We've already examined the encoder wheels and such, and have found no problems with it.
However, what we have nocied is that our super shifter's encoder shaft has more than the allowable axial play listed on the US digital website. By setting the transmission down on a flat table and using a dial caliper, we've discovered our transmission's encoder shafts have about 0.050" play (total, not +/-). So, to remedy this, we're next-day-airing some US digital fully housed and ball bearinged 250ct encoders and installing a HeliCal flexure coupling between the transmission and the encoder to isolate the encoder from possible damage by the transmission shaft.
And, completely unrelated, our plasma cutter quit and crashed (physically) today while running all of the parts for our final version of our shooter, as well as all the brackets to mount our pipes. I've had a rough day.
Thanks for your help and thought,
q