liminfoKUKA Error Code Reference
KUKA robot controller error code reference with causes and solutions
About KUKA Error Code Reference
The KUKA Error Code Reference is a searchable database of 55+ error codes for KUKA industrial robots running on KR C4 and KR C5 controllers with KSS software. Each entry includes the error identifier, a clear description, root-cause analysis, and numbered resolution steps tailored for robot programmers, maintenance engineers, and system integrators working in automotive, welding, palletizing, and general industrial automation.
Error categories cover the full KUKA ecosystem: SYS codes for controller hardware (temperature, PSU, battery, MFC, SmartPAD), MO codes for motion and axis faults (position deviation, speed/torque limits, mastering, singularity, encoder errors), DR codes for the drive system (KSP overcurrent/overvoltage, KPP faults, RDC communication, regenerative resistor), COM codes for fieldbus communication (EtherCAT, PROFINET, DeviceNet, EtherNet/IP, PROFIBUS, RSI), SR codes for SafeRobot safety functions (E-stop, door interlock, SOS, STO), and PGM codes for KRL programming errors.
Everything runs in your browser with zero data transmitted to any server. The tool supports category filtering, full-text search, and dark mode for use on the shop floor. No download, account, or installation required.
Key Features
- Searchable database of 55+ KUKA robot error codes organized into six categories (SYS, MO, DR, COM, SR, PGM)
- KR C4/C5 controller system errors including temperature, PSU, battery, MFC, SmartPAD, and fan module faults
- Motion and axis diagnostics for position deviation, speed/torque limits, soft limits, mastering, singularity, and encoder errors
- Drive system troubleshooting for KSP overcurrent/overvoltage, KPP faults, RDC communication, and motor temperature warnings
- Fieldbus communication errors covering EtherCAT, PROFINET IO, DeviceNet, EtherNet/IP, PROFIBUS DP, and RSI timeout
- SafeRobot safety codes for emergency stop, door interlock, enabling switch, speed/workspace violations, SOS, and STO
- KRL program errors including syntax faults, runtime errors, Submit interpreter issues, and license problems
- 100% browser-based with dark mode — no account, no download, completely free for industrial use
Frequently Asked Questions
What does KUKA error MO-1 (position deviation exceeded) mean?
KUKA MO-1 indicates the deviation between the commanded and actual position of a robot axis exceeded the allowable tolerance. Common causes include mechanical overload, collision with fixtures, worn reducer gears, or faulty motor encoder cables. To resolve: check for external interference, inspect the reducer for abnormal noise or backlash, verify encoder cable connections, adjust servo gain parameters in WorkVisual, and confirm the tool/base load data matches the actual payload.
How do I resolve KUKA SYS-3 (battery voltage low) error?
SYS-3 means the encoder backup battery voltage has dropped below the threshold. Each axis uses a 3.6V lithium battery to retain absolute position data. Replace the battery with the controller power ON to preserve position data. After replacement, confirm the error clears. If the battery was fully depleted before replacement, mastering (calibration) with the EMT tool will be required. Set a preventive replacement schedule of 2-3 years.
How do I perform mastering on a KUKA robot after MO-14?
MO-14 indicates mastering data is invalid, typically after battery depletion, encoder replacement, or reducer replacement. Steps: 1) Check $MASTERINGSTATE variable. 2) Use the EMT (Electronic Mastering Tool) to master each axis at its notch position. 3) If a backup of previous mastering data exists, restore it. 4) After mastering, verify all programmed positions before resuming production. Each axis must be mastered individually.
What causes KUKA EtherCAT communication error COM-1?
COM-1 indicates the EtherCAT fieldbus connection between the KR C4 controller and external slave devices has been interrupted. Check all EtherCAT cables (Cat5e minimum) for damage or loose connections. Verify slave device power and status LEDs. Use WorkVisual bus diagnostics to identify the exact slave that lost communication. Check the EtherCAT port LEDs (Link/Activity) on both the controller and each slave device in the daisy-chain topology.
How do I troubleshoot KUKA drive system errors (DR codes)?
KUKA DR codes cover KSP servo pack faults. DR-1 (overcurrent): check for mechanical interference and measure motor cable insulation. DR-2 (overvoltage): inspect braking resistor and check regenerative energy during deceleration. DR-3 (undervoltage): verify 3-phase 400V AC input stability. DR-5/DR-7 (temperature): check cooling fans and ambient temperature. DR-10 (KPP fault): check KPP LED status and measure DC bus output. DR-12 (RDC): inspect RDC board seating and cables.
What KUKA safety (SR) errors does this reference cover?
This reference covers eight SafeRobot safety codes: SR-1 (E-stop activated), SR-3 (safety door interlock violation), SR-5 (enabling switch error), SR-7 (axis speed violation in SafeRobot), SR-9 (workspace violation), SR-11 (SOS - Safe Operating Stop deviation), SR-13 (STO - Safe Torque Off activation), and SR-15 (safety controller checksum error). Each includes the safety-specific cause analysis and resolution procedure.
How do I fix KUKA KRL program error PGM-1 (syntax error)?
PGM-1 indicates a syntax error in the KRL (KUKA Robot Language) program. Check the line number shown in the error message. Common issues include missing END statements, mismatched parentheses, undeclared variables, or incorrect data types. Use the SmartPAD inline editor or WorkVisual to correct the code, then run the syntax check function before executing. For complex logic, use WorkVisual's offline programming and simulation features.
Is this KUKA error code reference free and safe to use?
Yes, the KUKA Error Code Reference is completely free with no usage limits, no account registration, and no software download. All processing happens locally in your browser, so no error code lookups or data are ever transmitted to any server. It is part of liminfo.com's collection of free online industrial automation and robotics tools.