OK, this Kuka KR150 is eating my lunch...and a lot more than that! Below is the information that I have tried to resolve it and still in the same spot. Any information would be helpful:
1133 fault code A6 exceeds torque limit. When A6 is initiated, it immediately faults to 1133. When A5 or A4 are called, they move, but will fault within around 2 seconds throwing the same code for A6. This is when movement speed is set to 100%. When the movement speed is set to 1%, A4 and A5 will move for around 10 seconds but then will give the same fault. A6 will still fault immediately.
Upon initial error, we checked voltages at the drive module as there was a question if the brake was released for A6. +24 was present. We swapped drive modules and the error occurred on the same motor, so we were told to have the motor checked. We did, and said the resolver was bad, so ordered new motor. With the replacement A6 motor, we had the exact same issue.
We then called A6 to move with it uncoupled from the machine and it had the same code. This eliminates mechanical issues in the rotary axis assembly. We reinstalled the motor and then swapped the cable from A6 to A4. The problem then followed it to A4, however still giving the same error (since the system thinks A4 is actually A6). This points to the cable, so I put the cables back to the correct motors in the original configuration, and then swapped the modules again. The error moved back to A6, which is still pointing to the cable.
We then started at the resolver cable and did a continuity check from each pin to the pin connector at resolver board. All pins checked good. Another continuity check was done on the other side of the board to the control via the input port at the control and checked out good. This shows the cable is good and could a bad resolver board. This board was replaced and the same problem is occurring.
This seems to me that it may be a parameter setting which has the torque values set very low....since it's a used machine, I'm not sure how the prior company had them set. If it is a a parameter setting, I have no idea which one and where it's located.
Any help would be extremely appreciated! 
