Originally Posted by
maver1ck
Assuming the machine was working and noone made changes to the setup pages to cause this problem....
Most align failures are caused by issues with the limit switches used for homing the machine. The machines use a roller switch to locate the align position. The plunger on these switches sticks over time, so the signal does not get to the control at the proper time to allow the align procedure to complete.
Use Contact Cleaner (or similar) to clean the plunger while actuating it manually until it moves freely. Once the plunger doesn't stick, your problem will most likely disappear.