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Komatsu 930E-4 Service Repair Manual A30693-A30749

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🏷️ Basic Information Identification Make: Komatsu Model: 930E-4 Vehicle Type: Large Mining Truck / Haul Truck Codes Manual Product Code: A30693-A30749 👋 Introduction Market Position Segment: Ultra-Class Mining Truck Application: Heavy-duty material handling in mining, quarrying, and large-scale construction operations. Competitive Analysis Competitors: Caterpillar 793 Series, Liebherr T 284, Hitachi EH4000, BelAZ 7547 Key Features Payload Capacity: Approximately 231 metric tons (255 short tons). Powertrain Type: Diesel-electric drive. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Page Count: N/A (Digital PDF) Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, fuel system, lubrication system, cooling system, exhaust system, air intake system, engine controls, emissions systems. Powertrain Systems: Transmission (GE7R818), drive shafts, differentials, axles, wheel planetary reduction gears, braking system (service brake, parking brake, retarder), hydraulic systems (steering, hoist, braking). Electrical Systems: Wiring diagrams, starter system, charging system, lighting, instrumentation, engine control module (ECM), transmission control module (TCM), vehicle control systems, AC/DC converters, battery system. Chassis And Body: Frame, suspension (front and rear), steering system components, body panels, cab interior, dump body, hydraulic hoist system, tires and wheels. Procedures Included Maintenance Procedures: Scheduled maintenance checks, lubrication points, fluid changes, filter replacements, component inspections, pre-operation checks. Repair Procedures: Engine component replacement, transmission overhaul, brake system repair, hydraulic cylinder and pump repair, electrical component diagnosis and replacement, suspension and steering linkage repair, axle and differential service. Troubleshooting Guides: Diagnostic flowcharts for common issues, error code explanations, symptom-based troubleshooting for engine, transmission, braking, and hydraulic systems. Specifications And Data: Torque specifications, clearances, fluid capacities, electrical resistance values, hydraulic pressures, wear limits. Technical Depth Depth: Comprehensive rebuild and diagnostic information suitable for trained technicians. 📊 Manual Specifications File Format Quality: High-resolution PDF, searchable text, bookmarked for easy navigation. Print Quality Print Capability: Printable for use in workshop environments. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Make Model: Cummins K50 Engine Configuration: V18 Displacement: 18.29 liters (1116 cubic inches) Performance Gross Horsepower: 1600 HP (1193 kW) @ 1800 RPM Peak Torque: N/A (Specific torque figures typically not advertised publicly, but significantly high) Fuel System Fuel Delivery: High-pressure common rail fuel injection system. Fuel Type: Diesel Cooling System Type: Heavy-duty engine cooling system with engine-driven fan. Lubrication System Oil Capacity: Approx. 72 Liters (19 US gal) Air Intake Filtration: Multi-stage air filtration system with pre-cleaners. Emission Controls Standards: Designed to meet applicable emissions regulations for heavy-duty off-road equipment of its era. 🔧 Transmission Standard Type: AC Electric Drive (GE7R818 Traction Motor) Manufacturer: General Electric (GE) - AC Wheel Motor Features Control System: Integrated AC traction motor control system with advanced diagnostics. Engine Coupling: Variable speed AC generators driven by the Cummins K50 engine. Drive Configuration: All-wheel drive (each rear wheel powered by an individual AC motor). 📐 Dimensions Exterior Length: Approx. 13.6 meters (44 ft 7 in) Width: Approx. 7.6 meters (24 ft 11 in) Height Top Of Cab: Approx. 4.9 meters (16 ft 1 in) Height Dump Body Raised: Approx. 10.9 meters (35 ft 9 in) Cargo Body Capacity Heaped: Approx. 126 m³ (165 yd³) Weights Operating Weight: Approx. 180,000 kg (396,830 lbs) Gross Vehicle Weight Rating Gvwr: Approx. 360,000 kg (793,664 lbs) Wheels Tires Tire Size: Standard: 40.00-57 or 42/90-57 (Large radial tires designed for mining applications). Wheelbase Wheelbase: Approx. 5.9 meters (19 ft 4 in) 🛡️ Safety Features Ratings Certification: Designed to meet stringent safety standards for heavy mining equipment, though formal crash ratings are not applicable. Active Features Braking System: Service brakes (wet multi-disc), parking brake, dynamic retarder system (engine braking and electrical braking). Steering System: Hydraulic power steering with advanced control for precise maneuverability. Visibility: Large cab windows, external lighting, optional rearview cameras. Passive Features Cab Protection: ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) compliant cab. Fire Suppression: Optional fire suppression systems available. Warning Systems Alarms: Reverse alarms, horn, warning lights. 💡 Technology Features Infotainment Cab Features: Focus is on operational data display and control rather than traditional infotainment. Features include advanced instrumentation and diagnostic displays. Driver Assistance Braking System: Integrated dynamic retarder system for controlled downhill speeds and brake wear reduction. Connectivity Telematics: Typically equipped with Komatsu's proprietary fleet management and monitoring systems (e.g., KOMTRAX) for remote diagnostics and performance tracking. Powertrain Control System: Sophisticated electronic control unit (ECU) managing engine, generators, and AC traction motors for optimal power delivery and efficiency. 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual for specific interval (typically based on operating hours, e.g., 250-500 hours). Hydraulic Fluid Change: Refer to manual for specific interval (typically based on operating hours, e.g., 1000-2000 hours). Air Filter Replacement: Based on monitoring of restriction indicators or specific operating hours. Fluid Specifications...
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Komatsu 930E-4 Service Repair Manual A30693-A30749
🏷️ Basic Information
Identification
Make:
Komatsu
Model:
930E-4
Vehicle Type:
Large Mining Truck / Haul Truck
Codes
Manual Product Code:
A30693-A30749
👋 Introduction
Market Position
Segment:
Ultra-Class Mining Truck
Application:
Heavy-duty material handling in mining, quarrying, and large-scale construction operations.
Competitive Analysis
Competitors:
Caterpillar 793 Series, Liebherr T 284, Hitachi EH4000, BelAZ 7547
Key Features
Payload Capacity:
Approximately 231 metric tons (255 short tons).
Powertrain Type:
Diesel-electric drive.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Page Count
Estimated Page Count:
N/A (Digital PDF)
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, fuel system, lubrication system, cooling system, exhaust system, air intake system, engine controls, emissions systems.
Powertrain Systems:
Transmission (GE7R818), drive shafts, differentials, axles, wheel planetary reduction gears, braking system (service brake, parking brake, retarder), hydraulic systems (steering, hoist, braking).
Electrical Systems:
Wiring diagrams, starter system, charging system, lighting, instrumentation, engine control module (ECM), transmission control module (TCM), vehicle control systems, AC/DC converters, battery system.
Chassis And Body:
Frame, suspension (front and rear), steering system components, body panels, cab interior, dump body, hydraulic hoist system, tires and wheels.
Procedures Included
Maintenance Procedures:
Scheduled maintenance checks, lubrication points, fluid changes, filter replacements, component inspections, pre-operation checks.
Repair Procedures:
Engine component replacement, transmission overhaul, brake system repair, hydraulic cylinder and pump repair, electrical component diagnosis and replacement, suspension and steering linkage repair, axle and differential service.
Troubleshooting Guides:
Diagnostic flowcharts for common issues, error code explanations, symptom-based troubleshooting for engine, transmission, braking, and hydraulic systems.
Specifications And Data:
Torque specifications, clearances, fluid capacities, electrical resistance values, hydraulic pressures, wear limits.
Technical Depth
Depth:
Comprehensive rebuild and diagnostic information suitable for trained technicians.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, searchable text, bookmarked for easy navigation.
Print Quality
Print Capability:
Printable for use in workshop environments.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Make Model:
Cummins K50
Engine Configuration:
V18
Displacement:
18.29 liters (1116 cubic inches)
Performance
Gross Horsepower:
1600 HP (1193 kW) @ 1800 RPM
Peak Torque:
N/A (Specific torque figures typically not advertised publicly, but significantly high)
Fuel System
Fuel Delivery:
High-pressure common rail fuel injection system.
Fuel Type:
Diesel
Cooling System
Type:
Heavy-duty engine cooling system with engine-driven fan.
Lubrication System
Oil Capacity:
Approx. 72 Liters (19 US gal)
Air Intake
Filtration:
Multi-stage air filtration system with pre-cleaners.
Emission Controls
Standards:
Designed to meet applicable emissions regulations for heavy-duty off-road equipment of its era.
🔧 Transmission
Standard
Type:
AC Electric Drive (GE7R818 Traction Motor)
Manufacturer:
General Electric (GE) - AC Wheel Motor
Features
Control System:
Integrated AC traction motor control system with advanced diagnostics.
Engine Coupling:
Variable speed AC generators driven by the Cummins K50 engine.
Drive Configuration:
All-wheel drive (each rear wheel powered by an individual AC motor).
📐 Dimensions
Exterior
Length:
Approx. 13.6 meters (44 ft 7 in)
Width:
Approx. 7.6 meters (24 ft 11 in)
Height Top Of Cab:
Approx. 4.9 meters (16 ft 1 in)
Height Dump Body Raised:
Approx. 10.9 meters (35 ft 9 in)
Cargo
Body Capacity Heaped:
Approx. 126 m³ (165 yd³)
Weights
Operating Weight:
Approx. 180,000 kg (396,830 lbs)
Gross Vehicle Weight Rating Gvwr:
Approx. 360,000 kg (793,664 lbs)
Wheels Tires
Tire Size:
Standard: 40.00-57 or 42/90-57 (Large radial tires designed for mining applications).
Wheelbase
Wheelbase:
Approx. 5.9 meters (19 ft 4 in)
🛡️ Safety Features
Ratings
Certification:
Designed to meet stringent safety standards for heavy mining equipment, though formal crash ratings are not applicable.
Active Features
Braking System:
Service brakes (wet multi-disc), parking brake, dynamic retarder system (engine braking and electrical braking).
Steering System:
Hydraulic power steering with advanced control for precise maneuverability.
Visibility:
Large cab windows, external lighting, optional rearview cameras.
Passive Features
Cab Protection:
ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) compliant cab.
Fire Suppression:
Optional fire suppression systems available.
Warning Systems
Alarms:
Reverse alarms, horn, warning lights.
💡 Technology Features
Infotainment
Cab Features:
Focus is on operational data display and control rather than traditional infotainment. Features include advanced instrumentation and diagnostic displays.
Driver Assistance
Braking System:
Integrated dynamic retarder system for controlled downhill speeds and brake wear reduction.
Connectivity
Telematics:
Typically equipped with Komatsu's proprietary fleet management and monitoring systems (e.g., KOMTRAX) for remote diagnostics and performance tracking.
Powertrain Control
System:
Sophisticated electronic control unit (ECU) managing engine, generators, and AC traction motors for optimal power delivery and efficiency.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual for specific interval (typically based on operating hours, e.g., 250-500 hours).
Hydraulic Fluid Change:
Refer to manual for specific interval (typically based on operating hours, e.g., 1000-2000 hours).
Air Filter Replacement:
Based on monitoring of restriction indicators or specific operating hours.
Fluid Specifications
Engine Oil:
Refer to manual for specific API service classification and viscosity grade (e.g., API CJ-4, SAE 15W-40 or similar).
Hydraulic Fluid:
Refer to manual for specific type and viscosity (e.g., AW hydraulic oil, ISO VG 46 or similar).
Coolant:
Heavy-duty diesel engine coolant (OAT or HOAT, consult manual for specific type and freeze protection level).
Transmission Fluid:
N/A (Electric drive system does not use traditional transmission fluid).
Known Issues
Common Wear Items:
Brake components, hydraulic seals, suspension bushings, drivetrain elements, air intake system components due to operating environment.
Diagnostic Focus:
Monitoring engine performance, hydraulic pressures, electrical system integrity, and braking system responsiveness is crucial.
📚 Vehicle History
Brand Heritage
Company Focus:
Komatsu is a global leader in the design, manufacture, and sale of construction, mining, and industrial machinery.
Model Evolution
Series:
The 930E series represents Komatsu's commitment to ultra-class haul trucks, building upon previous generations of mining equipment.
Advancements:
The 930E-4 typically incorporated enhancements in powertrain efficiency, operator comfort, and advanced electronic control systems over earlier models.
Production
Manufacturing Location:
Typically manufactured at Komatsu facilities specializing in large mining equipment (e.g., USA).
Production Years:
The 930E-4 model designation indicates a specific generation, likely produced from the early to mid-2000s onwards, with continuous updates.
🏆 Awards & Recognition
Recognitions
Industry Standing:
Consistently recognized as a leading performer and reliable machine in the ultra-class mining truck segment.
Ratings
Performance:
Highly rated for productivity, payload capacity, and operational efficiency in demanding mining environments.
Certifications
Manufacturing Standards:
Manufactured under ISO 9001 quality management standards.
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