Ok need more help. Turns out it was the X axis jamming, with tech support help, went through the following things to try to fix it:
- Square the table - Done, 1/16th out of square
Check gear backlash making sure spur gears do not have any weight on them - Done, 4 thou clearance between the rack and gear
Check Drive Cards in controller - Done, swapped connections no change
Check Motor - Done, swapped motors on axis, still no change.
Check Inside Controller - Done, blew out any dust per recommendation
Remove drive shaft and test with only motor turning spur gear - Done, problem fixed.
So I checked the driveshaft for damage, and spur gear for damage, use a dial indicator and no runout at all. reinstalled and it won't work. To recap the motor drives the gantry X+ but when it transitions to X- it often sits there and buzzes. This only happens at feedrates in excess of 100 IPM. When I mean often I mean every file I run but not on ever X- move. without the motors energized I can push the gantry without any resistance whatsoever so at this point I can only summarize that the motor is shot, which would make sense since I noticed that some of my students whom I trained to use the machine were pushing the gantry while motors were energized and not using the jog, I have heard that is very bad.
At this point unless anyone can suggest something else out I plan to purchase a new motor to replace this one and try it. At the same time I am also going to purchase another motor mounting bracket, pulley, belt and mounting hardware and cable to run another X axis motor on the opposite side and eliminate the driveshaft using the motor I have, much like the never models have. I plan to add more weight to the table including air nozzle system to keep the racks clean, oxy fuel setup and a fume extractor so I can use the extra power. While the motor I have appears to not be pulling its weight, adding a new motor and using this one as well, will definitely improve my available torque at high feed rates, which appears to be the problem.