KUKA KSS00060 Info: Log File Full – Causes, Diagnostics & How to Fix

Error Code Overview

• Error Code: KSS00060
• Category: Data Management / Maintenance / Storage System
• Severity: Low (Informational)
• System: KRC Controller / Windows SQL Database / Archive Service
• Impact: No immediate motion stop, but new diagnostic logs cannot be recorded

Quick Fix for KUKA KSS00060

If KUKA KSS00060 Info: Log File Full appears on the SmartHMI:

• Back up important log data before deletion
• Delete old or unnecessary log files
• Clear archived troubleshooting records no longer needed
• Restart the KRC controller after cleanup
• Monitor whether the warning returns
• Investigate excessive log generation if storage fills again quickly

In most cases, KSS00060 simply means the controller’s internal log storage has reached capacity.

What Is KUKA KSS00060 Log File Full?

KSS00060 Log File Full indicates that the controller’s internal log storage is full and cannot accept new entries.

This does not stop robot motion, but it creates a diagnostic blind spot:

• No new faults or events will be recorded
• Troubleshooting becomes more difficult
• System performance may degrade over time

In short:
KSS00060 is a storage limit warning, not a motion or safety fault.

What Happens When KSS00060 Occurs

• The system displays a log storage full message
• New diagnostic data is no longer saved
• Existing logs remain accessible
• Robot operation continues normally

👉 The real risk is losing future fault traceability, not immediate downtime.

Common Causes of KSS00060 Log File Full

1. Normal Log Accumulation Over Time

The most common cause is long-term buildup of diagnostic records.

• controller runs for months or years without cleanup
• logs gradually consume available storage

2. Excessive Alarm Generation

Frequent or repeating faults can rapidly fill log storage.

• recurring communication faults
• repetitive safety warnings
• unstable sensors or device signals

3. Old Archive Files Not Removed

Stored backups and maintenance archives may occupy significant space.

• archives exported repeatedly but never deleted
• temporary files accumulate over time

4. Limited Storage Capacity on Older Controllers

Older KRC systems may have limited internal storage partitions.

Aging HDD or SSD hardware fills up more quickly.

How to Troubleshoot KUKA KSS00060

Step 1 – Back Up Important Logs

• Export critical logs to external storage (USB or network)
• Preserve data needed for future diagnostics

Step 2 – Clear Old Log Files

• Access log management via SmartHMI or WorkVisual
• Delete outdated or unnecessary logs
• Archive logs if needed before deletion

Step 3 – Configure Log Rotation

• Enable automatic log rotation if supported
• Set limits based on time or storage size
• Prevent future log overflow

Step 4 – Increase Storage Capacity

• Upgrade controller storage if supported
• Use external storage for log offloading if necessary

Step 5 – Monitor Log Generation

• Check for repeated faults generating excessive logs
• Fix root causes instead of repeatedly clearing logs

Step 6 – Contact Technical Support

• If logs cannot be cleared or the issue persists, deeper system inspection may be required

Recommended Replacement Parts

Pro Diagnostic Tip

If KSS00060 returns quickly after cleanup, storage size is usually not the real issue.

Common root causes include:

• background faults flooding the log system
• devices repeatedly reconnecting
• unstable safety circuits generating constant warnings

A healthy KUKA system should not refill logs rapidly under normal conditions.

How to Fix KSS00060 Permanently

• Normal storage full → delete or archive old logs
• Excessive logging → fix underlying repeated faults
• Limited storage → upgrade storage hardware
• Corrupted file structure → perform system recovery or reimage

How to Prevent KUKA Log Storage Warnings

• regularly archive or delete logs
• review alarm history periodically
• fix repetitive nuisance alarms early
• maintain at least 15% free storage space
• replace aging storage devices proactively

Related Errors

• KSS01009 Log file error– Thecritical failure that occurs if KSS00060 is ignored.
• KSS01010 Diagnostic message only– Frequent sources of "Log noise."
• KSS01004 File system error– Canoccur if the log database becomes corrupted due to lack of space.
• KSS00050 Service interval reached– Another informational alert that contributes to log entries.

👉 These errors may be related to systemperformance issues that can also result in large log files or loggingdifficulties.

FAQ

What is the KSS00060 Info: Log File Full error?

The KSS00060 Info: Log File Full error is a storage warning indicating that the robot controller’s log file has reached its maximum size, preventing the system from recording new diagnostic data.

How do I fix the KSS00060 Log File Full error?

To fix th is, clear old logs , enablelog rotation , and archive important logs . You can also consider using external storage to avoid filling the controller’s internal storage.

Can I continue operating the robot with th is error?

Yes, the KSS00060 error does notstop robot operation, but it prevents new diagnostic data from being logged, which may hinder future troubleshooting.

How do I prevent the log file from filling up aga in?

Configure log rotation and increasestorage capacity if needed. Regularly clear logs and ensure that there issufficient space for new log data.