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The problème to restar a new print after stoped begin always by crash of nozzle and retract of filament
Did you figure this out? What is your start (take out G28) and end gcode?
1) print a calibration cube and verify it is the correct dimensions. also check for a loose pulley.
2)completely normal, once energized the steppers should be hard to move. You can move them without damaging them, no problem.