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Access Diagnostics menu: HMI → Diagnosis → Actual Values → Channel [%1] → Axis Positions. Record current machine coordinates and compare against programmed block target.

Navigate to Parameters → Machine Data → 3600 (Axis-Specific) series. Verify MD 36100 (positive limit) and MD 36110 (negative limit) for the axis triggering the alarm. Check if programmed position falls outside this range.

Do not blindly increase soft limits without verifying physical machine safety and end-stop hardware clearance.

Review active G10 offset registers (SD 42000-42199 depending on offset number) and verify coordinate transformation is not compounding position error. Cross-check with MD 28050 (zero offset enable).

If limits are correctly set, edit the NC program to move within legal boundaries, or adjust soft limits via Parameters → Machine Data if machine geometry has been verified.

Access Diagnosis → Kinematic Simulation (if available in HMI) or review Active Kinematics in Parameters → Machine Data → 3200 (Kinematics). Verify MD 32010 (kinematics type) matches configured machine structure.

Check rotary axis soft limits: MD 36100/36110 for A, B, C axes. Many 5-axis machines have ±180° or ±90° limits. Verify programmed tool orientation does not require exceeding these ranges.

Increasing rotary axis limits may introduce collision zones—verify with machine builder specifications and simulation.

Inspect NC program for unrealistic tool orientation angles (AABB, ABBC commands). Recalculate post-processor output or manually adjust approach angles to remain within workspace.

If kinematics parameters have been modified, reload and verify via Commissioning → Axis Configuration to ensure transformation matrices are correct.

Query active coordinate system offset via Diagnosis → Offset Data or Parameters → Offset Management. Identify which G54-G59 offset table is active and review offset values in SD 42000 series (work offset) and SD 32000 series (tool offset).

Manually calculate transformed position: [programmed coordinate] + [active G54-G59 offset] + [tool length offset]. Verify result falls within machine soft limits (MD 36100/36110).

Check for unintended DRF (MD 28020, MD 28021) or rotating frame settings that may further offset coordinates. Disable if not required via Parameters → Coordinate System → Reference Point offset.

Correct the active offset values or reprogram the block using geometry that accounts for currently active offsets. Verify with MDI test move (Jog mode) before restarting automatic cycle.