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Ultimaker 2 Extended + upgrade kit + noob install = death rattle

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Hello everyone,

Go easy on me here but my brother and I own an Ultimaker 2 extended which we just have upgraded it to the + via the upgrade kit. All went well during installation. However, now when we power the unit on and try to add material, the head unit does not home correctly and violently rattles.

Specifically, I searched Ultimaker's WIKI and they mentioned something about the end stops. We checked and both end stop switches are working fine. The head unit literately cannot get there. Something gets into a major bind when it tries to do it itself (during material add). However, if we move the unit by hand, it seems to be fairly smooth.

Any ideas on where we should begin? We've completed multiple calibrations via the calibration tools. No avail.

Video of our death rattle here:

Any help is much appreciated!

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Oh wow. That's not an endstop issue but just as loud. First know that this machine is tough and you can do this 100 times without breaking anything (at least worse than it is now).

Well I'm not sure. Often I'll see the video and go "yep. Seen that 100 times". But not this time.

Theory 1: when you put the metal side covers back over the steppers you pinched the X motor cabling (the stepper on the right rear corner). Look to see if any cables are under the cover before you remove it and are being pinched. You may have to repair a wire.

I mean it's certainly an X axis problem. Although the Y axis is pretty noisy also.

Theory 2: your axis are not perpendicular and there is huge friction. Try pushing the head around with power off. You should be able to push it around without moving the printer also (or just barely enough force to also move the printer across the table if you don't hold it). If friction is high then concentrate on that first. No more than one drop of light oil (any mineral oil like 3-in-one or sewing machine oil - but don't use WD40 - WD40 is a cleaner and not a lubricant). Read the installation instructions again about perpendicular axes.

Theory 3: your set screws are loose such that they sometimes grip and someties slip. This seems hard to believe as the axis actually goes backwards sometimes.

If you hadn't just upgraded I would also be suspicious about your stepper drivers overheating but that usually happens after the machine has been printing for 10 minutes. Not right at the start.

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