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Komatsu 930E-4 Service Repair Manual A30796 & UP

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🏷️ Basic Information Identification Make: Komatsu Model: 930E-4 Vehicle Type: Mining Truck / Dump Truck Codes Manual Product Code: A30796 & UP 👋 Introduction Market Position Komatsu Mining Division Role: Essential documentation for the reliable operation and maintenance of large-capacity mining haul trucks. Competitive Analysis Manual Value Proposition: Provides factory-authorized procedures, ensuring accuracy and efficiency compared to third-party or generic repair guides. Key Features Manual Usability: Allows for printing specific sections or the entire manual, offering flexibility for on-site or shop use. Information Accuracy: Directly from Komatsu, guaranteeing the most up-to-date and correct technical information. 📋 Manual Details Coverage Areas Manual Coverage Scope: Complete factory service and repair Page Count Estimated Page Count: Hundreds of pages Manual Type Manual Classification: Workshop Service Repair Manual Language Primary Language: English Format Delivery Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Powertrain Coverage: Engine, transmission, drivetrain, braking system (dynamic and parking), steering system. Electrical Coverage: Vehicle electrical system, battery, charging system, starter, lighting, instrumentation, controls, and diagnostic systems. Hydraulic Coverage: Hydraulic systems for hoist, steering, braking, and other operational functions. Chassis And Body Coverage: Frame, suspension, cab, body panels, dump body, and associated structures. Procedures Included Maintenance Procedures: Scheduled maintenance, lubrication, fluid checks and changes, filter replacement, general inspections. Repair Procedures: Component removal, disassembly, inspection, repair, reassembly, and installation. Troubleshooting Guidelines: Diagnostic procedures, fault code interpretation, symptom-based troubleshooting charts. Overhaul Procedures: Detailed instructions for major component overhauls (engine, transmission, hydraulics). Technical Depth Diagnostic Capability: Advanced diagnostics, including electrical system analysis and component testing. Rebuild Depth: Comprehensive rebuild procedures for all major mechanical and hydraulic systems. Specification Detail: Precise torque values, clearances, tolerances, and assembly instructions. 📊 Manual Specifications File Format Digital File Type: Likely PDF; optimized for printing and digital viewing. Print Quality Document Fidelity: High-resolution scans/digital files for clear diagrams and text. Binding Type Physical Manual Binding: N/A (Digital Download) - Assumed printable for traditional binding. Paper Type Suggested Print Paper: N/A (Digital Download) - Optimized for standard printing paper. ⚙️ Engine Specifications Primary Engine Engine Model: Cummins QSK60 Engine Type: V16 Diesel Engine Performance Engine Displacement: 59.9 Liters (3656 cubic inches) Gross Horsepower Rating: 1865 HP (1391 kW) @ 1800 RPM (typical rating, may vary by configuration) Peak Torque Rating: Over 7000 lb-ft (9490 Nm) (typical rating, may vary by configuration) Fuel System Fuel Delivery System: High-pressure common rail, electronically controlled injection Emission Control Emission Standards Compliance: Designed to meet Tier 2 and Stage II regulations (depending on region of sale). Cooling System Cooling System Type: Heavy-duty, high-capacity radiator and fan system. 🔧 Transmission Standard Transmission Type: AC Electric Drive System (Hitachi Electric Variable Machine Control - EVMC) Optional Optional Transmission Type: N/A (Standard on 930E-4) Features Drive System Components: Engine-driven alternator, AC traction motors (in each rear wheel hub), power converters, and control electronics. Traction Control: Advanced electronic control for optimal traction and power management. 📐 Dimensions Exterior Overall Length: Approx. 15.2 m (50 ft 3 in) Overall Width: Approx. 9.7 m (31 ft 10 in) Overall Height Laden: Approx. 7.5 m (24 ft 7 in) to top of cab; dump body height varies when raised. Cargo Rated Payload Capacity: Approx. 310 US tons (281 metric tons) Body Volume Struck: Approx. 174 cubic meters (228 cubic yards) Weights Operating Weight Approx: Approx. 535,000 lbs (242,700 kg) Gvw Max Rated: Approx. 1,190,000 lbs (540,000 kg) Wheelbase Wheelbase Dimension: Approx. 7.5 m (24 ft 7 in) Ground Clearance Ground Clearance: Approx. 0.7 m (2 ft 4 in) at center articulation. 🛡️ Safety Features Ratings Safety Certification: Designed to meet rigorous mining industry safety standards (specific certifications may vary by region/client). Active Features Braking System Type: Wet disc brakes, hydromechanically actuated; dynamic braking via electric drive system retardation. Parking Brake System: Spring-applied, hydraulically released multiple disc brakes acting on drive shafts. Anti Lock Braking System: Standard ABS integrated into the electric drive system. Passive Features Cab Design Safety: ROPS (Roll-Over Protective Structure) compliant cab, advanced visibility features, emergency egress. Fire Suppression System: Provisions for and often includes an integrated fire suppression system (e.g., Ansul). Visibility Enhancements Lighting System: Powerful halogen or LED lighting for high-visibility operation in all conditions. 💡 Technology Features Infotainment Cab Electronics Suite: Integrated systems for machine monitoring, diagnostics, payload management, and operator interface. Driver Assistance Electric Drive Control: Sophisticated control algorithms manage power distribution, speed, and retarding for optimal performance and safety. Connectivity Telematics Integration: Designed for integration with Komatsu's KOMTRAX™ or similar fleet management and telematics systems for remote monitoring and data logging. Automation Readiness Autonomous Operation Capability: This platform often serves as a base for advanced semi-autonomous or fully autonomous mining operations, with factory-prepared systems. 🔧 Maintenance Service Intervals Engine Oil Change Interval: Typically 500-1000 hours, dependent on operating conditions and oil analysis (refer to manual for specifics). Hydraulic Fluid Change Interval: Typically 2000-4000...
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Komatsu 930E-4 Service Repair Manual A30796 & UP
🏷️ Basic Information
Identification
Make:
Komatsu
Model:
930E-4
Vehicle Type:
Mining Truck / Dump Truck
Codes
Manual Product Code:
A30796 & UP
👋 Introduction
Market Position
Komatsu Mining Division Role:
Essential documentation for the reliable operation and maintenance of large-capacity mining haul trucks.
Competitive Analysis
Manual Value Proposition:
Provides factory-authorized procedures, ensuring accuracy and efficiency compared to third-party or generic repair guides.
Key Features
Manual Usability:
Allows for printing specific sections or the entire manual, offering flexibility for on-site or shop use.
Information Accuracy:
Directly from Komatsu, guaranteeing the most up-to-date and correct technical information.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Complete factory service and repair
Page Count
Estimated Page Count:
Hundreds of pages
Manual Type
Manual Classification:
Workshop Service Repair Manual
Language
Primary Language:
English
Format
Delivery Format:
Downloadable Digital Format (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain Coverage:
Engine, transmission, drivetrain, braking system (dynamic and parking), steering system.
Electrical Coverage:
Vehicle electrical system, battery, charging system, starter, lighting, instrumentation, controls, and diagnostic systems.
Hydraulic Coverage:
Hydraulic systems for hoist, steering, braking, and other operational functions.
Chassis And Body Coverage:
Frame, suspension, cab, body panels, dump body, and associated structures.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, lubrication, fluid checks and changes, filter replacement, general inspections.
Repair Procedures:
Component removal, disassembly, inspection, repair, reassembly, and installation.
Troubleshooting Guidelines:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting charts.
Overhaul Procedures:
Detailed instructions for major component overhauls (engine, transmission, hydraulics).
Technical Depth
Diagnostic Capability:
Advanced diagnostics, including electrical system analysis and component testing.
Rebuild Depth:
Comprehensive rebuild procedures for all major mechanical and hydraulic systems.
Specification Detail:
Precise torque values, clearances, tolerances, and assembly instructions.
📊 Manual Specifications
File Format
Digital File Type:
Likely PDF; optimized for printing and digital viewing.
Print Quality
Document Fidelity:
High-resolution scans/digital files for clear diagrams and text.
Binding Type
Physical Manual Binding:
N/A (Digital Download) - Assumed printable for traditional binding.
Paper Type
Suggested Print Paper:
N/A (Digital Download) - Optimized for standard printing paper.
⚙️ Engine Specifications
Primary Engine
Engine Model:
Cummins QSK60
Engine Type:
V16 Diesel Engine
Performance
Engine Displacement:
59.9 Liters (3656 cubic inches)
Gross Horsepower Rating:
1865 HP (1391 kW) @ 1800 RPM (typical rating, may vary by configuration)
Peak Torque Rating:
Over 7000 lb-ft (9490 Nm) (typical rating, may vary by configuration)
Fuel System
Fuel Delivery System:
High-pressure common rail, electronically controlled injection
Emission Control
Emission Standards Compliance:
Designed to meet Tier 2 and Stage II regulations (depending on region of sale).
Cooling System
Cooling System Type:
Heavy-duty, high-capacity radiator and fan system.
🔧 Transmission
Standard
Transmission Type:
AC Electric Drive System (Hitachi Electric Variable Machine Control - EVMC)
Optional
Optional Transmission Type:
N/A (Standard on 930E-4)
Features
Drive System Components:
Engine-driven alternator, AC traction motors (in each rear wheel hub), power converters, and control electronics.
Traction Control:
Advanced electronic control for optimal traction and power management.
📐 Dimensions
Exterior
Overall Length:
Approx. 15.2 m (50 ft 3 in)
Overall Width:
Approx. 9.7 m (31 ft 10 in)
Overall Height Laden:
Approx. 7.5 m (24 ft 7 in) to top of cab; dump body height varies when raised.
Cargo
Rated Payload Capacity:
Approx. 310 US tons (281 metric tons)
Body Volume Struck:
Approx. 174 cubic meters (228 cubic yards)
Weights
Operating Weight Approx:
Approx. 535,000 lbs (242,700 kg)
Gvw Max Rated:
Approx. 1,190,000 lbs (540,000 kg)
Wheelbase
Wheelbase Dimension:
Approx. 7.5 m (24 ft 7 in)
Ground Clearance
Ground Clearance:
Approx. 0.7 m (2 ft 4 in) at center articulation.
🛡️ Safety Features
Ratings
Safety Certification:
Designed to meet rigorous mining industry safety standards (specific certifications may vary by region/client).
Active Features
Braking System Type:
Wet disc brakes, hydromechanically actuated; dynamic braking via electric drive system retardation.
Parking Brake System:
Spring-applied, hydraulically released multiple disc brakes acting on drive shafts.
Anti Lock Braking System:
Standard ABS integrated into the electric drive system.
Passive Features
Cab Design Safety:
ROPS (Roll-Over Protective Structure) compliant cab, advanced visibility features, emergency egress.
Fire Suppression System:
Provisions for and often includes an integrated fire suppression system (e.g., Ansul).
Visibility Enhancements
Lighting System:
Powerful halogen or LED lighting for high-visibility operation in all conditions.
💡 Technology Features
Infotainment
Cab Electronics Suite:
Integrated systems for machine monitoring, diagnostics, payload management, and operator interface.
Driver Assistance
Electric Drive Control:
Sophisticated control algorithms manage power distribution, speed, and retarding for optimal performance and safety.
Connectivity
Telematics Integration:
Designed for integration with Komatsu's KOMTRAX™ or similar fleet management and telematics systems for remote monitoring and data logging.
Automation Readiness
Autonomous Operation Capability:
This platform often serves as a base for advanced semi-autonomous or fully autonomous mining operations, with factory-prepared systems.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically 500-1000 hours, dependent on operating conditions and oil analysis (refer to manual for specifics).
Hydraulic Fluid Change Interval:
Typically 2000-4000 hours, dependent on operating conditions and fluid analysis (refer to manual for specifics).
Filter Replacement Schedule:
Engine oil, fuel, hydraulic, and air filters have specific replacement intervals detailed in the manual, often tied to engine hours.
Fluid Specifications
Engine Oil Grade:
API CJ-4 or CK-4, SAE 15W-40 (refer to manual for exact OEM specification and alternative grades).
Hydraulic Fluid Type:
Komatsu genuine hydraulic fluid or equivalent ISO VG 46 anti-wear hydraulic oil.
Coolant Specifications:
Proprietary Komatsu or approved heavy-duty ELC (Extended Life Coolant) with appropriate water mix.
Known Issues
Common Wear Points:
Brake component wear, suspension articulation points, hydraulic system seals, electrical connector integrity.
Diagnostic Challenges:
Complexities of the AC electric drive system require specialized diagnostic tools and expertise for accurate fault isolation.
Preventive Maintenance
Importance Of Sampling:
Regular oil and hydraulic fluid analysis is critical for early detection of component wear and contamination, preventing major failures.
📚 Vehicle History
Brand Heritage
Komatsu Mining History:
Komatsu is a global leader in construction and mining equipment, known for robust and innovative solutions.
Model Evolution
930E Series Development:
The 930E series represents a long-standing lineage of Komatsu's ultra-class haul trucks, evolving in payload capacity, efficiency, and technology.
Production
Production Era 930E-4:
Produced from approximately the mid-2000s onwards, representing a significant technological advancement over earlier models.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 930E-4 model may not be publicly cataloged, Komatsu haul trucks consistently receive recognition for innovation, efficiency, and reliability in the mining sector.
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