What the D1041 alarm means

The brake release circuit for an axis failed its self-check; the controller will not allow motion because a brake may not release (or may release unsafely). This is a routine repair in our workshop for Kawasaki E / F / C series (AS language) systems, and we normally pin it down during the first site check.

Most common causes

  • Brake release relay or driver fault on the servo/power board
  • Open in the brake release wiring
  • 24 V supply for the brake circuit degraded
  • Faulty brake coil
Field note: Begin with the first item in the list; it has a far higher on-machine occurrence rate than the others.

Step-by-step field fix

  1. Identify the axis and measure the brake coil resistance
  2. Check the brake release wiring and connectors
  3. Measure the 24 V brake supply under load
  4. Inspect the brake release relay/driver stage
  5. Replace the faulty component and verify the brake holds and releases cleanly
Safety first: For Kawasaki d1041, a failed brake means a vertical axis can drop - a person underneath is a severe-accident case, so we require mechanical support first and no repeated power-on trials. The self-serviceable action is Identify the axis and measure the brake coil resistance; anything past that falls under a dropping vertical axis and needs a certified engineer. On Kawasaki d1041: the only safe self-action is stopping the axis, holding power off and supporting the arm mechanically; gap measurement, torque testing and brake replacement are engineer work.

How we diagnose brake faults on site

Kawasaki d1041 belongs to the brake family. On Kawasaki d1041 the failing stage is cabinet drive boards (1GA / 1FA class) and power-stage modules per axis on the E-Controller / D-Controller / F-Controller - the electromagnetic brake: brake supply, coil, friction lining and mechanical gap - directly tied to whether an axis can drop. We start reading Kawasaki d1041 at the pendant ERROR HISTORY with AS error numbers (D / E / P prefixes).

The chain involved in Kawasaki d1041 runs: brake control signal -> brake supply circuit -> electromagnetic coil -> friction lining and disc -> axis holding.

If Kawasaki d1041 shows a slow drop after power-off: Brakes are wear parts: the lining thins with use, braking torque falls and the gap grows. The signature is a slow axis drop after power-off, or failure to hold under heavier load. We measure actual gap and holding torque against factory figures, and inspect the lining surface for oil - contamination collapses the friction coefficient, and adjusting the gap will not fix that; it needs cleaning or replacement. After any brake change we run a static hold test and hand over only when there is no creep.

Field notes on this page cover Kawasaki d1041 (Axis Brake Release Circuit Abnormal); written by the Henghuan repair team, updated 2026-10-01.

Real Field Case

Machine: Kawasaki RS080N (2016)

Symptom: A Kawasaki RS080N raised D1041 (axis brake release circuit abnormal).

What we did: We measured the brake-release circuit supply and components, found and replaced the faulty part, then tested brake release.

Result: The brake released normally after the circuit repair and the alarm cleared; about 3 hours.

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Related Brakes alarms

P1001 — Program Cannot Be Executed in Teach Mode W1013 — Encoder Battery Voltage Low (Warning) E1027 — Safety Circuit Cut E1028 — Motor Overload (Axis XX) E1029 — Encoder Revolution Count Abnormal (Axis XX) E1030 — Encoder Data Abnormal (Axis XX)
Same family: this code belongs to the Brake alarms family - the page collects all Brake-family codes we have handled, with the common inspection order and spares.
Other brands: we also keep field-fix libraries for Staubli · Epson · Nachi and more — see the complete alarm code hub.

Frequently asked questions

QWhat does the Kawasaki d1041 alarm mean?

The brake release circuit for an axis failed its self-check; the controller will not allow motion because a brake may not release (or may release unsafely). This is a routine repair in our workshop for Kawasaki E / F / C series (AS language) systems, and we normally pin it down during the first site check. Kawasaki d1041 sits in the brake family; on our work orders the highest-frequency trigger for this code is "Brake release relay or driver fault on the servo/power board".

QCan I clear a Kawasaki d1041 alarm myself?

Whether Kawasaki d1041 clears on its own depends on the outcome of "Identify the axis and measure the brake coil resistance". Finish the flow with "Replace the faulty component and verify the brake holds and releases cleanly" to confirm Kawasaki d1041 - do not skip it. If that step is clean, the second most frequent cause on Kawasaki d1041 is "Open in the brake release wiring". After clearing Kawasaki d1041, watch it for one shift. A second trip means stop and let an engineer arrive with the right test gear for a dropping vertical axis.

QWith a brake alarm like Kawasaki d1041, can we keep producing for now?

The commonest causes we see on Kawasaki d1041 are "Brake release relay or driver fault on the servo/power board, Open in the brake release wiring, 24 V supply for the brake circuit degraded", so we stock the van against those. For Kawasaki d1041 specifically, we carry the brand's common brake assemblies, relays and supply modules; every change ends with a static hold test. For Kawasaki d1041, brake faults carry drop risk so we prioritise them, and after replacement we hold-test on site before handover. Before we roll, tell us what Kawasaki d1041 shows on the pendant ERROR HISTORY with AS error numbers (D / E / P prefixes) and what the machine was doing - phone or video triage is free.

This page on Kawasaki d1041 was compiled from actual repair records of the Henghuan Robotics repair team. Alarm notes are our own summary for troubleshooting reference only and may vary with controller and software version — please consult Kawasaki documentation or contact us if in doubt. Henghuan is an independent service provider, not affiliated with or endorsed by Kawasaki.