Makerbot 5th Gen and Belt Tightening and or Pully Replacement

This is my first blog to hopefully help others maintain their 5th Generation Makerbot Replicator or Replicator +.

BELT TIGHTENING and PULLEY REPLACEMENT (Option)

My Replicator had over 1,000 hrs on it when I noticed print quality taking a dump and the belt was overly loose.  I searched the Internet looking for an FAQ on how to take the top cover off the Makerbot to tighten the belt.  Believe it or not - no FAQ and no pictures.

First off - If you don't have Makercare, then the work here is all up to you.  You can get belts at Fargo3D for $22 each at this time.  The pulley is also $22 and you will need 2 of those as well.  Remember - working on your machine is your own responsibility.  These instructions are directional only.

Step 1:  Unload filament and let the Smart Extruder+ ("SM") cool down to 50C and fan off.  Remove extruder and buildplate.  Put aside carefully.

Step 2:  Disconnect power from the Makerbot

Step 3:  Turn the Makerbot around so the back faces you.  Take a Torx screwdriver set and loosen and remove ALL screws on the back panel.  Note all of them have washers except the 2 torx at the bottom and the 4 that connect to the powerswitch/plug.

Step 4:  Your machine should look like this

Step 5:  You can pull the filament tray all the way out BUT you will need to unscrew the left or the right panel to put it back in.  The panel is held on by 3 screws.  Remove those and remove the feed tray.

Step 6:  Move your extruder to the middle of the build area.  Look to where your display is and you should see a small wire coming out.  This wire is for the camera.  VERY carefully detach the wire from the display.  You will need a long nose plyers or small hands to do this.  The connector is keyed so the holes are at the bottom.  A flashlight is helpful!

The wire is pictured here - wire is to the left.

Step 7:  Carefully lift the rear of the top cover up and pivot it very gently to the front.  There are 3 clips that hold the front of the cover to the body of the Makerbot.  You will need a small flat blade screwdriver to pull the top of the clips TOWARDS you (you are at the rear of the Makerbot).  Once you have losened all 3, gently pull up.  The top cover will pop off gently BUT the power cable is still connected to the top lid and the body of the Makerbot.  Lean the top cover to the side carefully.  Your machine should look like this:

Step 8: With the top cover removed you will see the idler pulleys in the front left and front right.  The front left of the Makerbot has the pulley that adjust belt tension.  Examine your belt and see if it is stretched out or not.  Mine with 1,000+ hrs was stretched out and I was maxed out on the belt tension so I had to replace it.  It is along belt.  Note and take pictures of how the belt moves through the pulleys inside the Extruder Head and gantry.  To change out the pulley, simply unscrew it from the top and replace with the new ones you got from Fargo3D or elsewhere.

Step 9:  Once you have the belt in place and belt clip.  You will need to adjust the tension on the belt by turning the allen/torx to tighten the belt.  You do not need to make the belt CRAZY tight - just tight enough so that there's no slop and feels relatively firm.  Over tightening will cause the pulley to wear and cause other issues.  So use your judgement on tightness.

Step 10:  Move gantry and head around to ensure that everything is moving SMOOTHLY.  Start re-assembly process making SURE that no wires are pinched especially the camera wire.  You will need to find a helping hand to hold the lid while you put the camera wire back to the lid of the Makerbot.  Once the wire is on, place the lid gently ensuring no wires are caught in the front or back.  Gently tap the top cover and the 3 clips will snap into place.  The lid should not be off in anyway and should look exactly like it was before you took it off.   Replace the feed tray, screw in the 3 screws ensuring that it is LEVEL with the other one.  These rails for the feed tray go through the 2 holes in the back of the panel.  Replace all screws.  You are now DONE and back in action.