15.1. Assembly of the Bondtech MK3S Mosquito Extruder

(1) 1.5x60mm Hexagon Socket Head Screwdriver for Electronic Applications

(2) 2.0x75mm Hexagonal Screwdriver

(3) 2.5x75mm Hexagonal Screwdriver

(4) Scalpel

(5) Electronics Pliers

(6) Pliers Wrench

(7) Engineer Scriber

(8) Countersink

(1) Superglue

(2) Zip Ties

(1) Bondtech MK3S/ MK2.5 Mosquito Extruder

(2) Slice Engineering Hotend Mosquito/ Mosquito Magnum (see manual 14.1.)

(3) Fan Shroud (Lüfterauslass)

(4) Fan Holder

(5) Lever

(6) Ball Holder

(7) x-Carriage

(8) Sensor Cover

(1) Radial Fan

(2) Sunon Fan

(3) SuperPINDA /Pinda 2

(4) Filament Sensor Extension Cable

(5) Motor Cable

(1) Bondtech Drivegear

(2) Long Magnet

(3) Short Magnet

(4) 7mm Steel Ball

(5) Thumbscrew Assembly

(6) Filament Sensor

(1) 2x Black Washers

(2) 8x M3 Nuts

(3) 5x M3 Square Nuts

(4) M2x12mm Hexagon Socket Head Cap Screw (silver)

(5) M3x8mm Hexagon Socket Head Cap Screw

(6) 3x M3x10mm Hexagon Socket Head Cap Screws

(7) 5x M3x16mm Flat Head-Head Socket Cap Screws

(8) M3x18mm Hexagon Socket Head Cap Screw (silver)

(1) 2x M3x20mm Hexagon Socket Head Cap Screws

(2) M3x35mm Hexagon Socket Head Cap Screw

(4) M3x40mm Hexagon Socket Head Cap Screw

Open the extruder.

Insert the small magnet into the lever.

If the magnet is loose, fix it with a little super glue. If the magnet is difficult to insert, we recommend using a pliers wrench.

Place the lever in the extruder back (the one without motor) and secure it with a M3x18mm Hexagon Socket Head Cap Screw (silver).

Now, loosen the screw until the lever can be moved freely.

Insert the long magnet into the slot to the left of the lever.

Make sure that the two magnets repel each other.

If the magnet is still movable in the slot, fix it with super glue.

You can now test the mobility of the lever through the opening for the filament.

Take the ball holder and check the hole for filament residues. If there are any residues, remove them carefully (e.g. with a scalpel).

Insert the 7mm steel ball into the holder.

Insert the holder with ball into the top of the extruder back.

Insert the filament sensor and secure it with the M2x8mm Hexagon Socket Head Cap Screw (silver).

Test the mobility of the lever again.

If the lever's mobility is compromised, loosen the screw on the filament sensor minimally or check the lever for filament residue, removing it if necessary.

Test the mobility of the lever again.

Now, place the sensor cover on top and secure it with a M3x10mm Hexagon Socket Head Cap Screw.

Remove the hinge and shaft from the back of the extruder.

Align the gear (with the shaft) in the hinge as shown in Fig. 2 and press the shaft down until it engages.

Carefully press the shaft into position with a pliers wrench.

Re-assemble the hinge with the shaft to the back of the extruder.

Remove the shaft assembly from the front of the extruder.

Slide the gear onto the shaft and make sure that the M2 grub screw is aligned with the flat side of the shaft.

Tighten the screw so that the gear can only move up and down.

Insert the shaft assembly into the back of the extruder next to the hinge.

Make sure that there is a ball bearing (5x8x.2.5) in the cavity for the shaft.

Align the grooves in the gear to match the filament path and tighten the M2 grub screw.

Insert a M3 Square Nut into the hole, in the center of the extruder back. Make sure that the square nut is inside the left slot.

Remove shaft assembly from the back of the extruder and insert into the front of the extruder.

Make sure that there is a ball bearing (5x8x.2.5) in the cavity for the shaft.

Place your Mosquito/ Mosquito Magnum Hotend built in Manual 14.1. into the back of your extruder.

Make sure all components are seated properly before proceeding.

Now, put the front and back of the extruder together.

At the bottom of the front of the extruder, screw a M3x35mm Hexagon Socket Head Cap Screw through the extruder.

At the bottom of the front of the extruder, screw a M3x35mm Hexagon Socket Head Cap Screw through the extruder.

Install the Thumbscrew. Tighten the thumbscrew as much as possible and then loosen it again by 2-3 turns.

Insert a M3 Square Nut at the bottom of the back of the extruder.

Insert a M3 Square Nut into the top left corner of the back of the extruder.

On the Sunon Fan, enlarge the four screw holes with a countersink and remove the cable guide.

Plug the motor cable into the motor on the front of the extruder.

Push the motor cables into the cavity.

Place the Sunon Fan over it and be carefull to not damage the cables.

Pay attention to the orientation of the fan. The sticker on the fan must face inwards and the cable must come out to the rear.

Attach the Sunon Fan to the extruder using 4x M3x16mm Flat Head Screws.

Insert 2x M3 Nuts into the fan holder.

Attach the fan holder to the extruder with a M3x10mm Hexagon Socket Head Cap Screw.

Carefully attach the Radial Fan to the extruder, using 2x Black Washers and 2x M3x20mm Hexagon Socket Head Cap Screws.

Insert 6x M3 NUtsinto the back of the x-carriage.

Insert 2x M3 Square Nuts into the bottom of the front of the x-carriage.

Feed the filament sensor cable connector through the top slot in the x-carriage (Fig. 1).

Pull the cable all the way through and insert the filament sensor cable connector (as shown in Figure 3) into the slot until it engages.

Now, feed the filament sensor cable through the cable guide in the back of the x-carriage.

Finally, remove the filament sensor cable connector from the x-carriage to avoid damaging the filament sensor during the installation of the x-carriage.

Place the x-carriage on the back of the extruder.

Be careful not to damage the filament sensor cable.

At the top right, the x-carriage is fastened with a M3x40mm Hexagon Socket Head Cap Screw.

At the top left, the x-carriage is fastened with a M3x10mm Hexagon Socket Head Cap Screw.

Plug the filament sensor cable onto the sensor.

Make sure that the plug snaps into place.

Insert the pinda into its mounts and fasten it with a M3x16mm Flat Head-Head Socket Cap Screw at the level of the nozzle.

Plug the cable of the radial fan into the mount provided on the right side of the extruder and guide it to the x-carriage.

Run the cable along the extruder (as shown in Fig. 3) and secure it with a zip tie.

The assembly of the Extruder is completed now.

Continue with instructions 16.1 Installation and Wiring of the Bondtech MK3S Mosquito Extruder.