Komatsu 930E-4 DUMP Truck Service Shop Repair Manual (S/N: A30601 and UP)
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🏷️ Basic Information Identification Make: Komatsu Model: 930E-4 Vehicle Type: Dump Truck (Electric Drive) Serial Number Applicability: S/N: A30601 and UP Codes Internal Code: K930E4-SE-RP 👋 Introduction Market Position Segment: Ultra-Class Mining Dump Truck Application: Heavy-duty mining, quarrying, and large-scale earthmoving operations. Competitive Analysis Competitors: Caterpillar 797 Series, Liebherr T 284, BelAZ 75710 Key Features Articulated Chassis: Standard for maneuverability in challenging environments. Electric Drive System: Utilizes AC traction motors for high torque and efficient power transfer. Payload Capacity: Designed for payloads in the 200-ton to 360-ton range (depending on specific configuration and options). Advanced Controls: Features sophisticated electronic control systems for powertrain, braking, and steering. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Assembly, Disassembly, Servicing Page Count Estimated Page Count: Est. 1500+ pages (typical for this class of manual) Manual Type Type: Service Shop Repair Manual Language Language: English Format Format: Digital (PDF) expected for this model year and type 📖 Manual Coverage Systems Covered Powertrain: Engine, Electric Drive System (Propulsion Motors, Generators, Control Systems), Transmission (if applicable to specific configurations), Axles Hydraulics: Brake System Hydraulics, Steering System Hydraulics, Hoist System Hydraulics Electrical: Vehicle Electrical System, Control Systems (PLC, CAN Bus), Diagnostic Codes, Battery System, Lighting Chassis And Body: Frame, Suspension, Steering Linkage, Braking System Components (Pneumatic and Hydraulic), Hoist Cylinder, Body Structure, Cab Procedures Included Maintenance: Scheduled Maintenance, Lubrication Schedules, Fluid Checks and Replacements, Filter Changes Diagnostics: Troubleshooting Guides, Fault Code Diagnosis, Component Testing Procedures Repair And Overhaul: Component Disassembly, Reassembly, Overhaul Procedures, Component Replacement Guidelines Assembly: New Unit Assembly, Major Component Installation Technical Depth Depth: Comprehensive, covering from basic inspection to full component overhaul and system diagnostics. Diagnostic Tools: Information likely includes procedures for using proprietary diagnostic tools (e.g., Komatsu's diagnostic software). 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable for efficient information retrieval. Print Quality Quality: High-resolution scans suitable for digital viewing and printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Make Model: Cummins QSK60 (or MTU 12V4000) Engine Type: Turbocharged, Water-Cooled, Diesel Engine Displacement: 60 Liters (for Cummins QSK60) Performance Gross Horsepower: Typically 2300-2600 HP (depending on specific engine option and tuning) Peak Torque: High torque output, crucial for hauling heavy loads. Fuel System Injection Type: High-pressure common rail fuel injection system Fuel Type: Diesel Fuel Cooling System Type: Pressurized, thermostatically controlled cooling system. 🔧 Transmission Standard Type: Electric Drive System (AC Traction Motors powered by Diesel-Electric Generator Set) Optional Type: N/A (Electric drive is the defining characteristic) Features Motor Type: AC Traction Motors (typically dual motors, one per rear wheel or axle) Generator Type: AC Generator driven by the diesel engine, providing power to the traction motors and onboard systems. Control System: Advanced electronic control unit (ECU) managing engine, generator, and motor performance for optimal traction and efficiency. Retarder: Integrated dynamic braking (retarder) system using traction motors for speed control on downhill gradients. 📐 Dimensions Exterior Overall Length: Approx. 14-15 meters Overall Width: Approx. 7-8 meters Overall Height: Approx. 6-7 meters (to top of ROPS canopy) Ground Clearance: Significant, designed for off-road operation Cargo Body Capacity Cu M: Approx. 100-120 cubic meters (heaped) Payload Capacity Tonnes: Approx. 300-320 Tonnes (typical for 930E-4) Weights Operating Weight Kg: Approx. 200,000 - 230,000 kg (tare weight) Gross Vehicle Weight Kg: Approx. 500,000 - 550,000 kg (fully loaded) Tire Size: Typically 40.00 R57 or 53/80R63 🛡️ Safety Features Ratings Crash Test Results: N/A (Vehicle class not subject to standard automotive crash testing protocols). Active Features Braking System: Multi-circuit, oil-cooled, multi-plate brakes (service, parking, emergency) on all wheels. Dynamic braking via electric motors. Steering System: Hydrostatically driven power steering system with load sensing for stability. Traction Control: Integrated into the electric drive system for optimal grip. Passive Features Roll Over Protection: Integrated ROPS (Roll-Over Protective Structure) cab. Operator Visibility: Designed for maximum visibility, often with auxiliary cameras. Emergency Stop: Clearly marked emergency stop buttons throughout the machine. 💡 Technology Features Infotainment Cabin Features: Modern operator cabins include advanced climate control, ergonomic seating, and intuitive control interfaces. Infotainment typically limited to operational displays and communication systems. Driver Assistance Monitoring Systems: Onboard diagnostics and performance monitoring systems, payload monitoring, engine and drivetrain health monitoring. Telematics: Likely equipped with telematics for remote monitoring of machine health, location, and operational data (e.g., Komatsu's KOMTRAX). Connectivity Diagnostic Interface: CAN bus network for communication between various control modules. Diagnostic ports for interface with service tools. 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual, typically 250-500 operating hours depending on duty cycle and oil analysis. Filter Replacement: Fuel, oil, air filters typically replaced at intervals specified in the manual or based on condition monitoring. Hydraulic Fluid Change: Refer to manual, often 1000-2000 operating hours, with fluid analysis recommended. Fluid Specifications Engine...
Designed for maximum visibility, often with auxiliary cameras.
Emergency Stop:
Clearly marked emergency stop buttons throughout the machine.
💡 Technology Features
Infotainment
Cabin Features:
Modern operator cabins include advanced climate control, ergonomic seating, and intuitive control interfaces. Infotainment typically limited to operational displays and communication systems.
Driver Assistance
Monitoring Systems:
Onboard diagnostics and performance monitoring systems, payload monitoring, engine and drivetrain health monitoring.
Telematics:
Likely equipped with telematics for remote monitoring of machine health, location, and operational data (e.g., Komatsu's KOMTRAX).
Connectivity
Diagnostic Interface:
CAN bus network for communication between various control modules. Diagnostic ports for interface with service tools.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual, typically 250-500 operating hours depending on duty cycle and oil analysis.
Filter Replacement:
Fuel, oil, air filters typically replaced at intervals specified in the manual or based on condition monitoring.
Hydraulic Fluid Change:
Refer to manual, often 1000-2000 operating hours, with fluid analysis recommended.
Fluid Specifications
Engine Oil:
High-performance, heavy-duty diesel engine oil meeting API CK-4 or equivalent specifications. Viscosity grade varies with ambient temperature (e.g., SAE 15W-40, 10W-30).
Hydraulic Fluid:
ISO VG 46 or similar high-quality hydraulic fluid, often with specific Komatsu approvals.
Coolant:
Ethylene glycol-based engine coolant with a 50% mix of deionized water. Extended life coolant (ELC) often specified.
Brake Fluid:
Typically SAE J1703 or DOT 3/4 brake fluid for pneumatic brake actuation systems, hydraulic systems may use specific fluids.
Known Issues
Electrical System Reliability:
Complex electrical and control systems can be prone to issues if not maintained properly. Diagnostic expertise is crucial.
Traction Motor Wear:
Wear on traction motor brushes or bearings can occur with high hours and heavy operation.
Hoist Cylinder Seals:
Hydraulic cylinder seal leaks are common maintenance items due to high pressures and environmental factors.
Tire Maintenance:
Proper inflation and alignment are critical due to extreme loads and costs of replacement tires.
📚 Vehicle History
Brand Heritage
Company Origin:
Komatsu Ltd., a Japanese multinational corporation, is a leading manufacturer of construction, mining, and industrial equipment.
Legacy:
Komatsu has a long history of innovation in heavy machinery, including pioneering advancements in electric drive technology for mining trucks.
Model Evolution
Predecessors:
The 930E-4 is part of a lineage of ultra-class haul trucks, evolving from earlier models like the 930E.
Technological Advancements:
Each iteration has seen improvements in engine efficiency, electric drive systems, control technology, and operator comfort.
Production
Manufacturing Location:
Likely manufactured at Komatsu's mining equipment facilities, potentially in North America or Japan.
Production Period:
The 930E-4 was a significant model in the late 1990s and 2000s, with ongoing evolution.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Komatsu mining equipment is widely recognized for its durability, reliability, and performance in extreme conditions.
Ratings
Reliability Score:
High, based on industry reputation and operational uptime in demanding environments.
Certifications
Emissions:
Compliant with relevant regional emissions standards for heavy-duty off-road equipment of its era.
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