The time-out error message is received because the X motor drive system did not get to the encoder position within a certain time period.  This is usually caused by excessive slop in the X drive system. Imagine that the X-axis was commanded to go to X encoder position 35803. The axis moves there but overshoots a little. The motor reverses direction and moves, but again overshoots, the motor reverses again, moves, doesn't get there, moves again and then over shoots. Finally, the motion time period expires, the encoder is not at the desired location, so the error is displayed.  You can imagine that if the X belt was loose, and the X motor turns a fraction of 1 degree, all this does is take up slack, and the encoder never changes position. The solution is to find the source of the slack/slop and correct it.

1. The first item to check is the belt. Unfortunately, there is no measurement tool to determine proper belt tension. Common sense should dictate the tension, but as a simple test, pinch the belt in the middle, and using moderated force, push and pull on the belt and the movement should be no more than about 1 inch. The X idler assembly is on the left side of the belt, and the motor is on the right side.  Four screws will loosen the X motor plate (Note: loosen the bolts that hold the motor plate to the cross beam, not the bolts that hold the motor to the motor plate.) There is a small tensioning screw and nut assembly, between the X motor plate and the Cross beam. Unscrew the nut and the motor will slide to the left, releasing tension. To tighten the belt, the nut must be tightened to force the motor plate to the right. (Note: the tensioning screw must be held stationary while the nut is turned) When the tension is sufficient, tighten the 4 screws to secure the motor plate to the cross beam. Note: If the belt is too tight, it will wear out the idler bearings faster.
   
2. While the belt is loose, check the idler assembly. There are two bearings on the idler shaft and these bearings, especially the lower, can wear out. Spinning the pulley by hand, it should feel smooth. If the motion feels rough, replace the X idler assembly. Note whether the idler housing is silver (3/8" shaft) or black (1/2" shaft).
   
3. The belt itself can wear out. Note the presence of rubber dust around either the X motor pulley or the X idler pulley. Presence of black power dust is a good indication that the teeth of the belt are wearing down. This wear translates to slop between the belt and the pulley, especially on the motor pulley. This slop will cause X motion time-out errors.
   
4. The X motor is heavy duty and rarely wears out. However the pulley on the motor shaft can become loose. Check the two screws on the pulley clamp for tightness. Even a tiny amount of movement can cause problems. The motor can become defective in two ways, electrically or mechanically. Unplug the motor and measure the resistance between pins 1 and 2 (winding A). Then measure the resistance between pins 3 and 4 (winding B). These resistance values must match exactly. (the actual value is not important) If they do not, assume that some internal windings have shorted and replace the motor. Mechanically, it is impossible to determine the condition of the motor bearings by hand. Replacing the motor is the only sure way to rule a bad motor out. 
   
5. The X belt attaches to the gantry/head assembly by a belt clamp. Check this clamp for tightness.
   
6. Swap the X and Y motor driver cards.  The DIP switch and Jumpers should be set the same, and are directly interchangeable.
   
7. The X encoder is located up on the gantry. To access the X encoder, remove the left side plexiglass panel and locate the two, black, mechanical stop blocks. Remove the left stop block.  The encoder has a tri-state LED, which can change from green to yellow to red. The LED should be green throughout the entire range of travel. Often times there can be a build up of dust and lint between the encoder eye and the gold encoder strip. Remove the encoder and remove any contaminants using a swab and isopropyl alcohol. Make sure the lens is clean. Do not unplug the encoder with the machine powered on. This can blow the encoder’s op-amp. Reinstall the encoder and adjust as necessary to achieve the green LED for the complete range of motion. Adjustment is done by manually moving the encoder until the LED is green, and then tightening the two mounting screws.
   
8. Check the encoder gold strip for scratches, cuts, finger prints, oil, etc.  Clean with isopropyl alcohol and a clean cloth.
   

Following this procedure should solve the X motion time-out error. If not, contact BPM technical support.