What causes KUKA Robot alarm KRC0036?

Encoder malfunction or loss of commutation reference causing accumulated position error on endless axis. Continuous rotation command executed without periodic $REVO_NUM (revolution counter) reset or wrapping. Controller firmware error or memory corruption affecting axis position data structure. Extended operation without power cycle allowing position value to drift beyond valid numerical range. Defective incremental encoder with missing zero pulse or Hall sensor drift on endless rotation axis.

How do I fix KUKA Robot alarm KRC0036?

1. Power cycle the entire KRC4 controller and robot system to reset position counters 2. Check encoder connector integrity and signal quality using diagnostic tools in KUKA smartPAD 3. Verify $REVO_NUM parameter is within valid range (99999000 to 999999000) in system configuration 4. Manually move affected axis to mechanical zero position and reinitialize using teach pendant referencing procedure 5. Replace encoder or commutation sensor if diagnostic confirms hardware failure on endless axis 6. Contact KUKA service to perform firmware update if controller memory corruption is suspected

KUKA Robot codes

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KUKA Robot Controller

Overtravel/Limit · Basic

Alarm KRC0036

KUKA Robot KRC0036 - RANGE OVERFLOW ** **

An endless (revolute) axis has accumulated rotation value exceeding safe numerical limits, with actual position greater than +/- 90 times 10E15 increments or revolution counter outside valid range. This indicates potential encoder failure, controller memory corruption, or continuous rotation without proper reset.

KUKA RobotOvertravel/LimitBasic

KRC0036

KUKA Robot KRC0036 - RANGE OVERFLOW ** **

RANGE OVERFLOW ** **

Common Causes

Encoder malfunction or loss of commutation reference causing accumulated position error on endless axis
Continuous rotation command executed without periodic $REVO_NUM (revolution counter) reset or wrapping
Controller firmware error or memory corruption affecting axis position data structure
Extended operation without power cycle allowing position value to drift beyond valid numerical range
Defective incremental encoder with missing zero pulse or Hall sensor drift on endless rotation axis

Troubleshooting Steps

1Power cycle the entire KRC4 controller and robot system to reset position counters
2Check encoder connector integrity and signal quality using diagnostic tools in KUKA smartPAD
3Verify $REVO_NUM parameter is within valid range (99999000 to 999999000) in system configuration
4Manually move affected axis to mechanical zero position and reinitialize using teach pendant referencing procedure
5Replace encoder or commutation sensor if diagnostic confirms hardware failure on endless axis
6Contact KUKA service to perform firmware update if controller memory corruption is suspected

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