Need help with Z Axis Stall

[SAA3840]

I've got a problem I cannot figure out. I keep getting a Z-axis stall, Err E06-0313, Press Stop.
The machine will measure my board just fine and then ask for the
1/16" carving bit. I installed the bit and the machine
ran through all the measurements just fine Except for the "Finding board thickness".
It takes a measurement on the keyboard side, runs across to the swing out plate and then comes back to "Find the board surface". Then it moves to the sliding bar, runs down into the curved hole, comes back up and moves to the other side of the slider. When it comes down
and touches the slider, I get the error message.
What is wrong?
I am running 1.186.10507 firmware,
There are 314hrs on the cut motor, the brushes have been replaced twice, the most recent time was a day or two ago.
It's a "B" machine, serial number starts with B.
I ran a sensor check and with the bit installed,
the reading on the "Z" was:
.176 at the brass wheel,
-2.196 all the way up
-.526 at the slider, touching same
0.208 with the bit touching the round bar the slider slides on.
With NO bit installed and the Z truck all the way down, the reading is 0.764.
I don't know what else I can add.
Can anyone offer a clue as to what's wrong?
I've read all the other threads on "Z" errors and tried all the suggested remedies. There is no longer a whole in the touch-point at the brass wheel.

Oh, if it matters, I have attached the .mpc for the project I'm trying to carve:

I reset the offsets to factory default and then reset the board thickness as per the troubleshooting file.
Still not fixed. For some reason the Z truck comes down on the far side of the slider too hard, like it wants to go deeper. That's when I get the error.
I even reset the offset for board thickness. Had no trouble with that, but it didn't solve my problem.

Should the repaired hole in the brass wheel touch point be raised up a bit? Higher than the spring-loaded lever the bit touches?
(Since the loading process gets as far as it does, I'm assuming the flat Z cable is OK.)

[bergerud]

As you know, that behavior is characteristic of the hole in the brass wheel touch point. You could try putting a dime there just to see. Otherwise, there is some other z depth measuring problem. As a second last resort, I would check the z encoder for dirt or loose disc. As a last resort, you may have to contact LHR . There are some internal stored parameters in the computer which, I believe, they have a file to restore.

As another test first, try a project with a shallow carve (<1/2") on a 4" thick board. The machine should not try and touch the sliding plate (and cannot get to it anyway). If you can get it to carve correctly, I think it would mean the problem is software parameters. If it is a hardware problem, it should find some other way to screw up. Does that make sense? Anyway, try it and see what happens.

[SAA3840]

OK, the problem has been resolved. Apparently epoxy isn't hard enough. I decided to swap out the tracking roller from my other machine and in the process I noticed that the hole in the spring-loaded lever had returned. I cut out a small piece of sheet metal and epoxied that to the lever and the problem was solved. Carve went fine. That is until I got a "Y" stall. I guess the sawdust built up too much. I vacuumed everything out and put in another project, which just happens to be almost identical to the one I was doing, and it's carving just fine. So I'm once again a happy camper...

[fwharris]

OK, the problem has been resolved. Apparently epoxy isn't hard enough. I decided to swap out the tracking roller from my other machine and in the process I noticed that the hole in the spring-loaded lever had returned. I cut out a small piece of sheet metal and epoxied that to the lever and the problem was solved. Carve went fine. That is until I got a "Y" stall. I guess the sawdust built up too much. I vacuumed everything out and put in another project, which just happens to be almost identical to the one I was doing, and it's carving just fine. So I'm once again a happy camper...

Good find! You might watch when the bit spin starts up as it is moving over to the touch area and if it continues to spin as it lowers down to touch press the stop button once. This will stop the spin before the bit reaches the touch point and keep it from trying to drill in. After it stops press the start button to continue with the measuring process.

[SAA3840]

Good find! You might watch when the bit spin starts up as it is moving over to the touch area and if it continues to spin as it lowers down to touch press the stop button once. This will stop the spin before the bit reaches the touch point and keep it from trying to drill in. After it stops press the start button to continue with the measuring process.

I tried that several times, instead of pressing "Stop", I simply opened the lid, that stopped everything. Then I pressed the "Start" button and continued. What's funny about the whole thing is after I put the little piece of sheet metal on the touch point by the brass roller, the machine never once went back to touch the sliding bar. Go figure......

[bergerud]

I think it only goes for the sliding bar when the carve depth exceeds 1/2".

[henry1]

For what its doing and your problem, I tend to think your cut motor need new brush and how many hrs you have on the cut motor you shouldn't have to put epoxy

[SAA3840]

For what its doing and your problem, I tend to think your cut motor need new brush and how many hrs you have on the cut motor you shouldn't have to put epoxy

I put new brushes in the cut motor about two days ago. So that was not the problem.