Komatsu 930E-2 DUMP Truck Service Shop Repair Manual (SN: A30292)
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🏷️ Basic Information Identification Make: Komatsu Model: 930E-2 Vehicle Type: Mining Dump Truck Serial Number Applicability: A30292 Generation Production Period Indicator: Specific to SN A30292, indicative of a particular production series within the 930E-2 lineage. Codes Model Code: 930E-2 👋 Introduction Market Position Market Segment: Ultra-class mining haul truck, designed for extreme conditions in large-scale mining operations. Payload Capacity Class: Typically in the 200-ton (180 metric ton) class, though the '930E' designation generally implies around 300 US tons (approx. 272 metric tons) of payload capacity. The '2' in 930E-2 denotes a specific series update. Competitive Analysis Key Competitors: Caterpillar (e.g., 797 series), Liebherr (e.g., T 284), BelAZ. Key Features Articulation Type: Rigid frame with front steer and rear drive axles. Propulsion System: Often features an AC electric drive system powered by an engine-driven generator, providing exceptional torque and precise control. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, maintenance, and assembly/disassembly of the Komatsu 930E-2 Dump Truck. Diagnostic Coverage: Includes troubleshooting guides and diagnostic procedures for all major systems. Page Count Estimated Pages: Detailed page count not provided in product information, but described as 'COMPLETE' indicating extensive documentation. Manual Type Type: Service Shop Repair Manual Language Language: Likely English, standard for heavy equipment service manuals of this era and origin, though specific confirmation is absent. Format Format: Not explicitly stated, but typically available as printed hard copy or digital PDF for such manuals. 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drive shafts, differentials, axles, and wheel systems. Hydraulics: Hoisting system, steering system, braking system, lubrication system, and ancillary hydraulic circuits. Electrical: Starter system, charging system, lighting, instrumentation, engine control unit (ECU), transmission control unit (TCU), vehicle management system (VMS), and integrated electric drive system (if applicable to SN range). Chassis And Body: Frame, suspension, steering linkage, body panels, dump body, cab structure, and mounting hardware. Procedures Included Maintenance: Preventive maintenance schedules, lubrication points, fluid level checks, filter replacement procedures, and general inspection guidelines. Assembly Disassembly: Step-by-step instructions for removing, inspecting, repairing, and reinstalling major components and sub-assemblies. Repair And Rebuild: Detailed repair instructions for individual components, including engine overhaul, transmission rebuild, hydraulic cylinder repair, and brake system servicing. Troubleshooting: Systematic diagnostic procedures, fault code explanations, and corrective actions for common and uncommon issues. Technical Depth Depth: Comprehensive, covering from basic fluid checks to complex electrical diagnostics and complete powertrain rebuilds. Diagnostic Tools And Equipment: May include references to specialized diagnostic tools and equipment required for accurate troubleshooting and calibration. 📊 Manual Specifications File Format Digital Format Expectations: If digital, expect a searchable PDF with clear diagrams and high-resolution images. Print Quality Print Quality Expectations: If printed, expect high-quality paper stock suitable for workshop environments, with clear text and legible diagrams. Binding Type Binding Type Expectations: If printed, likely spiral-bound or durable hardbound to facilitate use on workbenches. Paper Type Paper Type Expectations: If printed, durable paper that can withstand grease and workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Make Model: Typically Cummins QSK60 or GE AC electric drive system as primary propulsion. For QSK60, it's a 60-liter V12 diesel engine. Performance Gross Horsepower: For Cummins QSK60, typically around 2300-2700 hp (1715-2014 kW) depending on configuration and turbocharging. The electric drive system's output is managed by the AC traction motors. Peak Torque: While specific torque figures for the QSK60 are high, the electric drive system's torque is electronically controlled for optimal performance across the speed range, often exceeding 30,000 lb-ft at the wheels. Fuel System Fuel Type: Diesel fuel (ULSD or equivalent). Injection System: Common rail fuel injection (likely with electronic control for QSK60). 🔧 Transmission Standard Type: AC Electric Drive system. Consists of a diesel engine coupled to a generator, which powers AC traction motors in the rear wheels. This is a 'diesel-electric' or 'hybrid' powertrain. Optional Optional Configurations: While electric drive is standard for this class, specific generator/motor manufacturers and control systems may vary by option or update. Features Traction Control: Integrated traction control managed by the electronic control system for optimal grip. Retarder System: Dynamic braking (regenerative) via the electric drive motors, often supplemented by a mechanical retarder. 📐 Dimensions Exterior Overall Length: Approximately 14.5 - 15.0 meters (47.6 - 49.2 ft) Overall Width: Approximately 9.7 - 10.0 meters (31.8 - 32.8 ft) Overall Height: Approximately 6.3 - 6.5 meters (20.7 - 21.3 ft) Cargo Rated Payload Capacity: Typically 300 US tons (272 metric tons). Body Volume Heaped: Approximately 155-170 cubic meters (203-222 cubic yards). Weights Operating Weight: Around 200-220 metric tons (440,000 - 485,000 lbs). Gross Vehicle Weight Rating Gvwr: Around 480-500 metric tons (1,058,000 - 1,102,000 lbs). Wheelbase Wheelbase: Approximately 5.5 - 6.0 meters (18.0 - 19.7 ft). Tire Size Tire Size: Typically 53/80 R63 or similar large-diameter, wide-profile mining tires. 🛡️ Safety Features Ratings Safety Standards Compliance: Designed to meet stringent...
Specific to SN A30292, indicative of a particular production series within the 930E-2 lineage.
Codes
Model Code:
930E-2
👋 Introduction
Market Position
Market Segment:
Ultra-class mining haul truck, designed for extreme conditions in large-scale mining operations.
Payload Capacity Class:
Typically in the 200-ton (180 metric ton) class, though the '930E' designation generally implies around 300 US tons (approx. 272 metric tons) of payload capacity. The '2' in 930E-2 denotes a specific series update.
Competitive Analysis
Key Competitors:
Caterpillar (e.g., 797 series), Liebherr (e.g., T 284), BelAZ.
Key Features
Articulation Type:
Rigid frame with front steer and rear drive axles.
Propulsion System:
Often features an AC electric drive system powered by an engine-driven generator, providing exceptional torque and precise control.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, maintenance, and assembly/disassembly of the Komatsu 930E-2 Dump Truck.
Diagnostic Coverage:
Includes troubleshooting guides and diagnostic procedures for all major systems.
Page Count
Estimated Pages:
Detailed page count not provided in product information, but described as 'COMPLETE' indicating extensive documentation.
Manual Type
Type:
Service Shop Repair Manual
Language
Language:
Likely English, standard for heavy equipment service manuals of this era and origin, though specific confirmation is absent.
Format
Format:
Not explicitly stated, but typically available as printed hard copy or digital PDF for such manuals.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, drive shafts, differentials, axles, and wheel systems.
Starter system, charging system, lighting, instrumentation, engine control unit (ECU), transmission control unit (TCU), vehicle management system (VMS), and integrated electric drive system (if applicable to SN range).
Chassis And Body:
Frame, suspension, steering linkage, body panels, dump body, cab structure, and mounting hardware.
Procedures Included
Maintenance:
Preventive maintenance schedules, lubrication points, fluid level checks, filter replacement procedures, and general inspection guidelines.
Assembly Disassembly:
Step-by-step instructions for removing, inspecting, repairing, and reinstalling major components and sub-assemblies.
Repair And Rebuild:
Detailed repair instructions for individual components, including engine overhaul, transmission rebuild, hydraulic cylinder repair, and brake system servicing.
Troubleshooting:
Systematic diagnostic procedures, fault code explanations, and corrective actions for common and uncommon issues.
Technical Depth
Depth:
Comprehensive, covering from basic fluid checks to complex electrical diagnostics and complete powertrain rebuilds.
Diagnostic Tools And Equipment:
May include references to specialized diagnostic tools and equipment required for accurate troubleshooting and calibration.
📊 Manual Specifications
File Format
Digital Format Expectations:
If digital, expect a searchable PDF with clear diagrams and high-resolution images.
Print Quality
Print Quality Expectations:
If printed, expect high-quality paper stock suitable for workshop environments, with clear text and legible diagrams.
Binding Type
Binding Type Expectations:
If printed, likely spiral-bound or durable hardbound to facilitate use on workbenches.
Paper Type
Paper Type Expectations:
If printed, durable paper that can withstand grease and workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Make Model:
Typically Cummins QSK60 or GE AC electric drive system as primary propulsion. For QSK60, it's a 60-liter V12 diesel engine.
Performance
Gross Horsepower:
For Cummins QSK60, typically around 2300-2700 hp (1715-2014 kW) depending on configuration and turbocharging. The electric drive system's output is managed by the AC traction motors.
Peak Torque:
While specific torque figures for the QSK60 are high, the electric drive system's torque is electronically controlled for optimal performance across the speed range, often exceeding 30,000 lb-ft at the wheels.
Fuel System
Fuel Type:
Diesel fuel (ULSD or equivalent).
Injection System:
Common rail fuel injection (likely with electronic control for QSK60).
🔧 Transmission
Standard
Type:
AC Electric Drive system. Consists of a diesel engine coupled to a generator, which powers AC traction motors in the rear wheels. This is a 'diesel-electric' or 'hybrid' powertrain.
Optional
Optional Configurations:
While electric drive is standard for this class, specific generator/motor manufacturers and control systems may vary by option or update.
Features
Traction Control:
Integrated traction control managed by the electronic control system for optimal grip.
Retarder System:
Dynamic braking (regenerative) via the electric drive motors, often supplemented by a mechanical retarder.
📐 Dimensions
Exterior
Overall Length:
Approximately 14.5 - 15.0 meters (47.6 - 49.2 ft)
Overall Width:
Approximately 9.7 - 10.0 meters (31.8 - 32.8 ft)
Overall Height:
Approximately 6.3 - 6.5 meters (20.7 - 21.3 ft)
Cargo
Rated Payload Capacity:
Typically 300 US tons (272 metric tons).
Body Volume Heaped:
Approximately 155-170 cubic meters (203-222 cubic yards).
Weights
Operating Weight:
Around 200-220 metric tons (440,000 - 485,000 lbs).
Gross Vehicle Weight Rating Gvwr:
Around 480-500 metric tons (1,058,000 - 1,102,000 lbs).
Wheelbase
Wheelbase:
Approximately 5.5 - 6.0 meters (18.0 - 19.7 ft).
Tire Size
Tire Size:
Typically 53/80 R63 or similar large-diameter, wide-profile mining tires.
🛡️ Safety Features
Ratings
Safety Standards Compliance:
Designed to meet stringent mining industry safety regulations and standards.
Active Features
Braking System:
Wet multiple-disc brakes, dynamic braking (regenerative), and auxiliary retarder. Often features advanced anti-lock braking systems (ABS).
Steering System:
Hydraulically actuated power steering, often with steering assist and diagnostic capabilities.
Passive Features
Cab Design:
ROPS (Roll-Over Protective Structure) certified cab, designed for operator protection and visibility. Features include advanced HVAC, ergonomic controls, and safety glass.
Visibility Enhancements:
Large windows, integrated lighting systems, and potentially optional camera systems for enhanced situational awareness.
💡 Technology Features
Infotainment
Cab Interface:
Features an advanced operator interface with digital displays for machine monitoring, diagnostics, and control. Not typically 'infotainment' in a passenger car sense, but rather operational data and controls.
Driver Assistance
Vehicle Management System:
Komatsu's Vehicle Management System (VMS) provides real-time data on engine performance, payload, fuel consumption, system diagnostics, and operator alerts.
Propulsion Control:
Sophisticated AC traction control system managing power distribution to the wheels for optimal traction and efficiency.
Connectivity
Telematics And Monitoring:
Often equipped with telematics systems (e.g., Komatsu KOMTRAX) for remote monitoring of machine health, location, and operational data, enabling proactive maintenance.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to specific engine manual, but typically 250-500 hours for heavy-duty mining applications, depending on operating conditions and oil analysis.
Hydraulic Fluid Change:
Typically 1000-2000 hours, with regular fluid analysis to determine optimal intervals.
Transmission Fluid Change:
For electric drive systems, fluid changes are typically related to gearboxes and differentials, following manufacturer recommendations, often in the 2000-4000 hour range.
Fluid Specifications
Engine Oil Type:
API CK-4 or equivalent heavy-duty diesel engine oil, viscosity grade typically SAE 15W-40 or 10W-30 depending on ambient temperature (refer to manual for precise spec).
Hydraulic Fluid Type:
ISO VG 32 or VG 46 anti-wear hydraulic fluid, or Komatsu's specified fluid (e.g., Komatsu genuine hydraulic oil).
Coolant Type:
Heavy-duty coolant with a 50/50 mix of ethylene glycol and de-ionized water, with appropriate SCA (Supplemental Coolant Additives) or pre-charged coolant.
Gear Oil Type:
EP (Extreme Pressure) gear lubricant, viscosity grade SAE 80W-90 or 85W-140 for differentials and wheel drives, specified by Komatsu.
Known Issues
Common Wear Items:
Brake components, suspension bushings, hydraulic hoses and seals, engine wear parts, electrical connectors in dusty environments.
Electric Drive System Considerations:
Potential for wheel motor failures, generator issues, or traction control system glitches, requiring specialized diagnostics.
Filter Part Numbers
Engine Oil Filter:
Part numbers vary by engine manufacturer (e.g., Cummins filter numbers like LF9009 or equivalent).
Hydraulic Filter:
Specific Komatsu part numbers for hydraulic system filters (e.g., Komatsu P/N 206-49-21530 or equivalent).
📚 Vehicle History
Brand Heritage
Komatsu Mining Division:
Komatsu is a global leader in construction and mining equipment, with a long history of innovation and heavy-duty product development.
Model Evolution
930E Series Development:
The 930E series represents Komatsu's commitment to large-capacity haul trucks, evolving from earlier models to incorporate advanced technologies like AC electric drive systems for improved performance and efficiency.
Production
Manufacturing Location:
Primary manufacturing is in the United States (e.g., Peoria, Illinois) for Komatsu's mining truck division.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
Komatsu heavy equipment is consistently recognized for reliability, innovation, and performance in the mining sector. Specific awards for the 930E-2 model are not typically publicized as consumer awards but rather as sector-specific achievements.
Ratings
Performance Benchmarks:
The 930E-2 is a benchmark performer in its class for productivity, fuel efficiency (relative to payload), and operational uptime in demanding mining environments.
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