PRUSA RESEARCH ORIGINAL PRUSA XL TOOLCHANGER Failed

Prusa XL Docking Station Assembly

The mounting hardware for the docks, specifically the middle screw in the cable router, is prone to loosening due to operational vibration. This causes the dock to become non-perpendicular, resulting in the tool being picked up at an angle that the Tool Offset Calibration cannot mathematically reconcile. Tightening or replacing the dock assembly restores the fixed reference point needed for the nozzle to find the calibration pin.

X/Y Axis GT2 Timing Belts

The CoreXY motion system relies on precise belt tension (typically 80-100 Hz) to ensure repeatable tool pickups. If belts have stretched or are under-tensioned, the gantry suffers from backlash, causing the tool head to miss the load-cell-equipped calibration pin during the offset routine, resulting in a software timeout or 'out of bounds' error.

Kinematic Coupler Lubricant (Super Lube)

The toolchanger utilizes a kinematic coupling consisting of three metal pins. If these pins are dry, high friction prevents the tool from seating into the precise 'V' grooves of the carriage. This micro-misalignment is enough to cause the nozzle's Z-height and XY-offset to fluctuate between calibration probes, triggering a failure in the tool-to-tool consistency check.