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E00001
M04
[ { "code": "M04-A124", "message": "Sensor plausibility check failed" }, { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M04] ambient reported as 81.7 C, plant ambient is 24 C" ]
Machine behaving oddly since start of shift.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00002
M04
[ { "code": "M04-A124", "message": "Sensor plausibility check failed" }, { "code": "M04-A122", "message": "Flow rate below nominal" }, { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M04] ambient reported as 97.5 C, plant ambient is 24 C" ]
Operator requests inspection before next batch.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00003
M02
[ { "code": "M02-A113", "message": "Output speed unstable" }, { "code": "M02-A109", "message": "Abnormal noise reported by operator" }, { "code": "M02-A108", "message": "Flow rate below nominal" } ]
[ "[M02] output speed variance 9.7% under load, squeal reported" ]
Operator requests inspection before next batch.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00004
M02
[ { "code": "M02-A113", "message": "Output speed unstable" }, { "code": "M02-A112", "message": "Sensor plausibility check failed" }, { "code": "M02-A114", "message": "Temperature above warning threshold" } ]
[ "[M02] ambient reported as 90.2 C, plant ambient is 24 C" ]
Machine behaving oddly since start of shift.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00005
M02
[ { "code": "M02-A110", "message": "Motor overcurrent protection triggered" } ]
[ "[M02] phase current imbalance 9.3A / 8.8A / 21.5A" ]
Machine behaving oddly since start of shift.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00006
M01
[ { "code": "M01-A100", "message": "Flow rate below nominal" }, { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M01] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "electric_motor", "failure_mode": "misalignment", "repair": "realign motor-load coupling" }
E00007
M02
[ { "code": "M02-A108", "message": "Flow rate below nominal" }, { "code": "M02-A112", "message": "Sensor plausibility check failed" }, { "code": "M02-A111", "message": "Supply pressure below nominal" } ]
[ "[M02] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00008
M01
[ { "code": "M01-A100", "message": "Flow rate below nominal" }, { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M01-A101", "message": "Abnormal noise reported b...
[ "[M01] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00009
M03
[ { "code": "M03-A118", "message": "Sensor signal intermittent" } ]
[ "[M03] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00010
M03
[ { "code": "M03-A120", "message": "Temperature above warning threshold" }, { "code": "M03-A118", "message": "Sensor signal intermittent" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A117", "message": "Motor overcurrent protect...
[ "[M03] phase current imbalance 12.1A / 9.4A / 15.8A" ]
Issue appeared gradually over the last two days.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00011
M02
[ { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M02-A109", "message": "Abnormal noise reported by operator" } ]
[ "[M02] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00012
M01
[ { "code": "M01-A103", "message": "Supply pressure below nominal" }, { "code": "M01-A100", "message": "Flow rate below nominal" } ]
[ "[M01] differential pressure 1.11 bar across filter (limit 0.8)" ]
Issue appeared gradually over the last two days.
{ "component": "filter", "failure_mode": "clogging", "repair": "replace filter element" }
E00013
M01
[ { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A101", "message": "Abnormal noise reported by operator" } ]
[ "[M01] phase current imbalance 9.5A / 13.4A / 15.4A" ]
Problem occurs mainly under full load.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00014
M05
[ { "code": "M05-A130", "message": "Abnormal noise reported by operator" }, { "code": "M05-A131", "message": "Servo following error" } ]
[ "[M05] following error 1.10 mm exceeds window" ]
Operator requests inspection before next batch.
{ "component": "servo_motor", "failure_mode": "encoder_fault", "repair": "replace encoder" }
E00015
M02
[ { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M02-A110", "message": "Motor overcurrent protection triggered" } ]
[ "[M02] envelope spectrum shows BPFO harmonics, temp 80.9 C" ]
Operator requests inspection before next batch.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00016
M02
[ { "code": "M02-A110", "message": "Motor overcurrent protection triggered" } ]
[ "[M02] phase current imbalance 10.1A / 11.1A / 19.8A" ]
Problem occurs mainly under full load.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00017
M03
[ { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A119", "message": "Output speed unstable" } ]
[ "[M03] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00018
M01
[ { "code": "M01-A100", "message": "Flow rate below nominal" }, { "code": "M01-A103", "message": "Supply pressure below nominal" } ]
[ "[M01] differential pressure 1.37 bar across filter (limit 0.8)" ]
Issue appeared gradually over the last two days.
{ "component": "filter", "failure_mode": "clogging", "repair": "replace filter element" }
E00019
M04
[ { "code": "M04-A125", "message": "Quality check: surface finish out of spec" }, { "code": "M04-A124", "message": "Sensor plausibility check failed" } ]
[ "[M04] vibration 10.74 mm/s at 1x spindle speed, part finish out of spec" ]
Issue appeared gradually over the last two days.
{ "component": "spindle", "failure_mode": "imbalance", "repair": "balance spindle, check tool holder" }
E00020
M02
[ { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M02-A114", "message": "Temperature above warning threshold" } ]
[ "[M02] envelope spectrum shows BPFO harmonics, temp 88.8 C" ]
Operator requests inspection before next batch.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00021
M05
[ { "code": "M05-A128", "message": "Cycle time above nominal" }, { "code": "M05-A132", "message": "Supply pressure below nominal" } ]
[ "[M05] actuation time 102.07s vs nominal 0.40s, supply pressure sagging" ]
Problem occurs mainly under full load.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00022
M04
[ { "code": "M04-A126", "message": "Temperature above warning threshold" }, { "code": "M04-A122", "message": "Flow rate below nominal" } ]
[ "[M04] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "coolant_pump", "failure_mode": "cavitation", "repair": "clear suction line, check coolant level" }
E00023
M03
[ { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A121", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M03] no detailed log available for this time window" ]
Operator requests inspection before next batch.
{ "component": "gearbox", "failure_mode": "tooth_wear", "repair": "inspect gears, replace worn stage" }
E00024
M02
[ { "code": "M02-A111", "message": "Supply pressure below nominal" }, { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M02] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "electric_motor", "failure_mode": "misalignment", "repair": "realign motor-load coupling" }
E00025
M04
[ { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M04-A125", "message": "Quality check: surface finish out of spec" } ]
[ "[M04] vibration 8.05 mm/s at 1x spindle speed, part finish out of spec" ]
Operator requests inspection before next batch.
{ "component": "spindle", "failure_mode": "imbalance", "repair": "balance spindle, check tool holder" }
E00026
M04
[ { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M04-A126", "message": "Temperature above warning threshold" }, { "code": "M04-A122", "message": "Flow rate below nominal" } ]
[ "[M04] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00027
M02
[ { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M02] vibration RMS 9.91 mm/s, dominant at 2x running speed" ]
Machine behaving oddly since start of shift.
{ "component": "electric_motor", "failure_mode": "misalignment", "repair": "realign motor-load coupling" }
E00028
M01
[ { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M01-A106", "message": "Temperature above warning threshold" } ]
[ "[M01] envelope spectrum shows BPFO harmonics, temp 82.5 C" ]
Issue appeared gradually over the last two days.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00029
M05
[ { "code": "M05-A129", "message": "Part detection failure" }, { "code": "M05-A132", "message": "Supply pressure below nominal" } ]
[ "[M05] actuation time 93.28s vs nominal 0.40s, supply pressure sagging" ]
Problem occurs mainly under full load.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00030
M01
[ { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A105", "message": "Sensor plausibility check failed" } ]
[ "[M01] static pressure reads 7.4 bar while pump is off" ]
Issue appeared gradually over the last two days.
{ "component": "pressure_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00031
M04
[ { "code": "M04-A126", "message": "Temperature above warning threshold" }, { "code": "M04-A123", "message": "Abnormal noise reported by operator" } ]
[ "[M04] bearing temp 101.8 C rising, audible grinding reported" ]
Operator requests inspection before next batch.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00032
M04
[ { "code": "M04-A124", "message": "Sensor plausibility check failed" } ]
[ "[M04] no detailed log available for this time window" ]
Operator requests inspection before next batch.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00033
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A120", "message": "Temperature above warning threshold" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A118", "message": "Sensor signal intermittent" ...
[ "[M03] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00034
M02
[ { "code": "M02-A110", "message": "Motor overcurrent protection triggered" }, { "code": "M02-A109", "message": "Abnormal noise reported by operator" }, { "code": "M02-A113", "message": "Output speed unstable" } ]
[ "[M02] no detailed log available for this time window" ]
Issue appeared gradually over the last two days.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00035
M01
[ { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A101", "message": "Abnormal noise reported by operator" } ]
[ "[M01] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00036
M05
[ { "code": "M05-A128", "message": "Cycle time above nominal" }, { "code": "M05-A129", "message": "Part detection failure" } ]
[ "[M05] 5 missed part detections in last shift" ]
Issue appeared gradually over the last two days.
{ "component": "proximity_sensor", "failure_mode": "misadjustment", "repair": "readjust sensing distance" }
E00037
M01
[ { "code": "M01-A104", "message": "Hydraulic pressure unstable" }, { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M01] envelope spectrum shows BPFO harmonics, temp 94.8 C" ]
Operator requests inspection before next batch.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00038
M02
[ { "code": "M02-A108", "message": "Flow rate below nominal" }, { "code": "M02-A111", "message": "Supply pressure below nominal" }, { "code": "M02-A114", "message": "Temperature above warning threshold" } ]
[ "[M02] differential pressure 1.20 bar across filter (limit 0.8)" ]
Issue appeared gradually over the last two days.
{ "component": "filter", "failure_mode": "clogging", "repair": "replace filter element" }
E00039
M02
[ { "code": "M02-A114", "message": "Temperature above warning threshold" }, { "code": "M02-A112", "message": "Sensor plausibility check failed" } ]
[ "[M02] phase current imbalance 10.8A / 9.8A / 17.8A" ]
Machine behaving oddly since start of shift.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00040
M03
[ { "code": "M03-A117", "message": "Motor overcurrent protection triggered" }, { "code": "M03-A120", "message": "Temperature above warning threshold" }, { "code": "M03-A118", "message": "Sensor signal intermittent" }, { "code": "M03-A119", "message": "Output speed unstable"...
[ "[M03] phase current imbalance 10.8A / 10.5A / 17.2A" ]
Issue appeared gradually over the last two days.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00041
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A117", "message": "Motor overcurrent protection triggered" } ]
[ "[M03] output speed variance 8.6% under load, squeal reported" ]
Operator requests inspection before next batch.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00042
M02
[ { "code": "M02-A108", "message": "Flow rate below nominal" }, { "code": "M02-A111", "message": "Supply pressure below nominal" }, { "code": "M02-A113", "message": "Output speed unstable" } ]
[ "[M02] output speed variance 9.9% under load, squeal reported" ]
Machine behaving oddly since start of shift.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00043
M03
[ { "code": "M03-A118", "message": "Sensor signal intermittent" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" } ]
[ "[M03] speed signal dropouts 14 times in last hour" ]
Operator requests inspection before next batch.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00044
M05
[ { "code": "M05-A132", "message": "Supply pressure below nominal" }, { "code": "M05-A128", "message": "Cycle time above nominal" } ]
[ "[M05] actuation time 104.48s vs nominal 0.40s, supply pressure sagging" ]
Machine behaving oddly since start of shift.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00045
M05
[ { "code": "M05-A130", "message": "Abnormal noise reported by operator" }, { "code": "M05-A128", "message": "Cycle time above nominal" }, { "code": "M05-A132", "message": "Supply pressure below nominal" } ]
[ "[M05] actuation time 86.87s vs nominal 0.40s, supply pressure sagging" ]
Machine behaving oddly since start of shift.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00046
M05
[ { "code": "M05-A128", "message": "Cycle time above nominal" }, { "code": "M05-A131", "message": "Servo following error" }, { "code": "M05-A129", "message": "Part detection failure" } ]
[ "[M05] following error 0.73 mm exceeds window" ]
Operator requests inspection before next batch.
{ "component": "servo_motor", "failure_mode": "encoder_fault", "repair": "replace encoder" }
E00047
M02
[ { "code": "M02-A114", "message": "Temperature above warning threshold" }, { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M02-A111", "message": "Supply pressure below nominal" } ]
[ "[M02] no detailed log available for this time window" ]
Issue appeared gradually over the last two days.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00048
M04
[ { "code": "M04-A123", "message": "Abnormal noise reported by operator" }, { "code": "M04-A122", "message": "Flow rate below nominal" } ]
[ "[M04] no detailed log available for this time window" ]
Issue appeared gradually over the last two days.
{ "component": "coolant_pump", "failure_mode": "cavitation", "repair": "clear suction line, check coolant level" }
E00049
M05
[ { "code": "M05-A131", "message": "Servo following error" }, { "code": "M05-A129", "message": "Part detection failure" } ]
[ "[M05] 15 missed part detections in last shift" ]
Machine behaving oddly since start of shift.
{ "component": "proximity_sensor", "failure_mode": "misadjustment", "repair": "readjust sensing distance" }
E00050
M05
[ { "code": "M05-A129", "message": "Part detection failure" }, { "code": "M05-A132", "message": "Supply pressure below nominal" } ]
[ "[M05] actuation time 94.96s vs nominal 0.40s, supply pressure sagging" ]
Issue appeared gradually over the last two days.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00051
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A118", "message": "Sensor signal intermittent" } ]
[ "[M03] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00052
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A117", "message": "Motor overcurrent protection triggered" } ]
[ "[M03] output speed variance 4.6% under load, squeal reported" ]
Operator requests inspection before next batch.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00053
M04
[ { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M04] vibration 5.41 mm/s at 1x spindle speed, part finish out of spec" ]
Problem occurs mainly under full load.
{ "component": "spindle", "failure_mode": "imbalance", "repair": "balance spindle, check tool holder" }
E00054
M05
[ { "code": "M05-A131", "message": "Servo following error" }, { "code": "M05-A130", "message": "Abnormal noise reported by operator" }, { "code": "M05-A133", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M05] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "gearbox", "failure_mode": "tooth_wear", "repair": "inspect gears, replace worn stage" }
E00055
M02
[ { "code": "M02-A111", "message": "Supply pressure below nominal" }, { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M02-A109", "message": "Abnormal noise reported by operator" }, { "code": "M02-A113", "message": "Output speed unstab...
[ "[M02] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00056
M04
[ { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M04-A125", "message": "Quality check: surface finish out of spec" } ]
[ "[M04] no detailed log available for this time window" ]
Operator requests inspection before next batch.
{ "component": "spindle", "failure_mode": "imbalance", "repair": "balance spindle, check tool holder" }
E00057
M05
[ { "code": "M05-A129", "message": "Part detection failure" }, { "code": "M05-A133", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M05-A130", "message": "Abnormal noise reported by operator" } ]
[ "[M05] gear mesh frequency sidebands rising, oil sample shows metal particles" ]
Issue appeared gradually over the last two days.
{ "component": "gearbox", "failure_mode": "tooth_wear", "repair": "inspect gears, replace worn stage" }
E00058
M01
[ { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A101", "message": "Abnormal noise reported by operator" } ]
[ "[M01] bearing temp 103.5 C rising, audible grinding reported" ]
Problem occurs mainly under full load.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00059
M04
[ { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M04-A124", "message": "Sensor plausibility check failed" }, { "code": "M04-A122", "message": "Flow rate below nominal" } ]
[ "[M04] no detailed log available for this time window" ]
Issue appeared gradually over the last two days.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00060
M05
[ { "code": "M05-A129", "message": "Part detection failure" }, { "code": "M05-A132", "message": "Supply pressure below nominal" } ]
[ "[M05] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "proximity_sensor", "failure_mode": "misadjustment", "repair": "readjust sensing distance" }
E00061
M05
[ { "code": "M05-A133", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M05] gear mesh frequency sidebands rising, oil sample shows metal particles" ]
Issue appeared gradually over the last two days.
{ "component": "gearbox", "failure_mode": "tooth_wear", "repair": "inspect gears, replace worn stage" }
E00062
M02
[ { "code": "M02-A108", "message": "Flow rate below nominal" }, { "code": "M02-A111", "message": "Supply pressure below nominal" }, { "code": "M02-A114", "message": "Temperature above warning threshold" } ]
[ "[M02] differential pressure 0.98 bar across filter (limit 0.8)" ]
Issue appeared gradually over the last two days.
{ "component": "filter", "failure_mode": "clogging", "repair": "replace filter element" }
E00063
M05
[ { "code": "M05-A133", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M05-A130", "message": "Abnormal noise reported by operator" }, { "code": "M05-A128", "message": "Cycle time above nominal" } ]
[ "[M05] no detailed log available for this time window" ]
Issue appeared gradually over the last two days.
{ "component": "gearbox", "failure_mode": "tooth_wear", "repair": "inspect gears, replace worn stage" }
E00064
M03
[ { "code": "M03-A120", "message": "Temperature above warning threshold" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" } ]
[ "[M03] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00065
M01
[ { "code": "M01-A100", "message": "Flow rate below nominal" }, { "code": "M01-A106", "message": "Temperature above warning threshold" } ]
[ "[M01] differential pressure 1.24 bar across filter (limit 0.8)" ]
Machine behaving oddly since start of shift.
{ "component": "filter", "failure_mode": "clogging", "repair": "replace filter element" }
E00066
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A118", "message": "Sensor signal intermittent" } ]
[ "[M03] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00067
M01
[ { "code": "M01-A103", "message": "Supply pressure below nominal" }, { "code": "M01-A106", "message": "Temperature above warning threshold" }, { "code": "M01-A101", "message": "Abnormal noise reported by operator" } ]
[ "[M01] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00068
M02
[ { "code": "M02-A114", "message": "Temperature above warning threshold" }, { "code": "M02-A113", "message": "Output speed unstable" } ]
[ "[M02] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00069
M04
[ { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M04-A125", "message": "Quality check: surface finish out of spec" }, { "code": "M04-A126", "message": "Temperature above warning threshold" } ]
[ "[M04] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "spindle", "failure_mode": "imbalance", "repair": "balance spindle, check tool holder" }
E00070
M01
[ { "code": "M01-A104", "message": "Hydraulic pressure unstable" }, { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M01] no detailed log available for this time window" ]
Machine behaving oddly since start of shift.
{ "component": "hydraulic_valve", "failure_mode": "stiction", "repair": "clean or replace valve spool" }
E00071
M02
[ { "code": "M02-A112", "message": "Sensor plausibility check failed" } ]
[ "[M02] ambient reported as 81.1 C, plant ambient is 24 C" ]
Machine behaving oddly since start of shift.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00072
M02
[ { "code": "M02-A113", "message": "Output speed unstable" } ]
[ "[M02] output speed variance 7.4% under load, squeal reported" ]
Problem occurs mainly under full load.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00073
M04
[ { "code": "M04-A122", "message": "Flow rate below nominal" }, { "code": "M04-A123", "message": "Abnormal noise reported by operator" } ]
[ "[M04] coolant flow 10.8 L/min vs nominal 20, rattling noise" ]
Operator requests inspection before next batch.
{ "component": "coolant_pump", "failure_mode": "cavitation", "repair": "clear suction line, check coolant level" }
E00074
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A118", "message": "Sensor signal intermittent" } ]
[ "[M03] speed signal dropouts 15 times in last hour" ]
Issue appeared gradually over the last two days.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00075
M01
[ { "code": "M01-A104", "message": "Hydraulic pressure unstable" } ]
[ "[M01] no detailed log available for this time window" ]
Operator requests inspection before next batch.
{ "component": "hydraulic_valve", "failure_mode": "stiction", "repair": "clean or replace valve spool" }
E00076
M03
[ { "code": "M03-A120", "message": "Temperature above warning threshold" }, { "code": "M03-A121", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M03-A117", "message": "Motor overcurrent protection triggered" } ]
[ "[M03] phase current imbalance 10.3A / 12.7A / 20.7A" ]
Issue appeared gradually over the last two days.
{ "component": "electric_motor", "failure_mode": "winding_fault", "repair": "rewind or replace motor" }
E00077
M02
[ { "code": "M02-A109", "message": "Abnormal noise reported by operator" }, { "code": "M02-A114", "message": "Temperature above warning threshold" } ]
[ "[M02] no detailed log available for this time window" ]
Issue appeared gradually over the last two days.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00078
M01
[ { "code": "M01-A102", "message": "Motor overcurrent protection triggered" }, { "code": "M01-A103", "message": "Supply pressure below nominal" }, { "code": "M01-A100", "message": "Flow rate below nominal" }, { "code": "M01-A106", "message": "Temperature above warning thres...
[ "[M01] differential pressure 1.07 bar across filter (limit 0.8)" ]
Operator requests inspection before next batch.
{ "component": "filter", "failure_mode": "clogging", "repair": "replace filter element" }
E00079
M03
[ { "code": "M03-A118", "message": "Sensor signal intermittent" }, { "code": "M03-A121", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M03] speed signal dropouts 15 times in last hour" ]
Operator requests inspection before next batch.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00080
M03
[ { "code": "M03-A118", "message": "Sensor signal intermittent" } ]
[ "[M03] speed signal dropouts 14 times in last hour" ]
Issue appeared gradually over the last two days.
{ "component": "speed_sensor", "failure_mode": "intermittent", "repair": "reseat connector, replace cable if worn" }
E00081
M02
[ { "code": "M02-A114", "message": "Temperature above warning threshold" }, { "code": "M02-A109", "message": "Abnormal noise reported by operator" } ]
[ "[M02] envelope spectrum shows BPFO harmonics, temp 92.8 C" ]
Problem occurs mainly under full load.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00082
M01
[ { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M01] vibration RMS 8.50 mm/s, dominant at 2x running speed" ]
Machine behaving oddly since start of shift.
{ "component": "electric_motor", "failure_mode": "misalignment", "repair": "realign motor-load coupling" }
E00083
M04
[ { "code": "M04-A122", "message": "Flow rate below nominal" }, { "code": "M04-A124", "message": "Sensor plausibility check failed" }, { "code": "M04-A125", "message": "Quality check: surface finish out of spec" } ]
[ "[M04] ambient reported as 87.0 C, plant ambient is 24 C" ]
Problem occurs mainly under full load.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00084
M02
[ { "code": "M02-A114", "message": "Temperature above warning threshold" }, { "code": "M02-A115", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M02] no detailed log available for this time window" ]
Operator requests inspection before next batch.
{ "component": "bearing", "failure_mode": "wear", "repair": "replace bearing" }
E00085
M01
[ { "code": "M01-A103", "message": "Supply pressure below nominal" }, { "code": "M01-A104", "message": "Hydraulic pressure unstable" }, { "code": "M01-A105", "message": "Sensor plausibility check failed" } ]
[ "[M01] pressure oscillating 81.9-117.4 bar at 0.5 Hz" ]
Problem occurs mainly under full load.
{ "component": "hydraulic_valve", "failure_mode": "stiction", "repair": "clean or replace valve spool" }
E00086
M04
[ { "code": "M04-A123", "message": "Abnormal noise reported by operator" }, { "code": "M04-A122", "message": "Flow rate below nominal" } ]
[ "[M04] coolant flow 11.2 L/min vs nominal 20, rattling noise" ]
Issue appeared gradually over the last two days.
{ "component": "coolant_pump", "failure_mode": "cavitation", "repair": "clear suction line, check coolant level" }
E00087
M01
[ { "code": "M01-A105", "message": "Sensor plausibility check failed" }, { "code": "M01-A107", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M01] vibration RMS 4.73 mm/s, dominant at 2x running speed" ]
Issue appeared gradually over the last two days.
{ "component": "electric_motor", "failure_mode": "misalignment", "repair": "realign motor-load coupling" }
E00088
M04
[ { "code": "M04-A125", "message": "Quality check: surface finish out of spec" }, { "code": "M04-A123", "message": "Abnormal noise reported by operator" }, { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" } ]
[ "[M04] vibration 6.20 mm/s at 1x spindle speed, part finish out of spec" ]
Machine behaving oddly since start of shift.
{ "component": "spindle", "failure_mode": "imbalance", "repair": "balance spindle, check tool holder" }
E00089
M04
[ { "code": "M04-A123", "message": "Abnormal noise reported by operator" }, { "code": "M04-A126", "message": "Temperature above warning threshold" }, { "code": "M04-A127", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M04-A125", "message": "Quality check...
[ "[M04] bearing temp 96.9 C rising, audible grinding reported" ]
Machine behaving oddly since start of shift.
{ "component": "bearing", "failure_mode": "lubrication_loss", "repair": "relubricate and inspect seals" }
E00090
M03
[ { "code": "M03-A117", "message": "Motor overcurrent protection triggered" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A119", "message": "Output speed unstable" } ]
[ "[M03] output speed variance 7.2% under load, squeal reported" ]
Operator requests inspection before next batch.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00091
M02
[ { "code": "M02-A110", "message": "Motor overcurrent protection triggered" }, { "code": "M02-A112", "message": "Sensor plausibility check failed" } ]
[ "[M02] no detailed log available for this time window" ]
Operator requests inspection before next batch.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
E00092
M03
[ { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A118", "message": "Sensor signal intermittent" } ]
[ "[M03] output speed variance 8.3% under load, squeal reported" ]
Machine behaving oddly since start of shift.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00093
M05
[ { "code": "M05-A129", "message": "Part detection failure" } ]
[ "[M05] 10 missed part detections in last shift" ]
Problem occurs mainly under full load.
{ "component": "proximity_sensor", "failure_mode": "misadjustment", "repair": "readjust sensing distance" }
E00094
M02
[ { "code": "M02-A111", "message": "Supply pressure below nominal" }, { "code": "M02-A113", "message": "Output speed unstable" }, { "code": "M02-A109", "message": "Abnormal noise reported by operator" } ]
[ "[M02] output speed variance 5.3% under load, squeal reported" ]
Operator requests inspection before next batch.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00095
M03
[ { "code": "M03-A119", "message": "Output speed unstable" }, { "code": "M03-A121", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M03-A116", "message": "Abnormal noise reported by operator" } ]
[ "[M03] no detailed log available for this time window" ]
Problem occurs mainly under full load.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00096
M05
[ { "code": "M05-A128", "message": "Cycle time above nominal" } ]
[ "[M05] actuation time 100.87s vs nominal 0.40s, supply pressure sagging" ]
Operator requests inspection before next batch.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00097
M03
[ { "code": "M03-A116", "message": "Abnormal noise reported by operator" }, { "code": "M03-A117", "message": "Motor overcurrent protection triggered" }, { "code": "M03-A119", "message": "Output speed unstable" } ]
[ "[M03] output speed variance 9.4% under load, squeal reported" ]
Operator requests inspection before next batch.
{ "component": "belt", "failure_mode": "slippage", "repair": "retension or replace belt" }
E00098
M05
[ { "code": "M05-A133", "message": "Vibration level above ISO 10816 zone B" }, { "code": "M05-A130", "message": "Abnormal noise reported by operator" } ]
[ "[M05] gear mesh frequency sidebands rising, oil sample shows metal particles" ]
Machine behaving oddly since start of shift.
{ "component": "gearbox", "failure_mode": "tooth_wear", "repair": "inspect gears, replace worn stage" }
E00099
M05
[ { "code": "M05-A128", "message": "Cycle time above nominal" }, { "code": "M05-A132", "message": "Supply pressure below nominal" }, { "code": "M05-A130", "message": "Abnormal noise reported by operator" } ]
[ "[M05] actuation time 81.99s vs nominal 0.40s, supply pressure sagging" ]
Problem occurs mainly under full load.
{ "component": "pneumatic_valve", "failure_mode": "leak", "repair": "replace valve seals" }
E00100
M02
[ { "code": "M02-A108", "message": "Flow rate below nominal" }, { "code": "M02-A112", "message": "Sensor plausibility check failed" } ]
[ "[M02] ambient reported as 103.8 C, plant ambient is 24 C" ]
Issue appeared gradually over the last two days.
{ "component": "temperature_sensor", "failure_mode": "drift", "repair": "recalibrate or replace sensor" }
End of preview. Expand in Data Studio

LongHaul-Bench

Does a self-improving LLM agent get better or slowly rot over ~1,000 sequential tasks? LongHaul-Bench is a seed-reproducible synthetic industrial fault-diagnosis environment for measuring the long-horizon reliability of agents that learn from their own experience, under edge constraints (quantized small model, hard memory budget, offline).

Dataset structure

Each release is one synthetic plant (five machine types, 15 component types, 16 failure modes) plus a stream of 1,000 diagnostic episodes, generated from seed 42.

Config Episodes Difficulty Notes
v0-standard (default) 1,000 log dropout 0.3, symptom dropout 0.3 all paper results use this tier
v0-hard 1,000 log dropout 0.7, symptom dropout 0.5
v1-standard 1,000 standard knobs fault frequencies calibrated to the AI4I 2020 dataset

An LLM-free 91-line heuristic scores 99.9% / 86.3% / 73.3% exact accuracy on the easy / standard / hard tiers.

episodes.jsonl (loaded by the configs above), one episode per line:

Field Description
episode_id e.g. E00001; episodes are meant to be run in order
machine_id machine the fault occurs on
alarms list of {code, message}
log_excerpt HMI/PLC-style log lines (subject to dropout)
operator_note free-text note
ground_truth {component, failure_mode, repair}: for scoring only, never show it to the agent

world.json (per release, not loaded by the configs): the agent's tool corpus, with the alarm-code table, per-machine troubleshooting manual excerpts (the retrieval corpus), and maintenance history. The three releases share the same world file.

from datasets import load_dataset
from huggingface_hub import hf_hub_download
import json

episodes = load_dataset("renderfy/longhaul-bench", "v0-standard", split="test")
world = json.load(open(hf_hub_download("renderfy/longhaul-bench", "longhaul-v0-standard/world.json",
                                        repo_type="dataset")))

File integrity: SHA256SUMS matches the canonical files in the GitHub repository.

Protocol

The agent sees alarms, the log excerpt, and the operator note; it may call alarm_lookup, manual_search, and maintenance_history over world.json, and must output a JSON diagnosis (component + failure mode), scored by exact match. After each episode the environment returns outcome feedback that an improvement operator may write into a bounded experience memory (100 records in the paper). Feedback can be corrupted with plausible wrong diagnoses to test knowledge rot. The full harness is in the GitHub repository.

Reference results (paper, Qwen2.5-3B-Instruct Q4_K_M, five worlds)

Arm Exact accuracy (mean over 5 worlds)
frozen (no learning) 58.2%
append memory 62.0%
reflect memory 61.3%
reflect + 40% plausible corrupted feedback 55.3%
same, with manual-consistency gates 61.3%
manual oracle (correct manual row given) 76.8%

Memory helps only when recall surfaces the correct precedent often enough: in the paper's recall-precision decomposition the break-even recall precision is about 0.7, and plausible corruption causes rot mainly by lowering that precision (0.81 → 0.72 → 0.65 at 0/20/40% corruption).

Limitations

The environment is template-generated: fault frequencies can be calibrated to public data (v1), but symptom and log text are synthetic, and on the standard tier the LLM-free heuristic floor exceeds the 3B agent's oracle ceiling. Results characterize memory dynamics, not absolute diagnostic competence. No proprietary or employer data is used.

Citation

@misc{feryad2026longhaul,
  title     = {LongHaul-Bench: A Reproducible Benchmark for Long-Horizon Reliability of Self-Improving LLM Agents Under Industrial Edge Constraints},
  author    = {Feryad, Vahit},
  year      = {2026},
  publisher = {Zenodo},
  doi       = {10.5281/zenodo.23624799},
  url       = {https://doi.org/10.5281/zenodo.23624799}
}
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