X-Axis motor calibration issue - pulley loose

Similar to a question already posted, but the answer did not help my situation:

I recently finished putting my kit together and ran through the self-test on 3.0.9. I had to make an adjustment to the X-Axis motor/belt. Initially the motor would make a kind of loud "surging" sound and the printhead carriage would not move. I turned the unit off and tried moving the carriage along the X-Axis with my hand, but it was locked tight and would not move. The belt was very tight from when I assembled it. I experimented with loosening the belt and eventually got it to a point where I could manually move the carriage. At this point the self test passed.

Tonight I was going to move on to calibration, but decided to upgrade firmware to 3.0.10 and re-run the self test to be sure. After doing so, the test is now failing again on the X-Axis test, this time on the "pulley loose" condition. I tried tightening the belt a bit again, but even tightening it by just a single "tooth" gets me back to a point where the carriage won't move again. Is there something other than the belt tightness I need to be looking at? Looking for some suggestions on how to proceed.

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I tried multiple options,

- slight wd 40 on a kerchief and on the rods

- tightening

- loosening

I fixed it by setting the printer to auto home, and then running the self test.

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This fixed the issue for me also. Thanks!

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glad to hear it Eric! did you also need to nudge your extruder to the 'real'auto home point or did it work immediately?

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This did not help me unfortunately. I tried this and the motor did not make a "grinding" noise at the beginning of the test this time, but it still failed. I tried moving the pulley closer to the end of the shaft in case that mattered. At the same time I made sure it was properly tightened on the shaft (it was). Not knowing what the test is actually measuring to determine that the pulley is loose makes it hard to troubleshoot any further. I've double checked everything with this part against the assembly instructions and it all appears to be correct.

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@ruxviii Nope once I hit auto home it went right to it and from there I have had 0 calibration issues. I've been printing nonstop since finishing calibration and they are beautiful.

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@kse001 have you used a digital caliper yet to make absolutely sure that the horizontal frame is completely squared and the distance from x axis endstop to the counter-tightened nut is precisely 100mm on both sides? This is crucial. Also you must not overtighten the u bolts around the bearings or the bed plate will not move freely and will fail calibration.

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Hi Kyle,

try to check if you assembled correctly the pulley on the motor shaft. One screw from the pulley must be oriented towards the flat part (pad) on the shaft otherwise, the pulley can slip. This results in "pulley loose" warning.

See step 40 from Y axis 2. Y-axis assembly for the correct approach. I will update the manual in a similar manner for X axis as well.

Let me know if it helped and please don't forget to mark this as solution ;)

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Hello,

Sorry for the delayed response. This did not seem to be my issue. When I assembled the kit, I made sure to have the set screws tightened onto the flat portion of the stepper motor shaft, so it was already assembled correctly.

Kyle

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Kyle Ertel will be eternally grateful.
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