig 47 and 48...

Page 31: ...short motor belts pass over the bearings The wooden caps without hole go on the outside Some of the caps only need to be attached with one bolt at this time to help inserting the axles at a later stag...

Page 32: ...n cap with hole and a wooden cap without hole to the left panel Secure with two M3x16 bolts and two hex nuts Fig 54 and 55 3 In corner B attach a wooden cap with hole and a wooden cap without hole to...

Page 33: ...en cap without hole to the back panel Secure loosely with only one M3x16 bolt and one hex nut Fig 59 7 In corner D attach a wooden cap with hole and a wooden cap without hole to the back panel Secure...

Page 34: ...shaft long X linear shaft short Long timing belt Pulley 8 mm 2 2 4 10 1011 1012 1086 1088 Axles pack M3x16 bolt Hex nut Set screw Sliding block front back left right 4 4 10 4 1204 1209 1211 Nuts bolts...

Page 35: ...wards the left panel Fig 63 4 Place the following parts on the front X axle One timing pulley with the thin side facing outwards Place a long timing belt around this pulley Fig 64 The front sliding bl...

Page 36: ...X axle around this pulley Fig 69 The back sliding block Make sure that the T slot is facing inwards and the text is upright Fig 70 One timing pulley with the thin side facing outwards Place the long t...

Page 37: ...y with the thin side facing outwards Place a long timing belt around this pulley Fig 74 The left sliding block Make sure that the T slot is facing inwards and the text is upright Fig 75 One timing pul...

Page 38: ...t connected to the left Y axle around this pulley Fig 80 The right sliding block Make sure that the T slot is facing inwards and the text is upright One timing pulley with the thin side facing outward...

Page 39: ...Z stage consists of several parts You will start by preparing the aluminium base plate and heated bed that together form the Z stage After this the Z stage cap will be assembled and the Z stage can b...

Page 40: ...ed bed cable clip Table spring M3x10 bolt M3x12 bolt M3x14 bolt Hex nut Lock nut M4x10 bolt Glass retainer clip Knurled nut Washer M6 Countersunk bolt M3x8 Countersunk bolt M3x20 1 1 3 6 6 4 10 4 8 4...

Page 41: ...e corresponding holes in the corners Fig 84 3 Loosely secure them with four M4x10 bolts each use the 2 5 mm hex key Make sure that the bearings can still move a little bit you will calibrate them late...

Page 42: ...ATED BED Before you can place the heated bed on the base plate you need to attach some parts You need the heated bed the heated bed cable two glass retainers four small countersunk bolts M3x8 and four...

Page 43: ...aluminium side facing down and the screw terminal towards you 4 Insert the heated bed cables with the thick gray wires heater on the right side and the thin black wires sensor on the left side Fig 90...

Page 44: ...e and bed have been prepared you can connect them to finish the Z stage You need three long countersunk bolts M3x20 three springs three knurled nuts three large washers M6 two more glass retainer clip...

Page 45: ...grease on the round side Fig 93 2 Place the washers over the knurled nuts with the grease upwards Fig 94 3 Put the knurled nuts through the three holes of the base plate in the front right and back m...

Page 46: ...m of space between the bed s screw terminal and the aluminium base plate Adjust the front two nuts until there is about equal tension on the three springs You will fine tune this later Fig 100 7 Place...

Page 47: ...47 4 Z STAGE CAP The Z stage cap will be placed over the back of the Z stage to cover the bearings You need the wooden parts ten hex nuts six M3x12 bolts and 4 M3x14 bolts Fig 103 103...

Page 48: ...ts Fig 104 3 Fold the 6 mm wooden part 90 degrees and attach it to the middle parts with four M3x14 bolts and four hex nuts Fig 105 4 Place six hex nuts in the slots at the sides and attach the wooden...

Page 49: ...D Glass plate Heated bed Wooden part 3A Grease 1 1 2 1 1028 1159 1126 Axles pack M3x10 bolt M3x12 bolt M3x16 bolt Hex nut Z stage Z stage cap 4 2 4 6 1 1 1202 1203 1204 1209 Grease pack Laser pack Nut...

Page 50: ...nel until they are about halfway Fig 109 3 Place the Z stage and Z stage cap in the frame and over the Z linear shafts Fig 110 111 and 112 4 Now insert the Z linear shafts completely and make sure the...

Page 51: ...rew of the Z motor through the hole in the middle and screw into the trapezoidal lead nut of the Z stage Fig 117 and 118 7 Secure the Z motor to the bottom panel with four M3x10 bolts Make sure the mo...

Page 52: ...and make sure the Z stage is all the way at the top 2 Open the packet of grease and spread the grease down the lead screw in a straight line The grease will spread across the whole screw when the Z st...

Page 53: ...it down until it lays flat on the roll of tape Fig 123 4 Tighten the eight M4x10 bolts of the square flanged bearings with the 2 5 mm hex key Alternate between the left and right bearing Fig 124 Make...

Page 54: ...54 PRINT HEAD 5 The print head exists of several parts that must be assembled the housing hot end and fan When the print head is assembled it can be placed in the frame and can be aligned...

Page 55: ...1 1 2 1 1 1 1048 1049 1053 1054 1055 1067 1069 1185 1513 1065 1326 1501 1512 Hot end pack Print head coupling plate Wooden part FRONT Wooden part BACK Wooden part LEFT Wooden part RIGHT Wooden part T...

Page 56: ...the print head housing You will need the following parts Fig 127 1 Take the wooden part marked TOP and attach the black injection molded part with one M3x12 bolt and a hex nut Put this part aside you...

Page 57: ...ows of balls are in an x shape not a 4 Place one linear bearing in the RIGHT side of the print head housing 5 Fit the RIGHT side with bearing into the FRONT BACK sides of the print head housing Now pr...

Page 58: ...hot end isolator tube to the aluminium heater block Make sure the short side of the tube goes into the heater block Fig 137 3 Place the peek into the aluminium hot end holder Fig 138 4 Attach the pee...

Page 59: ...through the front left hole of the aluminium hot end holder with the hot end being in the front right hole and the print head housing Fig 140 141 142 and 143 It is easiest to guide the PT100 from the...

Page 60: ...0 in the middle hole Fig 144 and 145 3 Secure the PT100 and heater cartridge with one M3x10 bolt Fig 146 4 Guide the wires of the fan through the back left hole of the aluminium hot end holder and the...

Page 61: ...or Fig 151 and 152 4 Place the tube coupling collet into the front hole of the injection molded part Fig 153 5 Place the two 3 mm spacers around two of the thumb screws and put them through the left s...

Page 62: ...place by screwing them into the aluminium plate of the hot end assembly Fig 157 4 Position the fan correctly between the metal fancap and the hot end with the sticker facing downwards Fig 158 5 Use th...

Page 63: ...63 PLACING THE PRINT HEAD IN THE FRAME PARTS NEEDED Print head shaft X Y M3x30 bolt Hex nut 2 1 1 1046 1208 1209 Axles pack Wooden part C Print head 4 1 Pre assembled parts Nuts bolts pack 161...

Page 64: ...63 3 Place the X print head shaft into the left sliding block Fig 164 4 Tilt the right sliding block and insert the right side of the X print head shaft into the sliding block Fig 165 5 Close the claw...

Page 65: ...claws of the front and back sliding blocks Now place the wooden parts C to secure the Y print head shaft Fig 169 and 170 9 Tighten the four bolts of the wooden parts C Fig 171 and 172 Check if the sh...

Page 66: ...en the two pulleys attached to the short belts of the X and Y motor Push the pulley towards the frame and use the 2 mm hex key to tighten the set screw Fig 174 and 175 2 Tension the short belts by fir...

Page 67: ...e and place the X print head shaft into the calibration sticks Make sure the calibration sticks use the same notch 4 Tighten the set screw of the left pulley with the 2 mm hex key Fig 180 5 If needed...

Page 68: ...ch 4 Tighten the set screw of the back pulley with the 2 mm hex key Fig 183 5 If needed move the print head slightly to the left or right until the set screw of the front pulley connected to the long...

Page 69: ...f three parts that must be assembled before the feeder can be placed on the Ultimaker the main feeder housing clamp and drive bolt Once the feeder is placed on the Ultimaker the bowden tube and spool...

Page 70: ...er motor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1017 Injection molding pack Ball bearing 8 mm Small ball bearing Feeder quick fit coupling Knurled wheel Cap nut M8 Washer M8 Nut M8 Feeder spring Washer M3 M3x16...

Page 71: ...71 1 MAIN FEEDER HOUSING For the assembly of the feeder housing you will need the following parts Fig 186 186...

Page 72: ...to place the gear this might take some force 2 Place the wooden parts 10A and 10C in front of you as shown in the image Insert a ball bearing into the corresponding hole Make sure that the bearing is...

Page 73: ...r with two M3x25 bolts through part 10D and two M3x20 bolts through part 10C The motor s position will be adjusted later Fig 192 193 and 194 6 Place one M3x25 bolt through the hole in the top right co...

Page 74: ...74 2 CLAMP ASSEMBLY For the assembly of the feeder clamp you will need the injection molding parts small ball bearing feeder spring washer and nuts and bolts Fig 197 197...

Page 75: ...redundant piece of wood to fit the bearing in place 2 Insert four M3x16 bolts through the flat side of side plate A Fig 199 3 Place the mounting plate over the four bolts and put a hex nut in the T sl...

Page 76: ...n the U bracket and tighten Fig 206 and 207 Because of the tension on the spring it might take some force The length of the spring should be 11 mm 7 Attach the clamp assembly to the main feeder housin...

Page 77: ...3 DRIVE BOLT ASSEMBLY For the drive bolt assembly you will need the pre assembled feeder wooden gear wooden gear cap knurled wheel bolt clip M6 nut M6 washers M6 cap nut bolts and lock nuts Fig 210 2...

Page 78: ...ar Attach the two parts with three M3x14 bolts and lock nuts Make sure the lock nuts and the engraving are on the outside of the wooden gear cap Fig 212 and 213 3 Insert the knurled wheel through the...

Page 79: ...nd 219 7 Move the motor inwards so the black gear is pressed against the wooden gear Secure the two M3x25 bolts then rotate the wooden gear until one of the M3x20 bolts can be accessed through the hol...

Page 80: ...is end has been slightly drilled out to make the inserting of material easier 1 Take the bowden tube and place the end with the blue tape into the feeder quick fit coupling Fig 224 2 Place the clamp c...

Page 81: ...t to lock the bowden tube in place Make sure it stays fully inserted into the teflon coupler Fig 227 5 Take the print head cables PT100 heater cartridge and fan and line them up with the bowden tube W...

Page 82: ...82 SPOOL HOLDER PARTS NEEDED Wooden parts 11B short Wooden parts 11B long Wooden parts 11C 2 2 6 Laser pack 232...

Page 83: ...timaker filament 1 Take the two short wooden parts 11B and place two wooden parts 11C in the corresponding slots Fig 233 2 Firmly push the wooden parts 11C down until it clicks into place 3 Repeat the...

Page 84: ...84 ULTICONTROLLER 7 The UltiController is the display and control panel of your Ultimaker Original This chapter describes how to assemble it and place it on the front panel...

Page 85: ...ltiController right Knob UltiPanel rev 1 1 UltiController window 1 1 1 1 1 1 1 1129 1146 1522 Laser pack Double flat cable 10 wire Spacer 16 mm Nylon hex nut Nylon bolt M3x12 Nylon bolt M3x25 1 4 10 6...

Page 86: ...n and fit the UltiController window in the cutout Fig 237 3 Insert four nylon M3x25 bolts through the wooden part front put four 16 mm spacers over them and place the UltiPanel on top Fig 238 239 and...

Page 87: ...two nylon bolts M3x12 and two nylon hex nuts Fig 244 7 Attach the side part with two nylon bolts M3x12 and two nylon hex nuts each Make sure to place the side with the SD card slot over the SD card h...

Page 88: ...8 ELECTRONICS 8 The last step of the assembly process is connecting the electronics You will first mount the main board to the bottom side of the Ultimaker Original and then connect all the wires to i...

Page 89: ...89 PARTS NEEDED Jumper on main board Main board 2 1 4 2 1 1315 1546 Electronics pack M3x20 bolt Spacer 8 mm 4 4 1206 1502 Nuts bolts pack MOUNTING THE MAIN BOARD 249...

Page 90: ...wing steps 1 Place the Ultimaker on its left side and raise the Z stage 2 Insert four M3x20 bolts through the bottom panel from the inside and place the spacers around the bolts Fig 250 and 251 3 Hold...

Page 91: ...t matter Fig 254 2 Take the thick gray heated bed wires Use a small flat screwdriver to press on the terminal marked Heated bed and insert the heaters The positioning does not matter Fig 255 3 Gently...

Page 92: ...258 4 Take the plug from the feeder motor This is the shortest motor cable coming from the top right corner Connect it to E1 motor Fig 259 5 Use the Velcro parts to wrap all the motor wires together T...

Page 93: ...the controller 2 Connect the marked cable to exp 1 connect the other to exp 2 Fig 261 4 SENSORS 1 Connect the PT100 sensor to temp 1 Fig 262 2 Connect the black plug from the heated bed cable to temp...

Page 94: ...g 265 3 Take the black wired limit switch from the bottom right corner and connect it to z end stop Fig 266 Run the black wired limit switch under the main board before connecting it This ensures bett...

Page 95: ...Lastly push the main board towards the right panel as far as possible and completely tighten the four bolts to secure the main board in place Fig 268 Your electronics should now look like this 269 26...

Page 96: ...96 COVER PARTS NEEDED Electronics cover 1 Laser pack M3x20 bolt Spacer 8 mm 4 4 1206 1502 Nuts bolts pack 270...

Page 97: ...t Fig 271 2 Screw the four bolts into the main board s threaded spacers but only two turns Fig 272 3 Place the wooden electronics cover over the four bolts with the text facing towards you Fig 273 4 S...

Page 98: ...atulations You have completed the assembly of the Ultimaker Original Before you can start printing you must configure and calibrate your Ultimaker Original Therefore follow the steps described on our...

Page 99: ...www ultimaker com...

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