On Sat, Aug 28, 2010 at 04:08:21PM -0500, Stuart Stevenson wrote:

> max pocket number is 55. skipping tool 99999

There's an invalid line in your tool table

> [19076.980342] io[19939]: segfault at 08a40880 eip 0804b222 esp bfa1bcc0
> error 6

And then "io" (the subprogram that handles the tool change and
coolant etc) crashes.

>   Hope I have included all the details
>   Please review and tell me I am not crazy

I see you have random toolchanger enabled.  I think you have probably
found a bug triggered by an incorrect entry in your tool table.

Please post your tool table as-is, so maybe I can reproduce it and
fix it.  

After you make a copy, fix up your tool table so every pocket (P word)
is 55 or lower.  Eventually you will have one line for every pocket on
your machine including P0 which is the spindle.  Try a very minimal
tool table like

T0 P0 Z0.0
T1 P1 Z1.0
T2 P2 Z1.0

and see if it runs.

Your pictures look great.  It's awesome that you have the expertise
in-house to retrofit and maintain your machines.  What good insurance
that is for your business.

Chris

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