XYZ Warranty Repairs / Packaging and Firmware

Thanks for the reply.
That's exactly what I suspected originally so I replaced the x-axis sensor and motor wiring on this one with those from a fully functional 1.0. Made no difference, so I'm working on two fallback plans: 1)sending the 1.0a in for warranty service and 2)setting up a FlashForge Dreamer (to be delivered next week) to get production back up while I get this straightened out.
Is the wiring quality on the Davinci typical of what other manufacturers use or is it as appallingly bad as it seems? It's a real shame for an otherwise solid piece of equipment to have such poor quality wiring.

So very, very true _ and that's the sad thing about the Davinci. I would upvote that comment if I could.
I have a 1.0 and a 1.0A, both completely  trouble-free and both generally did very good prints, until this kerfluffle with the 1.0A.
The hardware itself is fairly well-made, with good quality components (the board, motors, rails, etc.) but the 'glue' that holds it all together _ the wiring _ is extremely flimsy stuff with the cheapest possible connectors that they could slap together. You simply can't do that in a wiring system that's under constant movement and flex, and it should come as no surprise to XYZ when this stuff breaks and causes issues.
Of all the places to cut corners, they picked something they probably thought most casual users would never notice (and, honestly, as long as nothing broke, and everything stays nicely hidden in wire loom, most would neither notice or care), but, good lord, if you ever have to pull one apart its fairly obvious they made a bad, bad decision when they put their wiring harness together.
I suspect that whatever I have going on started as a wiring issue, but has caused something else.