I have a KM5P. The machine was powered down for a week or ten days. I powered up the machine, went thru the start up procedures, inputing the spindle tool number, powering up the servos, calibrating the axis, etc. Not moving any of the machine axis after calibration, I started the spindle to warm it up. The spindle ran for a short period then stopped with a "Z axis servo error" message on the crt. Thinking the Z axis had some how over traveled, I manually jogged the Z axis from the home position by hand.

Powering the machine down and going thru the start up procedure, the error reappears when I try to calibrate the axis.

Thanks in advance,

bgmnn

I had the same error on my KM3-P. My mill has plastic "multi-pin" connectors made by Amp. Thes connectors get brittle and fracture, allowing poor contact between the internal "pins and sleeves". If you have this type of connection on your servo's, BE VERY CAREFUL! Wiggling the connectors while under power can cause you to blow transistors on the servo amps and quite possibly damage the servo board. I would start by shutting down the machine and checking the connection at the back of the cabinet for the Z-axis. I think it is more probable that the cabinet connector has been bumped or failed due to the load on the plastic, rather than the connection at the servo.

note that everything I just said is based on my KM3-P, I don't know what the KM5-P is.

Does your machine have a prox switch? I had a problem with my Tm-5 Z axis over travelling when I would home it. Turns out the switch was bad. The spindle would turn on Ok then would shut off. The prox was working intermittently

you must check all wiring/connection on Z axis area ( Spindle Wire or something ), I think you have some wire crack and short to ground when z axis moving, this problem also happen to last time, I found wire to spindle encoder crack and after re-wire all ok. good luck!!