KUKA Robot codes
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KUKA Robot Controller

System · Basic

Alarm KRC0239

KUKA Robot KRC0239 - BRAKE HOLDING TORQUE EXCEEDED

The brake holding torque capacity on one or more axes has been exceeded, preventing the mechanical brake from maintaining the robot in its stopped position against gravity or external loads. This indicates the brake alone cannot safely hold the robot stationary, creating a critical safety hazard of uncontrolled axis movement.

KUKA RobotSystemBasic

KRC0239

KUKA Robot KRC0239 - BRAKE HOLDING TORQUE EXCEEDED

BRAKE HOLDING TORQUE EXCEEDED

The brake holding torque capacity on one or more axes has been exceeded, preventing the mechanical brake from maintaining the robot in its stopped position against gravity or external loads. This indicates the brake alone cannot safely hold the robot stationary, creating a critical safety hazard of uncontrolled axis movement.

Common Causes

  • Payload mass or center of gravity shifted beyond safe holding limits for the mechanical brake
  • Brake friction material worn or degraded, reducing mechanical holding torque effectiveness
  • Robot positioned to maximize gravitational load on specific axes, overwhelming brake holding capacity
  • External force or side load applied to the tool during stationary operation exceeding brake design
  • Brake spring preload weakened or brake calibration drift due to thermal cycling or maintenance

Troubleshooting Steps

  1. 1Immediately stop all robot motion and verify the arm does not drift in the current position
  2. 2Check brake condition diagnostics and wear status in KUKA smartPAD maintenance information
  3. 3Reduce payload mass or use external mechanical support to relieve brake holding torque demand
  4. 4Reposition the robot to a configuration that minimizes gravitational moment on the affected axes
  5. 5Inspect brake assembly for wear, contamination, or misalignment during preventive maintenance
  6. 6Schedule KUKA service technician to replace brake components or recalibrate brake preload settings

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