Material Feed Failure, but Printer Keeps "Printing"
Sadly, I've not been able to use my Core one since October. Between delays in response from support and delays getting parts to me, this is my reality right now. I figured I would post here while waiting on support to see if there are any ideas.
I experienced a "hot end fan not running" error sometime back in late October and worked with chat/email to get me squared away on that. Replaced the hot end fan, to no avail, and eventually Prusa sent me a new loveboard. This did fix my error and the printer seemed back to normal, or so I thought. Since that time, I've had no successful prints on my machine.
Now, I am experiencing an issue with filament feeding that I cannot understand. I can load/unload filament like normal. I've even used the "purge more" function several times and filament continues to feed just fine. However, when I start a print job I get a few minutes into the print and all of a sudden material will stop feeding, but the printer will continue on it's path while putting down no filament. I can hear the stepper motor used for feeding the filament making what sounds like a "grinding" noise but I believe this is just what a stepper motor sounds like when too much force is required and it can't actually move. I will abandon the print, and can choose the "unload filament" and the stepper will make a momentary "grind" noise again, and then catch and eject the filament normally. I can then reload and do the entire process over again, but the print will always fail. I am using PLA, and have tried several different MFG's/colors now but all produce the same results. Temps are based on the pre-loaded settings in the prusa connect app for this filament. The file I am printing is the same file I was using when the hot end fan error cam up originally (made it about 75% of the way through that print before getting the "hot end fan not running" error).I have opened the idler swivel and cleaned the drive gear out with a toothpick. It did have a little build up in the gear, but it all came out easy. It was NOT the color of the current print which tells me it wasn't slipping on the material I had loaded in. I have tried slightly tightening the adjustment screws for the idler swivel as well with no change, but the material consistently has noticeable tooth marks in it suggesting it is grabbing just fine. I have done a cold pull process following the prusa guideline found here: https://help.prusa3d.com/article/cold-pull-26702-mk4s-13702-mk4-28702-mk3-9s-21702-mk3-9-23702-mk3-5-28702-mk3-5s-17702-xl_445071
The printer has roughly ~500 hours on it, and again, has not made one successful print since the loveboard was replaced. I have removed/reseated the nozzle to ensure it's all the way in. I have removed/reseated the teflon feed tube into the extruder as well and it feels firmly seated in there. I am unsure what else to test at this point. I have uploaded two videos to youtube that I will share here.
First video showing loading of filament, and extended purges working just fine:
http://youtube.com/watch?si%3D8jtLHPTNGmW1dbBu%26v%3DrZsrGJWWul0%26feature%3Dyoutu.be&source=gmail&ust=1765642406764000&usg=AOvVaw28RFkIq4QFtNWNmaQUSM2 G">youtube.com/watch?si=8jtLHPTNGmW1dbBu&v=rZsrGJWWul0&feature=youtu.be
Second video showing a print job from start until failure. (You can hear the extruder motor start making it's "grinding" noise around 12:50):
Appreciate any insight!
Thanks,
Mike