Thanks, BR549, I tried loading the latest rev of Mach 3, and ran the part (cutting air). It seemed to be fine, then I noticed I hadn't defined the tool 4 dia. After setting that to .125 dia. it was back to the same problem.
Tweakie, I attached a better screen shot, deleted most of the code so the portion of interest is larger so you can see the extra moves. Looks like Mach is thinking each arc segment needs a lead-in move. But why only these few segments and not the rest of the part outline?
Before the original post I tried several times re-drawing the arcs slightly different and re-posting the code. no change.
Will a Fanuc post processor work better? maybe I'll try that after the grandkids go home today.