Sometimes when I start a print the extruder bangs HARD into the end stop and then the print is canceled with a “must home” error. It will usually work if I then manually home all (but I still get a somewhat loud bang during homing) and click on retry print.
I’m sure there is a home command in my gcode, will check the slicer begin print macros.
The only time my Zero has made a loud noise and halted with an error was caused by the extruder cable drooping down and interfering with the Y axis homing.
Please keep us posted if you have more information about the problem and a solution.
had same problem, it happens when printer is already hitting endstops, and you home again.
Change your printer.cfg in stepper_x and stepper_y lines, it was 2, change to 5:
homing_retract_dist: 5
Now it retracts more and no bangs 