Problem Loading Master on HURCO KM-1

[JREEN2]

I recently purchased a HURCO KM-1 with 32K memory for my home shop. It uses a tape emulator for communication with the PC. This is my first CNC machine and I need a little help.

Background Information
The machine was functioning correctly prior to transporting it to my shop. I have hooked up power to the HURCO and I get the "LOAD MASTER" on the display when I close the disconnect. I made a 5 foot CAT 5 cable with 3 of the wires connected to 9 pin connectors, wired as shown on the emulator card manufactures web site (http://www.amtsinc.com/support/gcode.htm). I loaded the PC software and master file (RS232 version 1.2 and 33a1.mst) from the http://www.amtsinc.com/support/download.html download page onto my 133 mz lap top running Windows 95 (I have also tried an old 486). But I seem to be unable to load the master. Here is what I do and what happens when I try to load the master:
I boot the PC in Windows 95 then reboot in the DOS mode and close the disconnect at the machine. I have been told that the software will not work in a DOS window and I have also tried a DOS boot disk. I verify "LOAD MASTER" is displayed then select the 33a1.mst on the PC. The PC tells me to push the MASTER CLEAR and I push it at the machine. The PC recognizes that I have pushed the MASTER CLEAR then says something like it is simulating the tape leader. After a few seconds the PC says "Load in progress" but never seems to finish (I give it 10 or 15 minutes)
I have tried different baud rate settings in the software utilities - L2, 250DB, 100DB. Baud rate seems to be the only port setting I can change from the software. I see no activity on the progress bar at the PC. I have removed the cards in the controller, cleaned them and reinstalled them. Tech support for the emulator card suggested that I switch the memory cards (two 16K cards) and told be how. The thought here was that memory board #1 may be bad and switching them could help troubleshoot (partially load the master). There was no difference, still cannot load the master. So, I think it is probably some sort of communication problem with port settings or something. I plan to talk with Tech support again tommorrow. I assume that the port settings are controlled by the software. If not, how can I change them (data bits, stop bits, parity, protocol) in DOS? Anybody have ideas on what else I should check or try?