Make sure that your work offset for the G54 coordinate system offset, is zeros for all three axis to start with.
I'm not sure what kind of command in Mach2 ensures that your machine returns to exact home for the toolchange. Do you know if this logic is in place, and working? Relying on limit switches to find home is not the best method, IMO, because the repeatability is suspect. An encoder index is the best.
If you do use a G54 work offset (someday), you might have to take the precaution to cancel it with G53 before returning to the tool change position. It depends on the smarts behind the controller software.
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