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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Thanks for the suggestion. I thought it might work this time, but no luck. No "grinding" from the motor at the beginning of the test, but it still failed saying the pulley is loose. I removed the pulley and tried to adjust the position on the shaft a bit thinking maybe it was not in alignment with the other side so the belt was not perfectly straight. At the same time, I verified that the pulley was properly installed on the shaft (it was) and loosened the belt a notch so I could move it by hand with a little force.

Seems like a nice product if I could get it to work, but having no idea what it's measuring to determine that the pulley is loose makes it pretty hard to try to troubleshoot. It's funny, I ordered this kit in January, waited patiently for the 6 (or was it 8?) weeks it took to arrive, but as I've had this problem right from the beginning when trying to use it, I've lost a lot of my motivation. I've double and triple checked everything against the instructions so I'm at a loss.

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This did not fix it for me unfortunately. Not knowing what it is doing to determine whether the pulley is loose makes it hard to troubleshoot any further on my own. I removed the pulley and re-aligned it on the shaft, moving it a bit closer to the end to see if it helped. It didn't. I verified that the pulley was tightened properly on the shaft (it was) at the same time. Really not sure what to do at this point.

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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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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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Y - axis pulley loose error. Another possible cause.

When I ran the self test, I got the error message noting that the Y axis pulley was loose.

--Tried adjusting the set screws to ensure one was solidly on the flat surface. Still got error message.

--Tried tightening the belt. Still got the error message.

Worked: Finally I noticed that the Y-axis endstop cable was bent upward and may have been rubbing on the bottom of the build plate when the plate moved close to the endstop. Bent the cable downward . Y axis tested OK. (Raised the cable again and it failed the test. Lowered the cable and it passed.) Another cable tie now is keeping that cable away from the bed.

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Kyle Ertel will be eternally grateful.
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