Komatsu 860E-1KT Dump Truck Service Manual

Name: Komatsu 860E-1KT Dump Truck Service Manual
Brand: MidWestTech
SKU: CEBM025802
Price: 199.69 USD
Availability: InStock

1,947 pages · Publication CEBM025802

$199.69

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Models: 860E-1KT
Serial coverage: A30036-A30100
Manual type: Service Manual
Pages: 1,947
Publication: CEBM025802
Condition: Brand new

Komatsu 860E-1KT Dump Truck Service Manual, publication CEBM025802

What's inside

From the manual's own table of contents: 359 sections, 700 entries. See sample pages (PDF, 1058 KB)

Search the contents

Composition of shop manual

Foreword

How to read the shop manual

General safety

Precautions before operating the truck

Precautions while operating the truck

Working near batteries

Precautions before performing service

Precautions while performing service

Tires

Precautions for performing repairs

Precautions for welding on the truck

Handling electrical equipment and hydraulic components

How to read electric wire code

Standard torque tables

Conversion tables

Preparing for operation

Engine start-up

After engine start-up

Precautions during truck operation

Operating on a haul road

Starting on a grade with a loaded truck

Passing

Show all 359 sections

Dumping

Trolley operating instructions

Using the speed control feature

Safe parking procedure

Normal engine shutdown procedure

Sudden loss of engine power

Fuel depletion

Towing

Disabled truck operation26 topics

Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants
General information
Principles of refrigeration
Air conditioning system components
Air conditioning system electrical circuit
Steering circuit operation
Steering circuit components
Flow amplifier operation
Steering/brake pump operation
Steering cylinder wear data
Hoist circuit operation
Hoist circuit components
Hoist pilot valve operation
Hoist cylinder wear data
Service brake circuit operation
Secondary braking and auto apply
Rear wheel brake lock circuit operation
Parking brake circuit operation
Brake lines and test ports
Brake warning circuit operation
Brake assembly wear data
Front suspension wear data
Rear suspension wear data

Battery supply system

Auxiliary control cabinet components

Relay boards

Body-up switch

Body position switches (with proximity switch and magnet)

Service

Sensors

Interface module inputs and outputs

SR rectifier module

ST module (auxiliary voltage inverter)

SD phase modules

SR/ST/SD module removal

Inverter cabinet layout

Inverter cabinet water flow

Field regulator

Field regulator (discharge resistor)

Gate unit power supply

Gate unit power supply (diode)

Gate unit power supply (tuning resistor)

Control power filter

Filter for TCU

Terminal block bus bar

Fuses (analog sensor voltage)

Fuses (fuse holder for field regulator)

Fuses (control power and trolley box contactor)

Diode modules

Support capacitors

3-Phase capacitor bank (for ST module output voltage)

Air-cooled inductors (for ST module)

3-Phase transformer (for ST module)

Diagnostics box

Diagnostic and system monitoring panel

Current transducers

Current transducers (for ST module output)

Voltage transducers

Voltage transducers (for ST module output)

Voltage transducers (SiBAS® 24V DC bus monitoring)

Analog inclinometer

DC link capacitors

Ground tie capacitor41 topics

Low-inductance bus bar assembly
Free-wheeling diode for low-inductance bus bars
Contactor (grid box and main blower motor)
Contactor (control power)
Contactor (DC contactors)
Contactor (crowbar bypass)
Temperature probes (PT100 style)
Coolant inlet temperature sensor
Coolant outlet temperature sensor (external pad style)
IGBT module heat sink temperature sensor
Coolant outlet temperature sensor (internal style)
Circuit breakers
Inner circulating blower fan
Coolant pump
Motor for coolant pump
Coolant pressure sensor
Inner radiator
Ground voltage monitoring resistors
Protection thyristor assembly (crowbar)
Discharge reactor
Main blower motor
Grid box
Grid box blower motor
Grid box blower motor grease fittings
Main alternator
Main alternator circuit diagram
IGBT – inverter/chopper phase module
Troubleshooting information
Main input rectifier module
Internal circuit diagram
Upper ground tie resistor
Lower ground tie resistor
Troubleshooting
Speed sensor, alternator
Speed sensors, wheel motors
Traction motor
SIBAS ® 32 Traction Control Unit (TCU)
Overview of the SIBAS ® 32 systems
Removing and installing the SIBAS ® 32 cards
SIBAS ® 32 card device names
Structure of SIBAS ® 32 card part number

SIBAS ® 32 card interchangeability

SIBAS ® 32 card interactions

SIBAS ® 32 card detailed information

Blower subassembly

CPU card

DSP card

I/O card

TRACO card (optional)

Input voltage/frequency card

I/O analog card

Output pulse amplifier card

Input temperature sensor card

UWS card

Digital input card

Power start-up unit card

Binary output contactor drive card

24V / 24V power supply

24V / 15V power supply

24V / 5V power supply

Operation

Remote tank fill system

Transmission wear data

Standard value table for truck

Special tools

Service tools and equipment

Detecting leaks

System performance test

Checking system oil

System flushing

Installing the manifold gauge set32 topics

Recovering and recycling refrigerant
Evacuating the air conditioning system
Charging the air conditioning system
General information on system checkout
Steering system checkout procedures
Steering system checkout data sheet
Toe-in adjustment
Brake cooling and hoist system checkout procedures
Brake cooling and hoist system checkout data sheet
Hydraulic system flushing procedure
Front suspension pressure test
Rear suspension pressure test
Steering cylinder leakage test
Hoist cylinder leakage test
Brake circuit checkout procedure
Brake system checkout data sheet
Brake piston leakage test
Wet disc brake bleeding procedure
Parking brake bleeding procedure
Brake valve bench test and adjustment
Accumulator charging and storage
Accumulator leak testing (bladder style)
Accumulator leak testing (piston style)
Suspension oiling and charging procedures
Suspension pressure test
Payload meter initial setting procedure
KOMTRAX Plus and payload meter software
KOMTRAX Plus controller initial setting procedure
KOMTRAX Plus initialization check list
Precautions for replacing KOMTRAX Plus initialization form
KOMTRAX Plus controller
KOMTRAX Plus controller checkout procedure

Interface module software

Interface module checkout procedures

Abbreviations

Precautions

Qualified person

Customer monitor for SIBAS 32 control units

Installing and calling the customer monitor

Environment variables

Communication with the SIBAS 32 control unit

Calling up the customer monitor

Monitor prompt

Notes on operation of the customer monitor

Command buffer

Structure of the monitor windows

Window menu

Applic. Menu

Hardw. Menu

Hardware-Oriented Access via the Customer Monitor

Graphic Menu

Traco Menu

HW-Traco

SW-Traco

DAC_Traco

Events Menu

STatistics

History

LEL:Last EvL

LES:Last EvS

DLL:DC,LastL

DLS:DC,LastS

DAL:DC,All L

DAS:DC,All S

ML:Memory L

MS:Memory S

CN:Clear Norm

CA:Clear All

Test-Code

DS:Diag-Strc

User Menu

DAC_IO

Operat.Data38 topics

Energy Usage data
Mileage indicator
Operating cycles
Service Brake on data
Temperature data
Motor torque data
Engine speed data
Gear test
Acc test
Engine_Test
X_Test_Inx
STate intern
ST inverter status
Vehicle status
Pedal calib
Language
OFFline-test
Variables
IV:Vehic-ID
Commands
Settings
Parameters
Temp_prot
Appendix
Background commands
Monitor commands for the central processing unit
Monitor commands for the signal processing unit
Monitor Program – Loading software into the SIBAS
Loading software into the DSP procedure
Loading a DSP program Inverter A
Loading a DSP program Inverter B
Loading software into the CPU procedure
Loading ZR software Prog. jumpers Reset
Setting the system up After loading a new pgm
Loading the proper pgm file
Body position switches (with proximity switches and metal arms)
Body position switches (with proximity switches and magnets)
System checkout

Preliminary checks

Diagnosis of gauge readings and system performance

Troubleshooting by manifold gauge set readings

Fuse and circuit breaker locations

Fault Code A001: Left front suspension pressure sensor signal high

Fault Code A002: Left front suspension pressure sensor signal low

Fault Code A003: Right front suspension pressure sensor signal high

Fault Code A004: Right front suspension pressure sensor signal low

Fault Code A005: Left rear suspension pressure sensor signal high

Fault Code A006: Left rear suspension pressure sensor signal low

Fault Code A007: Right rear suspension pressure sensor signal high

Fault Code A008: Right rear suspension pressure sensor signal low

Fault Code A009: Incline sensor signal high

Fault Code A010: Incline sensor signal low

Fault Code A011: Payload meter speed sensor signal has failed

Fault Code A013: Body up switch has failed

Fault Code A014: Payload meter checksum computation has failed

Fault Code A016: Payload meter write to flash memory has failed

Fault Code A017: Payload meter flash memory read has failed

Fault Code A018: Right rear flat suspension cylinder warning

Fault Code A019: Left rear flat suspension cylinder warning

Fault Code A022: Carryback load excessive

Fault Code A100: An open circuit breaker has been detected on a relay board

Fault Code A101: High pressure detected across an hydraulic pump filter

Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level

Fault Code A111: Low steering pressure warning

Fault Code A115: Low steering precharge pressure detected

Fault Code A117: Low brake accumulator pressure warning

Fault Code A118: Brake pressure is low while in brake lock

Fault Code A126: Oil level in the hydraulic tank is low

Fault Code A127: IM-furnished +5 volt output for sensors is low

Fault Code A128: IM-furnished +5 volt output for sensors is high

Fault Code A139: Low fuel warning

advance level 1 for cooling of hydraulic oil

advance level 2 for cooling of hydraulic oil

Fault Code A152: Starter failure

Fault Code A153: Battery voltage is low with the truck in operation35 topics

Fault Code A154: Battery charging voltage is excessive
Fault Code A155: Battery charging voltage is low
readings
Fault Code A166: Left rear hydraulic oil temperature sensor is low
Fault Code A167: Right rear hydraulic oil temperature sensor is low
Fault Code A168: Left front hydraulic oil temperature sensor is low
Fault Code A169: Right front hydraulic oil temperature sensor is low
Fault Code A170: Left rear hydraulic oil temperature sensor is high
Fault Code A171: Right rear hydraulic oil temperature sensor is high
Fault Code A172: Left front hydraulic oil temperature sensor is high
Fault Code A173: Right front hydraulic oil temperature sensor is high
Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage
Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage
Fault Code A184: J1939 data link is not connected
Fault Code A194: Left front hydraulic oil temperature is high
Fault Code A195: Right front hydraulic oil temperature is high
Fault Code A196: Left rear hydraulic oil temperature is high
Fault Code A197: Right rear hydraulic oil temperature is high
Fault Code A198: Hoist pressure 1 sensor is high
Fault Code A199: Hoist pressure 2 sensor is high
Fault Code A200: Steering pressure sensor is high
Fault Code A201: Brake pressure sensor is high
Fault Code A202: Hoist pressure 1 sensor is low
Fault Code A203: Hoist pressure 2 sensor is low
Fault Code A204: Steering pressure sensor is low
Fault Code A205: Brake pressure sensor is low
Fault Code A206: Ambient temperature sensor is high
Fault Code A207: Ambient temperature sensor is low
having applied
having released
Fault Code A215: Brake auto apply valve circuit is defective
brake command valve circuit
been attempted
Fault Code A230: Parking brake has been requested while truck still moving
Fault Code A231: The body is up while traveling or with selector in forward or neutral

Fault Code A233: Drive System Control Link is not connected

Fault Code A235: Steering accumulator is in the process of being bled down

Fault Code A237: The CAN/RPC connection to the display is open

Fault Code A238: Drive System and IM are reporting different park brake status

Fault Code A239: The Drive System and IM are reporting different brake lock status

Fault Code A240: The keyswitch input to the Interface Module is open

Fault Code A242: Fuel gauge within the dash display panel is defective

is defective

Fault Code A246: Payload meter reports truck overload

Fault Code A247: Low steering pressure warning for display to operator

Fault Code A248: Status module within the dash display panel is defective

Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted

Fault Code A250: Battery voltage is low with the truck parked

to ground

Fault Code A252: Start enable output circuit is either open or shorted to ground

Fault Code A253: Steering bleed circuit is not open while running

Fault Code A256: Red warning lamp in the dash display (driven by IM) is open

Fault Code A257: Payload CAN/RPC is not connected

Fault Code A258: Steering accumulator bleed pressure switch circuit is defective

Fault Code A260: Park brake failure

Fault Code A261: Low brake accumulator pressure warning for display to operator

Fault Code A262: Steering bleed valve circuit open during shutdown

Fault Code A264: Park brake relay circuit is defective

Fault Code A265: Service brake failure

Fault Code A266: Selector switch was not in park while attempting to crank engine

Fault Code A267: Park brake was not set while attempting to crank engine

Fault Code A268: Secondary engine shutdown while cranking

Fault Code A270: Brake lock switch power supply is not on when required

Fault Code A271: Shifter not in gear

Fault Code A272: Brake lock switch power supply is not off when required

pressure switch circuit

Fault Code A274: A brake setting fault has been detected

Fault Code A275: A starter has been detected as engaged without a cranking attempt

Fault Code A277: Park brake applied while loading37 topics

Fault Code A278: Service brake applied while loading
Fault Code A279: Low Steering Pressure Switch bad
Fault Code A280: Steering accumulator bled switch bad
Fault Code A281: Brake lock degrade switch bad
without the engine running has reached 7
parking brake was not set
secondary shutdown switch was operated
was turned off
delay relay circuit
after the latched keyswitch circuit is off
Fault Code A295: The right front park brake is not setting up
Fault Code A296: The left front park brake is not setting up
Fault Code A297:The right rear park brake is not setting up
Fault Code A298: The left rear park brake is not setting up
Fault Code A299: The right front park brake is not releasing
Fault Code A300: The left front park brake is not releasing
Fault Code A301: The right rear park brake is not releasing
Fault Code A302: The left rear park brake is not releasing
Fault Code A303: Shifter is defective
Fault Code A304: (A30004 & Up) Auto lube grease level fault
Fault Code A305: (A30004 & Up) Auto lube circuit is defective
Fault Code A309: No brakes applied when expected
Fault Code A310: Low fuel warning
Fault Code A311: Brake lock switch is on when it should not be
low readings
high readings
Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low
Fault Code A316: Starter engagement has been attempted with engine running
Fault Code A317: Operation of brake auto apply valve without a detected response
Fault Code A318: Unexpected power loss to Interface Module
Fault Code A328: Drive system not powered up
Fault Code A350: Overload on output 1B
Fault Code A351: Overload on output 1E
Fault Code A352: (A30003) Overload on output 1H
Fault Code A352: (A30004 & Up) Overload on output 1H
Fault Code A353: Overload on output 1J
Fault Code A354: Overload on output 1K

Fault Code A355: Overload on output 1L

Fault Code A356: Overload on output 1M

Fault Code A357: Overload on output 1N

Fault Code A358: Overload on output 1P

Fault Code A359: Overload on output 1R

Fault Code A360: Overload on output 1S

Fault Code A361: (A30003) Overload on output 1T

Fault Code A361: (A30004 & Up) Overload on output 1T

Fault Code A362: Overload on output 1U

Fault Code A363: Overload on output 1X

Fault Code A364: Overload on output 1Y

Fault Code A365: Overload on output 1Z

Summary

EVENT CLASSIFICATION

L3C SYS: Time slice overflow CPU T1

L3C SYS: Time slice overflow CPU T2

L3C SYS: Time slice overflow CPU T3

L3C SYS: Time slice overflow CPU T4

L3C SYS: Time slice overflow CPU T5

L3C SYS: Time slice overflow CPU T6

L3C SYS: Time slice overflow CPU T7

L3C SYS: Time slice overflow CPU T8

L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE

L3D SYS: Pulse inhibit/asa inhibit PSU–Start-up

L1A SYS: SIBAS® blower fault

L1B SYS: Undervoltage in SIBAS® battery for BRAM

L3C SYS: SIBAS® power supply failure 24V for pulse amplifier

L3C SYS: SIBAS® power supply failure +5V

L3C SYS: SIBAS® power supply failure +15V

L3C SYS: SIBAS® power supply failure –15V

L3C SYS: SIBAS® power supply failure +24V

L3C SYS: SIBAS® power supply failure –24V

L3C SYS: FPGA clock missing for PSU

L3C SYS: Pulse inhibit by reset in PSU from CPU

L3C SYS: General protection error (G10)

L3C SYS: Total block

L1B SYS: Permanent inhibit fault active

L1B SYS: Regular inhibit fault active

L1A SYS: GW Test stopped by A/D converter faulty

L3C DSP A: Initialization fault detected by DSP

L3C DSP A: SW-WatchdoG

L3C DSP A: Initialization fault detected by CPU

L1B DSP A: SW-Traco triggered

L1B DSP A: SW-Traco full44 topics

L3C DSP A: Time slice overflow T1
L3C DSP A: Time slice overflow T2
L3C DSP A: Time slice overflow T3
L3C DSP A: Time slice overflow T4
L1A DSP A: Communication HSCX data from DSP B missing
L1A DSP A: Communication HSCX data from DSP T missing
L3C DSP A: Current offset during pulse block
L3C DSP A: Current offset during no pulse block
L3A DSP A: Overcurrent fault
L3C DSP A: Current transducer defective phase U
L3C DSP A: Current transducer defective phase W
L1A DSP A: Modulation software fault
L3A DSP A: Active current controller at limit
L3A DSP A: Active current reference at limit
L1A DSP A: Braking chopper controller at limit
L3C DSP A: Phase unbalance too large
L3A DSP A: Pulse block by DSP software
L3C DSP A: U/F Card defective
L3C DSP A: Difference in current of phase U overlimit
L3C DSP A: Difference in current of phase W over limit
L3C DSP B: Initialization fault detected by DSP
L3C DSP B: SW-Watchdog
L3C DSP B: Initialization fault detected by CPU
L1B DSP B: SW-Traco triggered
L1B DSP B: SW-Traco full
L3C DSP B: Time slice overflow T1
L3C DSP B: Time slice overflow T2
L3C DSP B: Time slice overflow T3
L3C DSP B: Time slice overflow T4
L1A DSP B: Communication HSCX data from DSP A missing
L1A DSP B: Communication HSCX data from DSP T missing
L3C DSP B: Current offset during pulse block
L3C DSP B: Current offset during no pulse block
L3A DSP B: Overcurrent fault
L3C DSP B: Current transducer defective phase V
L3C DSP B: Current transducer defective phase W
L1A DSP B: Modulation software fault
L3A DSP B: Active current controller at limit
L3A DSP B: Active current reference at limit
L1A DSP B: Braking chopper controller at limit
L3C DSP B: Phase unbalance too large
L3A DSP B: Pulse block by DSP software
L3C DSP B: U/F Card defective
L3C DSP B: Difference in current of phase V over limit

L3C DSP B: Difference in current of phase W over limit

L3C DSP T: Initialization fault detected by DSP

L3C DSP T: SW-Watchdog

L3C DSP T: Initialization fault detected by CPU

L1B DSP T: SW-Traco triggered

L1B DSP T: SW-Traco full

L3C DSP T: Time slice overflow T1

L3C DSP T: Time slice overflow T2

L3C DSP T: Time slice overflow T3

L3C DSP T: Time slice overflow T4

L1A DSP T: Communication HSCX data from DSP A missing

L1A DSP T: Communication HSCX data from DSP B missing

L3C DSP T: Current offset during pulse block

L3C DSP T: Current offset during no pulse block

L3A DSP T: Overcurrent fault

L3C DSP T: Current transducer defective phase U

L3C DSP T: Current transducer defective phase V

L3C DSP T: Current transducer defective phase W

L3C DSP T: Sum of output current not equal zero

L1A DSP T: Modulation software fault

L1A DSP T: Voltage controller at limit

L3C DSP T: Phase unbalance too large

L3A DSP T: Pulse block by DSP software

L3C DSP T: U/F Card defective

L3C DSP T: Crowbar fired by DSP T

L1C DSP T: Voltage transducer U34 not ok

L3C IO: Supervision bus clock

L3C IO: Supervision I/O clock

L3C IO: Incorrect FPGA version identifier

L3C IO: Incorrect FPGA application version identifier

L3C IO: Incorrect module version identifier

L3C/L1A IO: AD Converter faulty

L3C IO: GW Comparator faulty during start-up test

L3C IO: Test voltage not equal zero

L1A IO: SIBAS® Temperature out of range

L3C IO: Incorrect EBIN card identifier

L3C IO: Front plug monitoring

L3C IO: CPU Watchdog triggered

L3C IO: DSP A Watchdog triggereD

L3C IO: DSP B Watchdog triggered

L3C IO: CPU Reset triggered

L1B IO: CPU Traco triggered

L3A IO: Pulse block from I/O

L3A IO: DC link voltage A level 1 exceeded44 topics

L3A IO: DC link voltage B level 1 exceeded
L3C IO: Trolley line overvoltage
L3B IO: Trolley line overcurrent
L2B IO: Trolley line current transducer faulty
L2B IO: Trolley line voltage transducer faulty
L3A IO: Throttle pedal out of range
L3A IO: Retard pedal out of range
L1A IO: Cruise speed control module out of range
L3C UWSA1: Supervision bus clock
L3C UWSA1: Supervision module clock
L3C UWSA1: Incorrect FPGA version identifier
L3C UWSA1: Incorrect FPGA project identifier
L3C UWSA1: GW Comparator faulty during start-up test
L1A UWSA1: ADC Faulty
L3C UWSA1: Configuration failure
L1A UWSA1: Hardware failure counter / processor
L3A UWSA1: Peak current protection active
L3D UWSA1: Peak current protection pulse start
L3D UWSA1: Number of peak current protection >limit
L3D UWSA1: Supervision switching frequency
L1A UWSA1: Overvoltage level 1 exceeded
L3D UWSA1: Limit 5 overcurrent phase U
L3D UWSA1: Limit 5 overcurrent phase V
L3D UWSA1: Limit 5 overcurrent phase W
L3D UWSA1: Limit 5 overvoltage DC bus
L3D UWSA1: Checkback INVA1 L1U faulty
L3D UWSA1: Checkback INVA1 L1L faulty
L3D UWSA1: Checkback INVA1 L2U faulty
L3D UWSA1: Checkback INVA1 L2L faulty
L3D UWSA1: Checkback INVA1 L3U faulty
L3D UWSA1: Checkback INVA1 L3L faulty
L3D UWSA1: Checkback chopper A faulty
L3C UWSB1: Supervision bus clock
L3C UWSB1: Supervision module clock
L3C UWSB1: Incorrect FPGA version identifier
L3C UWSB1: Incorrect FPGA project identifier
L3C UWSB1: GW Comparator faulty during start-up test
L1A UWSB1: ADC Faulty
L3C UWSB1: Configuration failure
L1A UWSB1: Hardware failure counter / processor
L3A UWSB1: Peak current protection active
L3D UWSB1: Peak current protection pulse start
L3D UWSB1: Number of peak current protection >limit
L3D UWSB1: Supervision switching frequency

L1A UWSB1: Overvoltage level 1 exceeded

L3D UWSB1: Limit 5 overcurrent phase V

L3D UWSB1: Limit 5 overcurrent phase U

L3D UWSB1: Limit 5 overcurrent phase W

L3D UWSB1: Limit 5 overvoltage DC bus

L3D UWSB1: Checkback INVB1 L1U Faulty

L3D UWSB1: Checkback INVB1 L1L Faulty

L3D UWSB1: Checkback INVB1 L2U Faulty

L3D UWSB1: Checkback INVB1 L2L Faulty

L3D UWSB1: Checkback INVB1 L3U Faulty

L3D UWSB1: Checkback INVB1 L3L Faulty

L3D UWSB1: Checkback chopper B Faulty

L3C UWSA2: Supervision bus clock

L3C UWSA2: Supervision module clock

L3C UWSA2: Incorrect FPGA version identifier

L3C UWSA2: Incorrect FPGA project identifier

L3C UWSA2: GW Comparator faulty during start-up test

L1A UWSA2: ADC Faulty

L3C UWSA2: Configuration failure

L1A UWSA2: Hardware failure counter / processor

L3A UWSA2: Peak current protection active

L3D UWSA2: Peak current protection pulse start

L3D UWSA2: Number of peak current protection >limit

L3D UWSA2: Supervision switching frequency

L1A UWSA2: Overvoltage level 1 exceeded

L3D UWSA2: Limit 5 overcurrent phase U1

L3D UWSA2: Limit 5 overcurrent phase V1

L3D UWSA2: Limit 5 overcurrent phase W1

L3D UWSA2: Limit 5 overvoltage DC bus

L3D UWSA2: Checkback INVA2 L1U faulty

L3D UWSA2: Checkback INVA2 L1L faulty

L3D UWSA2: Checkback INVA2 L2U faulty

L3D UWSA2: Checkback INVA2 L2L faulty

L3D UWSA2: Checkback INVA2 L3U faulty

L3D UWSA2: Checkback INVA2 L3L faulty

L3D UWSA2: Checkback chopper C faulty

L3C UWSB2: Supervision bus clock

L3C UWSB2: Supervision module clock

L3C UWSB2: Incorrect FPGA version identifier

L3C UWSB2: Incorrect FPGA project identifier

L3C UWSB2: GW Comparator faulty during start-up test

L1A UWSB2: ADC Faulty

L3C UWSB2: Configuration failure

L1A UWSB2: Hardware failure counter / processor

L3A UWSB2: Peak current protection active

L3D UWSB2: Peak current protection pulse start44 topics

L3D UWSB2: Number of peak current protection >limit
L3D UWSB2: Supervision switching frequency
L1A UWSB2: Overvoltage level 1 exceeded
L3D UWSB2: Limit 5 overcurrent phase V1
L3D UWSB2: Limit 5 overcurrent phase U1
L3D UWSB2: Limit 5 overcurrent phase W1
L3D UWSB2: Limit 5 overvoltage DC bus
L3D UWSB2: Checkback INVB2 L1U Faulty
L3D UWSB2: Checkback INVB2 L1L Faulty
L3D UWSB2: Checkback INVB2 L2U Faulty
L3D UWSB2: Checkback INVB2 L2L Faulty
L3D UWSB2: Checkback INVB2 L3U Faulty
L3D UWSB2: Checkback INVB2 L3L Faulty
L3D UWSB2: Checkback chopper D Faulty
L3C UWSST: Supervision bus clock
L3C UWSST: Supervision module clock
L3C UWSST: Incorrect FPGA version identifier
L3C UWSST: Incorrect FPGA project identifieR
L3C UWSST: GW Comparator faulty during start-up test
L1A UWSST: ADC Faulty
L3C UWSST: Configuration failure
L1A UWSST: Hardware failure counter / processor
L3A UWSST: Peak current protection active
L3D UWSST: Number of peak current protection >limit
L3D UWSST: Supervision switching frequency
L3C UWSST: Crowbar is fired without command
L3D UWSST: Limit 5 overcurrent phase U
L3D UWSST: Limit 5 overcurrent phase V
L3D UWSST: Limit 5 overcurrent phase W
L3D UWSST: Limit 5 overvoltage DC bus
L3D UWSST: Checkback INVST L1U Faulty
L3D UWSST: Checkback INVST L1L Faulty
L3D UWSST: Checkback INVST L2U Faulty
L3D UWSST: Checkback INVST L2L Faulty
L3D UWSST: Checkback INVST L3U Faulty
L3D UWSST: Checkback INVST L3L Faulty
L3C UWSST: Checkback crowbar faulty
L1A BUS: CAN Communication failure
L1A BUS: Serial link communication failure
L1A BUS: Truck is over loaded
L1B TR: Transient traco is triggered
L1B TR: Transient traco is full
L1A ETM: ADC Failure for ETM1
L1A ETM: ADC Failure for ETM2

L1A ETM: ADC Failure for ETM3

L1A ETM: ADC Failure for ETM4

L1A MEFA: ADC Failure

L3C HL: Gate unit power supply A defective

L3C HL: Gate unit power supply B defective

L1A DRZ: LIMP Mode A active

L1A DRZ: Limp mode B active

L1A DRZ: Low battery voltage

L1B BUS: Engine floor input increasing minimum engine speed

L1B DM: Data store switch pressed

Inside this manual

Real pages from this service manual (1,947 pages). Open the sample pages (PDF, 1057 KB)

Sample pages from the Komatsu 860E-1KT Dump Truck Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page, Foldout diagram

Specifications, page 140: 10 Structure, functions and maintenance standard
Diagram, page 260: 10 Structure and Function
Troubleshooting, page 800: Fault Code A250: Battery voltage is low with the truck parked
Color page, page 1,786: 50 Disassembly and assembly
Color page, page 486: 30 Testing and adjusting
Foldout diagram, page 1,884: Auxilliary control cabinet

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 860E-1KT are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual CEBM025802$199.69

Operator's manuals

Operation & Maintenance Manual CEAM019501 · 179 pagesCovers 860E-1KTSerial: A30003$69.59Details

Operation & Maintenance Manual CEAM021602 · 185 pagesCovers 860E-1KTSerial: A30004 - A30014$69.75Details

Operation & Maintenance Manual CEAM022401 · 189 pagesCovers 860E-1KTSerial: A30015 - A30030$69.65Details

Operation & Maintenance Manual CEAM026004 · 211 pagesCovers 860E-1KTSerial: A30036 and up$69.57Details

Operation & Maintenance Manual CEAM031801 · 101 pagesCovers 860E-1K, 860E-1KT, 960E-1K, 960E-2K, 960E-2KT$69.93Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,947 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).