From the PathPilot interface, on the Status tab, examine the axes' Limits LEDs.

1. If one or more of the status lights are illuminated, try Disable the Limit Switches (Stuck on a Limit Switch) first.

2. If all of the status lights are off, continue to the next step.

Locate the physical switches on the machine and manually activate them while watching the LEDs in PathPilot.

1. If the switches illuminate their respective status light, they are working; inspect the limit switch flags.

2. If a switch doesn’t illuminate its status light, continue to the next step.

3. If a switch illuminates multiple status lights, continue to the next step.

4. If a status light stays on even when the switch isn’t depressed, continue to the next step.

On the machine control board, located the J2 connecter and use a small piece or wire to jump the 414 wire to the 409 (X-axis), 410 (Y-axis), 411 (Z-axis) while watching the LEDs in PathPilot.
If you have a status light that stays on, remove the 409 (X-axis), 410 (Y-axis), 411 (Z-axis) before testing with the jumper.

1. If one of the status lights doesn’t illuminate, replace the machine control board.

2. If the status lights illuminate correctly, continue to the next step.

Locate the malfunctioning limit switch, take a picture for future reference, and then remove the wires with a screwdriver.

With the switch in its normal state (not depressed), measure the resistance across the switches NC (normally closed) and C (common) terminals with digital multimeter set to resistance.

1. If the digital multimeter reads OL, shows a resistance in the MΩ, and/or doesn’t produce continuity tone, replace the switch.

2. If the switch measure 0-5 Ω, continue to the next step.

With the switch depressed, measure the resistance across the switches NC (normally closed) and C (common) terminals with digital multimeter set to resistance.

1. If the switch measure 0-5 Ω, replace the switch.

2. If the digital multimeter reads OL, shows a resistance in the MΩ, and/or doesn’t produce continuity tone, reinstall the switch.

Inspect the wiring on the malfunctioning switch for loose ferrules, terminal connections, fraying, or broken line.

From the PathPilot interface, on the Status tab, examine the axes' Limits LEDs.

1. If one or more of the status lights are illuminated, try Disable the Limit Switches (Stuck on a Limit Switch) first.

2. If all of the status lights are off, continue to the next step.

From the PathPilot interface, on the Settings tab, verify that the Enclosure Door Switch setting matches the hardware on your machine.
The installation of the door requires modifying the limit switch wiring, which can cause issues if not correctly set in PathPilot.

Locate the physical switches on the machine and manually activate them while watching the LEDs in PathPilot.

1. If the switches illuminate their respective status light, they are working; inspect the limit switch flags.

2. If a switch doesn’t illuminate its status light, continue to the next step.

3. If a switch illuminates multiple status lights, continue to the next step.

4. If a status light stays on even when the switch isn’t depressed, continue to the next step.

On the machine control board, located the J2 connecter and use a small piece or wire to jump the J2-4 wire to the J2-1 (X-axis), J2-2 (Y-axis), J2-3 (Z-axis) while watching the LEDs in PathPilot.
If you have a status light that stays on, remove the J2-1 (X-axis), J2-2 (Y-axis), J2-3 (Z-axis) before testing with a jumper.

1. If one of the status lights doesn’t illuminate, replace the machine control board.

2. If the status lights illuminate correctly, continue to the next steps.

Locate the malfunctioning limit switch, take a picture for future reference, and then remove the wires with a screwdriver.

With the switch in its normal state (not depressed), measure the resistance across the switches NC (normally closed) and C (common) terminals with digital multimeter set to resistance.

1. If the digital multimeter reads OL, shows a resistance in the MΩ, and/or doesn’t produce continuity tone, replace the switch.

2. If the switch measure 0-5 Ω, continue to the next step.

With the switch depressed, measure the resistance across the switches NC (normally closed) and C (common) terminals with digital multimeter set to resistance.

1. If the switch measure 0-5 Ω, replace the switch.

2. If the digital multimeter reads OL, shows a resistance in the MΩ, and/or doesn’t produce continuity tone, reinstall the switch.

Inspect the wiring on the malfunctioning switch for loose ferrules, terminal connections, fraying, or broken line.

Jog the machine to its reference position.

From the PathPilot interface, on the Settings tab, clear the Limit Switches checkbox. Then, on the dialog box, select OK.

Push in the Emergency Stop button on the operator box.

Adjust the limit switch flag so that the limit switch's red LED is off.

Take the machine our of Emergency Stop, press the Reset button, and, in the PathPilot interface, select Reset. Then jog the machine off of the limit switch.

From the PathPilot interface, on the Settings tab, select the Limit Switches checkbox to re-enable the limit switches and then reference the axes.
If the machine crashes again before triggering the limit switch, repeat Steps 2 through 6.