KRC0044

Common Causes

• Robot arm joint mechanically jammed by collision, tool interference, or cable entanglement restricting motor rotation
• Program commanded motion velocity too high or acceleration too aggressive for actual payload mass versus specification
• Servo motor rotor winding short circuit or bearing failure causing abnormal current draw at startup
• Encoder feedback signal corrupted or disconnected causing amplifier to draw excessive current attempting to reach target position
• Load cell or force-torque sensor miscalibrated, causing control algorithm to command excessive compensatory current

Troubleshooting Steps

1. 1Remove power immediately by pressing red emergency stop button and perform 60-second wait before investigating root cause
2. 2Manually verify the affected axis moves freely without binding by gently hand-rotating joint through full range while powered down
3. 3Use SmartPAD diagnostics to review axis current history graph and identify whether overcurrent was instantaneous spike or sustained rise
4. 4Verify programmed tool payload in WorkVisual robot configuration matches actual mounted end-effector weight within tolerance specifications
5. 5Inspect motor connector and encoder cable for visible damage, corrosion, or loose crimped contacts using visual inspection
6. 6Contact KUKA field service to perform motor winding resistance test and encoder signal analysis if mechanical clearance and program parameters are correct