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Here's my take on it. I think you have two options depending on what modules you have. If you have advance multi-axis then you can use a swarf toolpath with a 4-axis output. If you don't have...

you have to clean the software limits by pressing the O(P) and Cancel keys on startup. That will clear the software limits and allow you to home it.

Try taking the lubricator reservoir off and clean the intake screen. I had the same problem and that solved it.

50 years. wow. that must mean you know everything. Now don't I feel foolish for trying to help the OP with his problem.

The biggest factor in combating knurl problems is making sure that your circumference is close to a multiple of your knurl pitch. If it isn't you will fight it all day long.

If you are using a stand alone second operation, I usually create a copy of the part on a new level and flip it around.

I have several machines with sub spindles. In that case I set a new WCS to...

you can get away with a straight plunge in the z-axis with a two flute endmill, but you are far better off using a 3/16 and running a helical boring cycle.