RE: Xl extruder stops
Hi, just a heads up from my 5T, I went the whole way- New dwarf-connector, new cables, new dwarf boards - that did not help. But since. New FW 6.2.4 all problems are gone … 10 x 15 hrs prints - not a single stop … I think they found it …
RE: Xl extruder stops
New to this forum but I wanted to add my experience with the XL. Very similar issues as everyone else for a long time. I have gone back and forth with support on this issue. Here is a history of our attempted repairs:
1. Support suggested removing the dwarf cover connector to reduce cable tension. It did not solve the issue
2. They sent us a new version of the connector that was supposed to help with cable tension. it did not solve the issue.
3. They sent us replacement dwarf cables saying ours were most likely faulty. That did not solve the issue.
4. They sent us replacement dwarf boards. That did not solve the issue.
5. Finally they let us send it back to get a repair from the printed solid facility. When we got it back we were confused from their report as it seemed like they only replaced the cables, and claimed it was fixed. The ones they just sent to us as replacements. We confirmed with them after that they in fact ONLY replaced the cables as "that was all that was wrong with the printer, so that was all the only repair made".
We sent them our printer on 3/14/2025, close to the date of the last post on this thread.
It took about 3-4 months but we were getting the errors again recently. Mostly we would get the errors however sometimes the motor would just stop but it would continue to "print". When it did throw the error it would either do it on the first layer, close to the previously discussed .16mm z height, or 2/3s through the print.
6. After more back and forth with support they said they wanted us to send the printer back to printed solid. I obviously did not want to do that considering the repair they did last time. I asked to tell me if all they are going to do is replace the dwarf assembly, and if so I am not interested and would just like a full printer replacement at this point. They claimed that with this error they typically do not replace the machine, however they are super confident that if they are just going to replace the dwarf assembly that it will work. So we sent it back on 7/11/2025.
Just to note I have always been on the most updated FW possible, even the prerelease versions when available.
I wanted to add to the thread because no one has posted since march, and in my own experience it is not a solved issue, and in my opinion it does not seem like Prusa figured it out either. But maybe this repair will be different, I am not holding my breath though.
Is anyone else still having this issue?
RE: Xl extruder stops
Well it's taken over a year. Currently running 5th replacement motherboard. It's working at the moment for three days. Maybe our luck has changed with that and latest firmware. Am I a satisfied customer? Absolutely not. We now have another printer on the way from the competition. I hate to say it, but after this experience, no more Prusas. I need my machines to work not gather dust. This has cost us dearly. Good luck everyone.
RE: Xl extruder stops
fter printing now over months with heavy loads I just can say that this error never showed up again. At my machine new FW fixed the issue. It is working rock solid since the FW update - knock on wood
RE: Xl extruder stops
I haven't seen it anymore. Yay! Hope it stays this way. I wish you good luck!
RE:
It still occurs occasionally for me. I’m on the latest firmware and have printed the dwarf cable connectors - not the official prusa ones, the first iteration from the community (I just haven’t got around to doing the official Prusa ones yet). They definitely helped to reduce the frequency of the issue from almost every print to only very occasionally. But what I find is if it does re-occur, it will keep re-occurring until I unscrew the dwarf connector, unplug and re-connect the dwarf cable into the dwarf board, and re-attach the connector. That then solves it for “some time”. So with 6.2.4 the issue does still re-occur and for me at least and seems 100% related to the dwarf cable/dwarf board connection. I’ll print the official Prusa connectors this weekend and see how that goes over time. Hopefully that’s a more reliable fix.
Now the rant, if Prusa wants to genuinely solve this, I reckon they need to redesign the dwarf cable/dwarf board to use a pin-based connection versus a “contact” based connection and offer everyone a free upgrade. It’s just not good enough that the community are expected to eat this. If this was a car there would have been a mass recall by now. It’s a shame because when it works it’s great, but when it works I’m like, “oh wow, it worked!”
RE: Xl extruder stops
Here as well. No more problem since the connector guide update suggested by Prusa, where I screwed the cable guides to the extruder covers. I knock on wood as well, because it was a very frustrating experience.
RE: Xl extruder stops
My XL is a 2-tool machine. Even after applying the improved connector, I still got a red screen error, and Tool #2 only started working normally after completing a cable replacement as well.
(The dwarf board in tool #2 was damaged for another reason and replaced.)
After that, Tool #1 showed red screen again, so I again received a replacement cable and dwarf board with instructions to "replace the cable first, and if the red screen appears again, replace the dwarf board."
I replaced the cable first and used it (ODO meter ; 506 hours).
It worked fine for a while, but at 798 hours, Tool #1 showed the red screen once more.
In other words, I encountered the red screen again after just 292 hours.
The warranty had already expired by then.
If the red screen occurs again, I'll replace it with the spare dwarf board I received.
I checked today and the ODO meter is now 861 hours.
I've only used it for 63 hours since the last red screen appeared.
While other users seem to have had their issues 100% resolved, I can't say my problem has been 100% fixed.
I'm currently dealing with a red screen issue on the heatbed (not the extruder).
hahaha
RE: Xl extruder stops
I have a 2-Tool XL and have had many annoying issues with the Nextruder, on Tool 2 only, stopping after the the first one or few layers. I replaced the cable connector with a new recommended design to no avail. new cable connector. I replaced it again with another improved design that secures the cable clip onto the board - newer cable connector. However, during the replacement, I noticed something off about the way the problematic Tool 2 cable connected to the PFTE tube and plastic cable guide at the orange clip compared to the way working Tool 1 is connected. The problematic Tool 2 cable ran horizontally straight to the clip with no slack. The working Tool 1 cable runs diagonally with extra cable bent between the orange clip and the extruder, leaving some slack between the cable orange clip and the extruder. With the slack in the cable, the cable bundle is free to whip around a bit without tugging on the extruder, isolating it from motion forces that could tug on the cable clip.
So I moved the orange cable clip on problematic Tool 2 up an inch or two and created some cable slack between it and extruder so that moving the cable/PFTE tube bundle left and right does not pull on the extruder. With the new connector installed and the slack created for the cable movement, I have had NO further failures. Too bad I made the 2 changes at once! I would advise testing the simple cable slack change first, then the new connector if the issue persists.