I have not been able to narrow it down to an exact margin where it does and does not work. As far as the lead in, I have turned it down to 0 percent and it still will not work. Even if I only put in .001 for an offset in say a .290 hole with a .250 endmill, for example I will get the same error when without the offset it runs fine.

My company is using the X3 version of MasterCAM and we have an issue making offsets on the inside of tight holes. We use Fanuc controls. We keep getting the 034 P/S alarm when we try to use endmills that are close in size to the hole we are trying to mill. The program runs fine until we try to make offset changes to make the hole smaller. We have remedied the problem on several occasions by using a smaller endmill. However,I do not believe that this should be necessary, since the endmills we want to use are smaller than the holes we are trying to mill. Does anyone have an idea about why this is?