Mechanical||

Prusai3

InstructionManual
DocumentNoMANUALWBSPi3DIYREV02

Mechanical
3DLabteKModel

1/20

Mechanical||

Content

Introduction .. 1
1. Mechanical..3
1.1. YAxisAssembly. 4
1.2. XAxisAssembly. 7
1.3. ZAxisAssembly. 9
1.4. ExtruderAssembly. 13
1.5. HotEndAssembly. 17

2/20

Mechanical||

INTRODUCTION

ThismanualisintendedtobeusedforassemblythemechanicalpartsofyourPrusai3.

Although many information about this printer model are available online, we would like
towarnabouttheinformationyouaregoingtocollect.
Unfortunately there are so many variation around the original project that not every
solutionavailableoninternetissuitableforallthevariation.

Incaseofdoubtyoucancontactusatthefollowingmail
3d.labtek@gmail.com

3/20

Mechanical||

PrintedParts

Ycornerx4

Ymotorx1

YIdlerx1

Yendstopholderx1

Ybelttensionerx1

Y624bearingguidex2

YLM8UUHolderx3

Xcarriageadapterx1

Zbottommotorx2

Ztopx2

Zendstopholderx1

Xendmotorx1
4/20

Mechanical||

XendIdlerx1

Xcarriagex1

Xendstopholderx1

X624bearingguidex2

GergExtruderV3x1

BigGearx1

smallgearx1
Idlerbearingx1

5/20

Mechanical||

YAXISASSEMBLY||1.1
PartsNeeded
PrintedParts Mechanical Other
YCornerx4
YMotorBracketx1
YBeltHolderx1
YBeltIdlerx1
YBushingx3
BeltGuidex2
M10ThreadedRodx2
M10Nutx12
M10Washerx24
M8ThreadedRodx4
M8Nutx22
M8Washerx44
Stripe2,5mmx4
M3x10mmx2
M3x20mmx6
M3Nutx12
M3Washersx12
M4x25mmx1
M4Nutx1

StepperMotorx1
BuildPlatex1(Aluminum)
MotorPulleyx1
Beltalmost1meter
LM8UUx3
RollerBearing624Zx2
Smoothrod405mmx2

Install the YBushing with the LM8UU already inside on the Aluminum Build plate
usingtheM3x25mmbolts,nutsandwashers.

6/20

Mechanical||

AssemblyofYAxis:
screw 4 x M10 Nuts on each M10 threaded rod, first placing 2 washers between the
middlenuts.

Fit The smooth rod on the top of the YCorners on both sides and tight the M10 Nut to keep
thedimensionofthesmoothrod.
Horizontal
InstalltheYBeltIdleralmostatcenterofoneofthefourM8Threadedrods.
InstalltheYMotorBracketontwooftheM8Threaderrods,placeitalmostatthecenter
InstalltheRodwithTheIdlerinoneYcorner,(topHole)
InstalltherodswiththeMotorbracketontheotherside
InstallthelastM8threadedrodintheremainingfreeholeontheidlerside.
Insert the Smooth rod in the Ycarriage and place the smooth rod on the YCorner, Adjust
thespacebetweentheYcorneraccordingtothedimensionoftheYCarriage.
Tight the M8 Nuts on the Y corner side, both, motor side and idler side, slide the y
Carriage until the end of the stroke (idler side) and fix the M8 nuts on the Ycorner checking
that the YCarriage is sliding Free, Slide the Ycarriage on the motor side and repeat the
operation.
InstalltheYBeltHolderontheYcarriage.
Install the motor on the motor bracket using the M3x 10mm bolts, Install the Pulley on the
7/20

Mechanical||

motorbutdonottightthegrubscrew.
Install two 624Z bearings inside the Bearing Guide, and using an M4x25mm insert the
twobearingsintotheYIdler,donottighttomuchbecausethebearingsmustturnfree ,
1
Place the YAxis upside down in the way that the build plate is touching the working
plane.
Take the belt and Calculate the needed length for the YAxis, passing through the motor,
idlerandbacktotheYBeltHolder.(bothsides)
Slide The axis of the motor side and verify that the belt pulley is aligned with the YBelt
Holder , fix the pulley to the motor shaft with the grub screw, slide the Yaxis to the idler side
2
and verify that the Belt holder is aligned with the Idlers bearing, if not adjust the position of
theidlerbearingandfixit.
Install the Belt on the Belt holder, on one side, pass through the motor pulley, and the
idler bearing and fix the other side to the belt holder, tight enough that the belt is well
tensioned.
TheYAxisisnowreadytobeinstalledontheAluminumFrame.

LeavetheYaxisapartandletsstartwiththenextsession.

1
Ifyouseethebearingtootightinsidetheidlerjustsandtheidleruntiltheyaremovingfree
2
Adjustthepositionifrequiredandfixthepulleytothemotorshaftwiththegrubscrew
8/20

Mechanical||

XAXISASSEMBLY||1.2
PartsNeeded

PrintedParts Mechanical Other

XEndMotorx1
XEndIdlerx1
Xcarriagex1
Beltguidex2

M3x15mmx4
M4x25mmx1
M4nutx1
StepperMotorx1
MotorPulleyx1
Beltalmost1meter
LM8UUx7
RollerBearing624Zx2
Smoothrod370mmx2
Option for ALuminum
XCarriage
M3x30mmx2
M3x25mmx4
M3Nutsx6
M3Wahersx10
Xcarriage Alu body 5
pieces
Eccentricx2

Install 2 LM8UU bearings inside the Xmotor, Install the Nema 17 motor on the Plastic
part using 4 M3x15mm, install the Pulley on the motor in the way that the teeth stay in
thecenteroftheinternalchannelofthepart
Install2LM8UUbearingsinsidetheXIdler
ToinstalltheM5nutinthenuttrapoftheXendmotorandidlerfollowthissteps
insert the M5 threaded rod in the hole with an M5 nut already screw on
it
screw another M5 nut on the opposite side and tight up to touch the
plasticparts
verify that the nut in the bottom part match the hex socket and tight the
otheruntilthenutfitcompletelyinsidethesocket.
repeattheoperationforthesecondXend(idlerormotor)
Install the 624Z bearing inside the Bearing Guide and install the 2 bearings inside the
XIdlerusinganM4x25mmBolt
3
Install 2 LM8UU Bearing on the Bottom smooth Rod and insert the rod in the bottom
holeoftheXmotor
4
Install 1 LM8UU Bearing on the Top smooth Rod and insert it in the top hole of the
XMotor
Plastics XCarriage : Position the X Carriage on the LM8UU and Fix the carriage
using2,5mmStripe.
ALuminum XCarriage: Take two bolts M3x25mm and pass inside the middle hole in
the back side of the carriage, screw the eccentric cylinder on the 2 bolts and tighten
untiltheendofthethread. Insert the Greg Support in the slot of the front side of the
3
Ifthebearingdonotfitcompletelywiththeguideremovetheinternalpartoftheguide.Bearingmustresultflatonce
insertedinside
4
ToidentifytheBottomholejustorientthemotortotheFramesideandtheflatpartoftheXMotorfrontNuttrapintop
position
9/20

Mechanical||

Xcarriage,placeinfrontofthebacksideofthecarriageandfixitwith2M3x30mm .
5
Insertthelast2M3x25mminthebottomofthecarriage. tight the bolts until
the Carriage is properly fixed but sliding free. Insert the nuts on the Eccentric bolts but
leftthemloose.

YourXaxisshouldlooklikethisnow

5
DonotplacewasheratExtruderside
10/20

Mechanical||

ZAXISASSEMBLY||1.3
PartsNeeded

PrintedParts Mechanical Other

ZBottomx2
ZTopx2
M3x25mmx8
M3x10mmx6
M3x15mmx4
M3Nutx18
M3Washersx36
M5Nutx4
M5Washersx2

StepperMotorx2
ZAxisCoupler
Smoothrod325mmx2

11/20

Mechanical||

Install the 2 Z Bottom on the

frame using 6 M3x25mm, six
washerandsizNuts

Install the 2 stepper motor for the

Z Axis on the ZBottom support
using6M3x10mm

Insert the two smooth rods in the

hole fi 8mm placed aside the
motor.

Do not force them to avoid

breakingoftheplasticparts
12/20

Mechanical||

Take the XAxis you assembled

before and insert the idler in the
smoothrod.

Push the XEnd Idler, until the

bearing inserted in the XEnds
matchtheZAxisSmoothrod.
13/20

Mechanical||

Insert the XAxis in the ZAxis

Smoothrod.
Slide gently the Xaxis until the
ZBottom motor support and if
required adjust gently the
positionoftheXEndIdler.
Slide back on the top of the
smoothrod

Install the ZTop support for the

Smooth rod using 2 M3x25mm
and 2 x M3x15mm bolts and
washersandnuts.

Your X & Z Axis should look like

thisnow.

14/20

Mechanical||

EXTRUDERASSEMBLY||1.4
PartsNeeded

PrintedParts Mechanical Other

ExtruderBodyx1
ExtruderIdlerx1
GearSmallx1
GearBigx1
GregAdapterx1
HobbedBoltx1
M8Nutsx2
M8Washersx7
M3x40mmx2
M4x20mmx2
M4x40mmx2
M8x20mmx1
M3x30mmx1
M3Nutsx3
M4Nutsx4
M3Washersx6
M4Washersx8
RollerBearing608Zx3
Springsx2

Insert the M8x20mm inside 1 of the

608Zbearing.

Install the M8 bolt with the bearing inside

theIdler.

Please note that you have to force the

bolttofitintheslot.

Insert some M8 Washers in the M8

Hobbedboltandone608Zbearing.
15/20

Mechanical||

Set the hobbed bolt in the Exstruder

body.

Verify that the drive art of the hobbed

bolt is aligned with the filament hole on
theExtruderbody.

If not add or remove washer until it is

aligned.

Insert the last 608Z into the Extruder

bodyontheoppositeside.

Insertonewasher

Set the M8 nut into the gear and screw

thegearonthehobbedbolt.

Itshouldlooklikethis.

Set another M8 nut on the hobbed bolt

and keeping the Big Gear with the hand
tightwitha13hexkeytheothernut.

Once you tightened verify that the

hobbed bolt can turn free. If it is tight
loose a bit the gear and tight again the
secondnut.
16/20

Mechanical||

Insert the idler the Extruder and fix it with

aM3x30mm.

To install the M4 nuts in the trap of

the extruder body you must preheat
thenutsusingasolder
Note that this is made on purpose, in
order to avoid the nuts turn into the
slotaftersometimeofusage.

Now, it is time to Install the motor on the

extruderbody.
Before fixing the motor, insert the Small
gear in the motor shaft but do not tight
theM3x10mm.

Also the M3 nuts of the little gear

must be inserted into the slot using
thesolder

Use 1 M3x10mm bolt to fix the motor on

the farest fixing point and turn the motor
until the small gear gets in touch with the
biggear.
If needed, adjust the position of the small
gear or increase the distance between
the big gear and the Extruder body using
anadditionalwasher.

17/20

Mechanical||

18/20

Mechanical||

HOTENDASSEMBLY||1.5
PartsNeeded

PrintedParts Mechanical Other

CoolingFanMountx1 Bodyx1
BarrelM6x1
HeaterBlockx1
Nozzlex1
HeaterCartridgex1
NTCThermistorx1
Selfshrinkingpipex2

OurHotEndsareshippedwiththebarrelalreadyfittedintotheextruderbody.

DONOTREMOVETHEBARRELUNLESSSTRICTLYNECESSARY

Onceinsertedwepolishtheinternalpartsinordertoavoidfilamentstacking.
Unscrewthetipandtheheaterblockfromthestainlesssteelbarrel,
Placingsomethinglittle,closetothethermistorbodybendonesideoftheterminal180
degrees,taketheheaterblockandcheckthatthethermistorisfittinginsidethehole.
Ifnecessary,closealittlethebendingwithaplieruntilitfitsthehole(Theholeis8mm
deep,besurethatthethermistorgoesthatdeep).
Cuttheselfshrinkingpipesandcovertheterminalsofthethermistor.
WithSilicateHightemperaturegluefill
theholeofthethermistorintheheater
block,insertthethermistorintheheater
block(asdeepasyoucan)andletthe
gluedry.
6
Ifyouareunabletofindthehigh
temperaturesilicateglueyoucanuse
theAGglue,usuallyusedforheatsink
onprocessor.
Inanycase,beforeproceedingwiththe
nextstepletthegluedry
Insertinthethermistorwirethelarger
selfshrinkingpipealreadycutinthemiddle,connectthetwoterminalsusingyoursoldering
ironandcoverthejunctionslidingtheshrinkingpipeonthat.
ScrewtheheaterblockontheBarreluptothelockingnut.
7
Cleanthetipinsideusingthetwocottonswab,nowplaceaverythinamountofAGglue
ontheendingpartofthebarrelthread andscrewthetiponthebarreltightenoughthatit
8
cannotbeunscrewbyhand.
6
Ifyouhaveanotherprinteryoucandryveryfastusingtheheatbed100degreesfor1hour
7
TheThermistorholemustbeplacedclosedtothetip.thelockboltforthecartridgemustbeintopposition
8
Donotputtheglueonthehole,left1or2mmfree.
19/20

Mechanical||

Removetheglueexcessfromthetopofthetipandscrewbacktheheaterblockuptothe
tip.Keepingthetipwitha13Hexkeytightheblockfirmly.
Removethefanconnectorfromthewire,andprolongthecableinthewaythatitreaches
yourpowersupply.
Weldtheterminalsontheheatercartridgecableandonthethermistorcable.
9

DONOTCONNECTTHECABLEYET

InstalltheHotEndintheGregsAdapter.
IfyouhavetheAluminumXcarriagedonot
PlacetheHotEndonthecarriageyet.

Installthecartridgeintheheaterblock,
pushingitstronglyinsidethehole.
fixitusingthegrubscrew

DONOTTIGHTENTOOMUCHTHEHEATERCARTRIDGEGRUBSCREWIN
ORDERTOAVOIDDAMAGETOTHECARTRIDGE

InstalltheGregsAdapterontheXcarriageofyourXAxis(OnlyforPlasticXCarriage)
usingtwoM3x40mm.
InsertthetoppartoftheHotEndintotheslotintheGregsExtruderforcingalittleif
needed.Verifywithapieceoffilamentthatitslidesfreeinsidethejunctionbetweenthe
GregsbodyandtheHotEndbody.
InstalltheGregsExtruderusingtwoM4x20mmontheGregsadapter(Xcarriagefor
ALUVersion).

9
Adjustthelengthofthecableaccordingtotheconnectionplaceonyourcontrollerboard
20/20