KRC0205

Common Causes

• Teach program contains movement command that drives axis position beyond the configured software limit value in SafeOperation settings
• Incorrect software limit values entered during robot installation or commissioning that do not match actual mechanical axis travel range
• Operator manual teach movement using KUKA smartPAD or teach pendant without awareness of current software limit boundaries
• External mechanical collision or impact that forced robot axis beyond normal range despite servo control attempting to prevent overshoot
• Corrupted or lost configuration of software limit values due to controller memory error or incomplete parameter backup restore

Troubleshooting Steps

1. 1Immediately release the teach pendant deadman switch to stop any active manual movement of the robot arm
2. 2Open the active KRL program in WorkVisual and identify which axis movement command triggered the software limit alarm condition
3. 3Navigate to SafeOperation tab in WorkVisual and verify that software limit values for all axes match the mechanical design specifications of your KUKA robot model
4. 4Manually move the affected axis back toward home position using teach pendant in manual mode with reduced speed until alarm clears
5. 5If limit values are incorrect, update them in WorkVisual SafeOperation settings, recompile the project, and download to KRC4 controller
6. 6Run a complete axis mastering routine through Maintenance menu on KUKA smartPAD to resynchronize position feedback and confirm encoder calibration