What causes KUKA Robot alarm KRC0302?

End-effector or tool load exceeds the axis weight capacity specification. Incorrect tool center of gravity (TCP) offset or mass parameter in the robot configuration. Robot arm positioned with axis at unfavorable mechanical advantage, concentrating load on single joint. Friction or binding in the axis gearbox due to mechanical wear or misalignment. Payload calibration error or undeclared additional weight mounted on the tool interface.

How do I fix KUKA Robot alarm KRC0302?

1. Verify the actual end-effector and tool mass against the robot's maximum payload specification for the affected axis 2. Confirm correct TCP offset and load mass parameters in the tool data configuration (Tool→Mass and Center of Gravity) 3. Move the robot to a neutral position and check if alarm persists; note the static torque percentage in the Diagnostics menu 4. Inspect the affected axis for mechanical resistance, binding, or unusual friction by manual teach pendant movement 5. Recalibrate or re-measure the tool load using the KUKA payload identification procedure if tool parameters were recently changed 6. If alarm persists after verification, contact KUKA service as the axis gearbox may require inspection or replacement

KUKA Robot codes

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KUKA Robot Controller

Servo/Axis · Basic

Alarm KRC0302

KUKA Robot KRC0302 - OVERLOAD OF GEAR TORQUE <axis number> BY <percentage value>

This alarm indicates that the static torque load on the specified robot axis has exceeded the maximum rated gear torque capacity by the displayed percentage value. The controller continuously monitors axis torque during motion and rest states, and triggers this alarm when the load permanently exceeds the mechanical design limit of the axis gearbox.

KUKA RobotServo/AxisBasic

KRC0302

KUKA Robot KRC0302 - OVERLOAD OF GEAR TORQUE <axis number> BY <percentage value>

OVERLOAD OF GEAR TORQUE <axis number> BY <percentage value>

Common Causes

End-effector or tool load exceeds the axis weight capacity specification
Incorrect tool center of gravity (TCP) offset or mass parameter in the robot configuration
Robot arm positioned with axis at unfavorable mechanical advantage, concentrating load on single joint
Friction or binding in the axis gearbox due to mechanical wear or misalignment
Payload calibration error or undeclared additional weight mounted on the tool interface

Troubleshooting Steps

1Verify the actual end-effector and tool mass against the robot's maximum payload specification for the affected axis
2Confirm correct TCP offset and load mass parameters in the tool data configuration (Tool→Mass and Center of Gravity)
3Move the robot to a neutral position and check if alarm persists; note the static torque percentage in the Diagnostics menu
4Inspect the affected axis for mechanical resistance, binding, or unusual friction by manual teach pendant movement
5Recalibrate or re-measure the tool load using the KUKA payload identification procedure if tool parameters were recently changed
6If alarm persists after verification, contact KUKA service as the axis gearbox may require inspection or replacement

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