What the E1028 alarm means

Feedback current from the power module exceeded the motor's continuous rating for the allowed time — the servo software overload curve tripped for the named axis. We fix this Kawasaki E / F / C series (AS language) fault almost daily, and one round of on-site checks usually confirms what is going on.

Most common causes

  • Arm interference with fixture, workpiece, or snagged cable
  • Brake not releasing on the axis
  • Damaged reducer/gearing or bearing
  • Payload above the robot's rated capacity
  • Overhauling motion beyond motor rating
  • Low gas-spring pressure on models with balancers
Field note: We have tallied real cases: the first cause tops the list, so start your diagnosis there.

Step-by-step field fix

  1. Jog the arm off the interference in teach mode
  2. Check that the axis brake releases with servo power on
  3. Inspect reducers and drive train for damage or binding
  4. Verify payload is within rating and gas-spring pressure is correct
  5. If current stays high with no mechanical cause, test the servo board, power module and motor
Safety first: For Kawasaki e1028, this alarm family involves the DC bus, which sits at several hundred volts and stays charged for minutes after power-off - touching terminals is a shock hazard. On site you may not carry out the first step yourself: Jog the arm off the interference in teach mode. Beyond that it is the DC bus and power stage work - leave it to a professional. On Kawasaki e1028: checking incoming voltage at the disconnect and looking at breakers and fuses is fine to do yourself; opening the cabinet to touch bus terminals or pulling power modules needs a qualified electrician.

How we diagnose drive alarms on site

Kawasaki e1028 belongs to the drive & power stage family. On Kawasaki e1028 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 fault sits on the energy chain: mains input, rectification, DC bus, braking resistor, inverter power devices and the drive board. We start reading Kawasaki e1028 at the pendant ERROR HISTORY with AS error numbers (D / E / P prefixes).

The chain involved in Kawasaki e1028 runs: three-phase mains -> rectifier -> DC bus (bus capacitors) -> brake chopper / braking resistor -> inverter (IGBT) -> motor.

Bottom line up front: Arm interference with fixture, workpiece, or snagged cable is the first suspect for Kawasaki e1028, but read it along the energy chain: Any link on this chain dropping voltage shows up at the end as a drive alarm, so order matters. We measure the mains first: more than 3% phase imbalance is enough to sag the bus under load, and plenty of bus over/under-voltage alarms are actually a grid problem wearing a robot costume. Mains fine, then the bus capacitors - bulged cases, weeping electrolyte or a lifted vent mean replacement; capacitance down 20% or more cannot hold the bus during braking. Last, the braking resistor: healthy values sit in the tens of ohms depending on rating, and an open or drifted resistor trips regenerative overvoltage directly.

Field notes on this page cover Kawasaki e1028 (Motor Overload (Axis XX)); written by the Henghuan repair team, updated 2026-10-01.

Real Field Case

Machine: Kawasaki BX200L (2015)

Symptom: A Kawasaki BX200L raised E1028 (motor overload, axis XX).

What we did: We located the specific axis, checked mechanical drag and load, found increased reducer resistance and serviced the reducer.

Result: The load returned to normal after reducer maintenance and the alarm cleared; about 4 hours.

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Related Drive & Power Stage alarms

D1028 — Servo Board DC Power Abnormal (Servo FPGA) D1562 — Power Sequence Board — AC External Voltage Too High E1294 — Servo Board IO 24V Dropped
Same family: this code belongs to the Drive & power stage alarms family - the page collects all Drive & power stage-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 e1028 alarm mean?

Feedback current from the power module exceeded the motor's continuous rating for the allowed time — the servo software overload curve tripped for the named axis. We fix this Kawasaki E / F / C series (AS language) fault almost daily, and one round of on-site checks usually confirms what is going on. Kawasaki e1028 sits in the drive & power stage family; on our work orders the highest-frequency trigger for this code is "Arm interference with fixture, workpiece, or snagged cable".

QCan I clear a Kawasaki e1028 alarm myself?

Whether Kawasaki e1028 clears on its own depends on the outcome of "Jog the arm off the interference in teach mode". Finish the flow with "If current stays high with no mechanical cause, test the servo board, power module and motor" to confirm Kawasaki e1028 - do not skip it. If that step is clean, the second most frequent cause on Kawasaki e1028 is "Brake not releasing on the axis". Do not chase takt through a repeating Kawasaki e1028. Left alone, drive & power stage faults tend to graduate from repairable to must-replace.

QFor drive/power alarms like Kawasaki e1028, what spares do you bring on site?

The commonest causes we see on Kawasaki e1028 are "Arm interference with fixture, workpiece, or snagged cable, Brake not releasing on the axis, Damaged reducer/gearing or bearing", so we stock the van against those. For Kawasaki e1028 specifically, we stock the van along the energy chain: braking resistors, bus capacitors, input fuses, drive-board supply parts and the common power modules for the brand. For Kawasaki e1028, drive alarms usually stop the whole line, so they sit at the front of our dispatch queue. Before we roll, tell us what Kawasaki e1028 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 e1028 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.