KRC0106

Common Causes

• Depleted or disconnected encoder backup battery in the robot base resulting in absolute encoder position loss during power-off periods
• KPP or RDC (Resolver Digital Converter) module replacement without proper master data transfer or mastering execution
• Severe mechanical impact or collision causing gearbox damage and physical encoder position shift relative to the mechanical hard stop
• Corruption of MasRef.dat or Machine.dat files in C:\KRC\ROBOTER\KRC\R1 directory due to improper shutdown or file system errors
• Software update or archive restoration that replaced axis-specific mastering data with incorrect template or backup values

Troubleshooting Steps

1. 1Step 1: Check encoder battery voltage at X40 connector on KPP using multimeter, voltage should be above 2.8VDC for lithium cells, replace if below threshold
2. 2Step 2: Navigate to Startup > Service > Mastering and verify which specific axes have lost mastering by reviewing status indicators
3. 3Step 3: Obtain mastering load data from robot nameplate located on axis 1 base or from archived commissioning documentation with EMD offset values
4. 4Step 4: If original mastering data unavailable, perform EMD mastering using KUKA mastering tool by jogging each axis to mechanical zero position marked on robot
5. 5Step 5: Load EMD values via Service > Mastering > Load Mastering, input axis-specific offset values and confirm, then perform reference motion
6. 6Step 6: If mastering fails or position deviation alarms occur, inspect mechanical gearbox integrity for damage, verify encoder cable continuity at motor flanges, escalate for encoder or gearbox replacement