Prusa XL Dwarf Cover and Cable Mount - Threaded Inserts - Strain Relief for Extruder Stop Error 17536

Error 17536 relates to an issue with the Dwarf Board connector and the original design of the cable strain relief. The strain on the connector can cause the extruder motor to stop spinning and until a recent beta firmware (6.2-RC1) the printer could not detect this error. On 6.2-RC1 and later, error 17536 triggers warning that the extruder motor stopped spinning.

Unfortunately this is not a recoverable error, and the print is typically lost.

Recently, Prusa published updated files for the Dwarf Board Cover and Cable Cover that accommodated 2 screws to attach the covers together to increase the stability of the connection during printing. I had a few issues with these updated designs, and made some modifications that worked in my situation. I do not guarantee these will solve error 17536, but the modifications were necessary or helped tremendously in my case.

Both parts now use M3x5x4 heat press inserts these are the Voron standard size, and ones that I have many of on hand. The Prusa updated design requires square M3 nuts, which I do not have on hand. I find threaded inserts much easier to use instead of fumbling with nuts that might sit too loose and fall out while trying to assemble the pieces. 

The cable cover now has slots for the mounting point to the dwarf cover - this way the mounting screws do not have to be fully removed to remove the tool head, reducing time spent if you need to swap tool heads. 

The Prusa cable cover was entirely too tight for my cables, the cover needs to clamp over a portion of the cable sheath to avoid pinching the cables too tightly, but the default file could not accommodate the sheath on my XL. It also had too match material joining the two halves together so they simply snapped apart when I tried to assemble them. 
The modified files here have more room for the cable sheath and less joint material - however, I do recommend PETG here, the ABS I used to print them was still too brittle to bend open enough to get the cable inside. In an enclosed XL I stuck with the ABS and just made sure to squeeze the cover tight when screwing it to the dwarf cover. Even snapped in half, the screws will keep this cover held tightly together. 

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Cable cover uses an M3x10 SHCS for the clamp, and two M3x10 SHCS for connecting to the Dwarf Cover. 

2025-02-09: Version 2 of Dwarf Cover now allows use of the original M3 Nylock Nut or Threaded Insert for the pivoting cable door depending on user preference. Thanks to @Tholi_2404733 for the request

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I am still evaluating this change in effectiveness to elimination the Error 17536 entirely, and should I need to make any more adjustments I will edit this Remix.

Modifications that I have in mind:
 

• The slots in the cable cover could come from the ‘back’ of the part which might make it easier to assemble with the screws partially inserted, currently it is a bit tricky to align the connector 
• Updating the cover to be truly two pieces, the flex does not feel very reliable even in PETG, and while it would require a second fastener, i would feel better about the rigidity of the connector
• There is a Jig in the Prusa XL parts directory for offsetting the connector to the cable cover, its a bit tricky to use while aligning and tightening the screw. I think this offset could be directly incorporated into the design of the cable cover itself eliminating the extra step of aligning the connector

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Prusa Help Page for Connector Assembly

Prusa Updated Dwarf Cover

Prusa Updated Cable Cover