My router ran flawlessly for two years.  Recently I had an issue with the tool path tool path progress stopping when Gcode was loaded.  Tech support could not resolve it and suggested a reinstall.  I reinstalled (v4300 to v5036), put all the settings back, and here are my issues.

Mach4 stops when executing a line with G90, G91, or G94.  G90.1 and G91.1 cause no problems.  Same results with the MDI.   Any ideas why they won't execute? These are common commands.   After removing them, I let the machine cut air for several minutes (with my mouse over the stop button) and it appeared to work fine except ...

Here's a bigger mystery to me.  The Z and Y axes move correctly.  When the X-axis is instructed to move 10 inches, the displayed machine coordinates change by 10 inches.  However, the displayed work coordinates change by about 15 inches and the actual motion is about 7 inches (appears to be a reciprocal relationship).  I have an x-soft limit set at 29 inches and could move the WCS X past 44 inches (at which point the machine coordinate was almost 29).  If the motor counts per unit (which I checked) were off in the setup, I would expect both coordinate systems to be wrong.  How can the displayed work coordinates move a different amount from the machine coordinates?  What do I check to resolve this?  I have no idea what to check.

Lastly, my estimated tool path does not appear in the tool path window nor do the soft limits.  I have not tried to solve this issue other than to do a few clicks.  I think that the first two issues might be related to this. 

I have a Pokeys57cnc control board connected by ethernet.

Thank you for any suggestions.

All issues were resolved with another reinstall of Mach4.