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Komatsu 860E-1KT with 16V160 Engine Dump Truck Service Manual

1,951 pages · Publication CEBM032000

$199.79
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Models
860E-1KT with 16V160 Engine
Serial coverage
A30101 and up
Manual type
Service Manual
Pages
1,951
Publication
CEBM032000
Condition
Brand new
Komatsu 860E-1KT with 16V160 Engine Dump Truck Service Manual, publication CEBM032000

What's inside

From the manual's own table of contents: 361 sections, 700 entries. See sample pages (PDF, 1180 KB)

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
Loading
Show all 361 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 capacitor42 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 set
Recovering and recycling refrigerant30 topics
  • 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
  • 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.Data37 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)
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 loading
Fault Code A278: Service brake applied while loading37 topics
  • 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 A314: (A30004 & Up) DCDC converter 12 volt circuit is high
  • 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
Fault Code A368: Siemens Brake Test Active
Fault Code A369: Siemens Brake Test Incomplete
Fault Code A370: Siemens Brake Test Torque Achieved for Park Brake
Fault Code A371: Siemens Brake Test Torque Achieved for Service Brake
Fault Code A372: Siemens Brake Test Torque Not Achieved for Park Brake
Fault Code A373: Siemens Brake Test Torque Not Achieved for Service Brake
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 active44 topics
  • 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 full
  • 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 triggered44 topics
  • 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 exceeded
  • 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 identifier44 topics
  • 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 start
  • 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

Inside this manual

Real pages from this service manual (1,951 pages). Open the sample pages (PDF, 1178 KB)

Sample pages from the Komatsu 860E-1KT with 16V160 Engine Dump Truck Service Manual: Specifications, Troubleshooting, Diagram, Color page, Color page, Foldout diagram
  • Specifications, page 411: 30 Testing and adjusting
  • Troubleshooting, page 801: Operator Action
  • Diagram, page 1,881: XS6731-1 SEPT 08
  • Color page, page 1,793: 50 Disassembly and assembly
  • Color page, page 479: 30 Testing and adjusting
  • Foldout diagram, page 1,888: Auxilliary control cabinet

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, 1,951 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

Komatsu 860E-1K, 860E-1KT, 960E-1K, 960E-2K, 960E-2KTOperation & Maintenance Manual · CEAM031801 · $69.93Komatsu 860E-1KTOperation & Maintenance Manual · CEAM019501 · $69.59Komatsu 860E-1KTOperation & Maintenance Manual · CEAM021602 · $69.75Komatsu 860E-1KTOperation & Maintenance Manual · CEAM022401 · $69.65Komatsu 860E-1KTOperation & Maintenance Manual · CEAM026004 · $69.57Komatsu 860E-1KTService Manual · CEBM021404 · $199.77Komatsu 860E-1KTService Manual · CEBM022006 · $199.85Komatsu 860E-1KTService Manual · CEBM025802 · $199.69

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).