Looking at you're set up again, I believe your Softlimits should be in the positives+.

I have my machine set up in the far right corner and I'm going from zero out negatively.
This might be why your softlimits are being set off, also you could check your "Machine coors" as opposed to your offset to see if your over the limit.

WOW I'm confused because I notice there are two of you with the same machine asking diffrent questions in this same thread 

Sploo,

could you post your XML file when you get everything up and running and keep this post updated with your experience for other KG users.

You probably have limit switchs but if you don't I found this useful:

"GET A NORMALLY CLOSED MOMENTARY SWITCH FROM MOUSER.com two major types of switches.
  1. THROW
  2. Momentary
   
  ANY momentary switch that is like the ones behind the buttons on your DVD Player or radio.  Push buttons. Will work.
  Make sure the position is starting at normally closed though. Meaning the power is flowing through it until you hit the button and break the current.   This is opposite of the way a normal momentary switch works..... Get a momentary wire it in and you are off and running"

So in Mach you want the switches on active low.

For the soft limits:

First I homed all of the axis’
I moved all the axis to there extremes and wrote down the DRO reading.

My set up is like this, now looking at it can’t remember why it was difficult to setup: 
   
     Softmin Home Auto Zero
X   -23.30    0.000     yes
Y   -35.00    0,000     yes
Z   -4.80      0.000     yes

James,
If you have or can use a SWF compiler program, I'll have the code done for the MDI for Flash screens in Mach within the next few days.

If you don't have a SWD compiler program we'll have a number of screens to chose from,actually the setup you want will be one of the first screens we'll have. I should have some time tonight to finish the code and construct a demo screen for you to test.

If you would rather not use Flash, Art is working on adding this to Mach in the future. Currently there is a calculator for DRO's in Mach and this will be adapted for the MDI as well.

If you want send me a sketch of what your thinking for your screen 

Brett,
I think I'm going to be spending allot of money at McMaster carr 
Thanks for the mother load of mother loads, best link I've ever gotten

Brett
  "Conveyor brush strip" thats what I needed to know,Thanks Brett, I used "Pond" flooring rubber 

I notice in the picture there is a  gap between the router and the Plexiglas,I usually have the Plexiglas box flush to the mount or if I drop it down I use the flooring rubber to keep suction.

I wish I could have found transparent rubber flaps, like restruant cooler have.

sploo,
Since I cut guitars I use the Y axis as my 39" and the X 25".

The pin out on my control box is a little bit diffrent than the new KG but you should only have to change the "motor outputs" "Dir LowActive" and "Step LowActive" to change there directions.

Once in awhile I'll wonder why my machine isn't running smooth and come to find I forgot to have it in "Constant Velocity" mode.

If your Limit switch's go off for no reason change your "Deboucne Interval" to around 800+, or turn off "Watch Dog"

One thing that took me awhile to get the hang of was the "Softlimits" let me know if you have any trouble and I can post some advice about them.

The "Click" sound your getting is the encoder continually checking it's position, this is okay. I hadn't thought of it till it was completely quiet in my shop and there I heard it. You can fine tune your Gecko's but I don't believe it effects anything.

There is nothing better than Mach. Benny and others are designing some amazing screens and Art and Brain are continually adding more abilities and componets to Mach. It is the best program and is not just limited to controlling CNC machines.

I didn't like K2's vacuum system so I bought some plexy glass, screws(much simpler just to use aquarium glue) and a dryer vent.
Used my K2 to cut out a hole and $10 later I had a great vacuum system. It's not pretty but works great, I need to see the bit and easly change it.

sploo,
Sorry about the delay,
No I have the later model the KG-3925 CNC Router Frame 39x25x5 '05 model with a physical precision metric ball screw, the step per are set to 10,160.

My motor are the DMG DAE HWA DC motor's with US Electronics encoders.

I'd first check in the "port & pins" to make sure your X Y Z signal's are enabled and are set correctly for Dir and setp (I've made this mistake before) and check your "motor tuning", because I have metric my steps are setup for 10,160.

I've gotten humming from having my Kernel speed set to 4500 and not having my motors tuned correctly.

Mach will leave all of your files untouched (besides the default Mach files like Mach3Mill.xml), you could try a number of diffrent setup files just give them diffrent names.

Which ver of Mach 3 are you using?
I'll try to think of other possabilities 

I have mine in a climate controlled environment and I don't use hazardous material, so any touch screen should do.
I bought a USB 19" touch screen on ebay for $250.00. Just make sure how it hooks up to your computer, they have alot of serial port connection ones.

I have a K239X25 if you need any help.

I've posted the set up file here: http://www.machsupport.com/forum/index.php?board=7.0
I have the metric pertition ball screws, so you might need to tune your motor's if you don't have these.

I wanted to mention that when/if (crossing my fingers) the new Flash interface is finished you'll be able to open up seaprate windows of any componet you want.

These windows can be dragged,resized,minimized,fullscreen,transparent backgrounds ext..
To test them out you would load the screen from this URL:

http://www.vileguitars.com/MachFlash/Mastercon/master.swf

and open up any of these exe files on your desk top.

vileguitars.com/MachFlash/Mastercon/new connection test.zip

vileguitars.com/MachFlash/Mastercon/new connection alpha test.zip (these have transparency).

They will communicate with Mach no matter where you place them.

Here is a picture of them on my desktop:


*Currently and very soon you will be able to run Mach from a web address, you will be able to control from anywhere in the world.
I find this useful for my self. Some of my projects take hours to cut out. I go up to my office and start working on the next project. I have a camera hooked up so I can watch the machine. Very soon I will be able to go on line, log in and control the machine from my office via the internet. I will have another post if any one wants to ask question or comments.