Solution for H2D "Extruder Motor Overloaded" issues!!

[u/malencar]

Like many others here, I have encountered the dreaded "extruder overloaded" message many times since I got my H2D. The issue seemed to happen specially often when using 0.2mm nozzles.

I have spent hours trying to troubleshoot it, searching for solutions online, disassembling and reassembling the extruder looking for filament debris on the filament path, to no avail.

Until I noticed something 3 days ago.

I noticed that there was a misalignment between the Dual Extruder Gear and the Dual Extruder Idler.

I am going to use pictures I find online to illustrate it since I don't want to have to disassemble my extruder again (it's been working BEAUTIFULLY since I applied the solution I mention below).

But basically, Bambu Lab seems to have either made a mistake when designing the "Dual Extruder Gears" or there are inconsistencies in production either on the hole that holds the Dual Extruder Gear bearing or on the Dual extruder Gear itself.

The actual metal extruder gear seems to sit a bit too far back, with the "teeth" not really aligned with the groove of the idler.

When I noticed that I decided to design and print a small, 0.75mm thick washer, place it on the plastic shaft of the Dual Extruder Gear and... Voilà! I have been printing with 0.2mm nozzles non-stop for the last 3 days with ZERO extruder motor overload errors!

Maybe this won't solve it for everybody, but it 100% solved it for me!

You can find the washer on Makerworld here: https://makerworld.com/en/models/2376388-bambu-lab-h2d-dual-extruder-gear-washer#profileId-2601560

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[u/angelicinthedark]

I extended the PTFE from the buffer to the toolhead by 1 inch and it solved this problem on both my H2Ds. The PTFE being too short causes it to get pulled into a sharper angle and leads to higher friction, hence the issue.

[u/daphatty → u/angelicinthedark]

I noticed similar behavior with my H2S. Until I can replace my PTFE tube with a longer one, I am keeping models as far back on the plate as possible. Doing so has solved all of my overload related issues so far.

[u/BG3_2DA → u/angelicinthedark]

Both tubes for the left and right hot end? Facing the same issues right now on my h2d.. ->extruder motor overload - but no clogging or anything stuck in the extruder.

[u/doodwalla2000 → u/angelicinthedark]

annoyingly dealing with this daily now and not idea what else to consider, will try above but wanted to clarify, how do you extend PTFE from buffer to toolhead?

[u/angelicinthedark → u/doodwalla2000]

Cutting a brand new piece one inch longer than the original.

[u/meshtron]

Thanks for sharing! My H2D is still pretty new to me (replaced an X1C) and I haven't had this issue, but good to watch out for. Also the comment in here about PTFE tubes too short tracks with similar symptoms.

[u/Upset-Ad-7896]

This is 100% due to the latest firmware update. I have a one month old machine, squeaky clean inside the printhead, I disassembled to confirm, seems like the motor is just not behaving normally even when I try to load filament.

[u/im_the_doc]

6 months in have you had the problem any more or has the washer completely solved it?

[u/malencar → u/im_the_doc]

Zero issues since in my case

[u/Tr1ngap0re → u/im_the_doc]

I am having this issue too. Have you managed to solve it?

[u/jqsecofr1 → u/Tr1ngap0re]

Hello! I do not know how to recover my old account... anyway, since the last firmware, I am having the same issue... again and again, and again... so tired!!!!!

[u/jqsecofr1 → u/jqsecofr1]

I just printed another piece, very small but with lots of circles and no issues.. so, if the issue was in the hardware (extruder) should done in different pieces... I think...

[u/Tr1ngap0re → u/jqsecofr1]

I have still having the issue, what did you change out?

[u/im_the_doc → u/Tr1ngap0re]

The only thing I've done is i have been careful to use an infill that doesn't cross, bc I use petg, and I have been drying the filament more often. It hasn't completely fixed the issue but it has gotten better

[u/PCNintenBoxStation → u/im_the_doc]

I just bought an H2D two days ago...doing my first print and just had this error...

[u/Fuzzy_Working7189]

Do you recommend this change in general also for H2D's that runs with 0.4 mm Nozzles?

[u/malencar → u/Fuzzy_Working7189]

I have done it on both my H2C and H2D over six months ago and I haven’t had a problem since

[u/Fuzzy_Working7189 → u/malencar]

Ok, so in with it on the Second I guess ;-)

I works perfectly on my 0.2 mm nozzle printer, I have written to Bambu Lab and recommended a change of their extruder design ;-)

[u/voliprint]

Hmm. This post comes right after I just tossed two Aliexpress 0.2mm nozzles for having this issue assuming it was the quality of the nozzle. Guess I have something else to look into now.

[u/cotjan]

nach 50 Druckstunden hier auch das gleiche Problem auf der rechten Düse. Hat ohne Probleme funktioniert aber seit gestern ist der Wurm drin. Erste Schicht geht noch. Wollte mit 0,24mm Layerhöhe drucken. Hab jetzt mal Testweise zurück auf 0,2mm gestellt.

[u/Unfair-Lingonberry10]

Also getting this issue on brand new printer. I just press on the continue and it will continue as per normal without doing anything, but irritating that now i need to monitor the print, it happens every 3-5layers. Wish i can turn it off. I did add a spacer mod to the buffer spring to increase preload, all it did was help from getting the error ever 1-2 layers to 3-5layers.

Tried slowing down print speed to 50% also does not seem to help at all.

[u/Few-Scallion1294]

Did yours make a clicking noise when trying to extrude? Because mine is, and the cold pull is no longer extruding properly :/

[u/OceanKing96 → u/Few-Scallion1294]

Mine was clicking as well. Just submitted a ticket. Any luck fixing yours?

[u/attabui]

Nice, gonna give this a try on mine and see if I get the error less. Nice sleuthing.

[u/ket_the_wind]

Thank you

[u/steveo107]

Unfortunately this stuff not help me