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Komatsu 930E-4 DUMP Truck Service Shop Repair Manual (S/N: A30693 and UP)

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🏷️ Basic Information Identification Make: Komatsu Model: 930E-4 Product Type: Service Shop Repair Manual Applicable Serial Numbers: A30693 and UP Generation Model Generation: Fourth Generation (930E-4) Codes Vehicle Code: 930E-4 👋 Introduction Market Position Vehicle Class: Heavy Duty Mining Truck Industry Segment: Large Capacity Off-Highway Haulage Target Application: Large-scale mining operations, quarrying, heavy construction Competitive Analysis Primary Competitors: Caterpillar 797 Series, Hitachi EH Series, Liebherr T Series Key Features Payload Capacity: 230-250 US Ton (approximately) Engine Type: Tiered, high-horsepower diesel Transmission Type: AC Electric Drive System Propulsion System: Electric motors driving rear wheels Fuel Efficiency: Optimized for large payload and long haul cycles Operator Comfort: Advanced cabin design and suspension 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Maintenance: Included Assembly: Included Disassembly: Included Servicing: Included Page Count Estimated Page Count: Varies (typically 1000+ pages for this class of equipment) Manual Type Type: Service Shop Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul procedures Powertrain: Transmission, drive axles, differentials, hydraulic systems Braking System: Service, adjustment, component replacement Electrical System: Wiring diagrams, component testing, troubleshooting Hydraulic System: Pump, valve, cylinder repair and testing, fluid specifications Suspension System: Component identification, service procedures Steering System: Components, troubleshooting, adjustments Body And Chassis: Frame, dump body, cab, lubrication points Cooling System: Radiator, fan, coolant specifications and service Fuel System: Tank, lines, filters, engine fueling Air Intake And Exhaust: Filters, turbocharger, mufflers Operator Station: Controls, instrumentation, cab components Procedures Included Routine Maintenance: Greasing, fluid checks, filter replacement Troubleshooting: Diagnostic flowcharts, symptom-based guides Component Replacement: Detailed step-by-step instructions for all major components Overhaul Procedures: Engine, transmission, hydraulic cylinder rebuilds Calibration: Sensors, control modules Adjustment Procedures: Brakes, clutch, steering linkages Diagnostic Testing: Electrical system diagnostics, hydraulic pressure tests Installation Procedures: Major component installations Technical Depth Depth: Deep, comprehensive Diagnostic Capability: Advanced diagnostics, fault code interpretation Rebuild Detail: Complete engine, transmission, and hydraulic system rebuilds Schematics: Detailed electrical and hydraulic schematics Torque Specifications: All critical fastener torque values Clearances: Component and bearing clearances Special Tools: Identification and usage of specialized tools 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content Viewing Requirements: Adobe Acrobat Reader or compatible PDF viewer Print Quality Printability: Printable for hard copy reference Binding Type Binding Type Physical: N/A (Digital Format) Paper Type Paper Type Physical: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Manufacturer: Cummins Engine Model: QSK60 Engine Configuration: V16, Turbocharged, Aftercooled Displacement: 1483 cu in (24.3 Liters) Performance Gross Horsepower Rating: Approximately 2300-2400 HP (May vary by specific configuration) Peak Torque: High torque output for heavy hauling Fuel System Fuel Type: Diesel Injection System: High-pressure common rail (Cummins先進システム) Fuel Filter Part Numbers: Refer to specific engine service manual or manual sections Cooling System Cooling System Capacity: Large capacity, multi-circuit Emission Controls Emission Standards: Compliant with relevant emissions regulations for heavy-duty off-road equipment 🔧 Transmission Standard Type: AC Electric Drive (Proprietary Komatsu System) Optional Options Available: N/A (Electric drive is standard for this model) Features Drive Motors: High-torque AC electric motors driving rear wheels Power Generation: Engine directly coupled to generator Regenerative Braking: Integrated into electric drive system Control System: Advanced electronic control module for power distribution and traction Fluid Specifications Electric Drive Fluid: Specialized synthetic lubricant for drive motors and gearboxes (refer to manual for specific type and part number) 📐 Dimensions Exterior Length: Approx. 28-30 ft (8.5-9.1 m) Width: Approx. 22-24 ft (6.7-7.3 m) Height: Approx. 15-17 ft (4.6-5.2 m) Wheelbase: Approx. 15-17 ft (4.6-5.2 m) Ground Clearance: Variable based on suspension settings and load Cargo Body Capacity Struck: Approx. 210 cu yd (160 cu m) Body Capacity Heaped: Approx. 268 cu yd (205 cu m) Weights Operating Weight: Approx. 300,000 - 350,000 lbs (136,000 - 159,000 kg) Payload Capacity: 230-250 US Tons (209-227 Metric Tons) Gvwr: Approx. 580,000 - 620,000 lbs (263,000 - 281,000 kg) 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) standard in cab Fire Suppression: Optional fire suppression systems available Active Features Automatic Braking: Integrated into electric drive system for controlled stops Traction Control: Advanced traction control managed by electric drive system Speed Governor: Electronically controlled speed limitation Passive Features Cab Structure: Reinforced operator cab for protection Seatbelts: Heavy-duty operator seatbelts Visibility: Large windows, optional work lights, rearview cameras 💡 Technology Features Infotainment Operator Interface: Advanced digital display for system monitoring, diagnostics, and machine parameters. Driver Assistance Payload Monitoring: Integrated payload monitoring system for optimizing loads. Gradeability Control: Electronically managed to optimize hauling on inclines. Connectivity Telematics: Komatsu KOMTRAX or similar telematics system for remote monitoring, fleet management, and predictive maintenance. Propulsion Technology Electric Drive Benefits: Improved fuel efficiency, reduced emissions, enhanced torque, and simpler powertrain compared to traditional mechanical transmissions. 🔧 Maintenance Service Intervals Engine Oil Change: Based on operating hours, typically 250-500 hours; consult manual for exact intervals...
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Komatsu 930E-4 DUMP Truck Service Shop Repair Manual (S/N: A30693 and UP)
🏷️ Basic Information
Identification
Make:
Komatsu
Model:
930E-4
Product Type:
Service Shop Repair Manual
Applicable Serial Numbers:
A30693 and UP
Generation
Model Generation:
Fourth Generation (930E-4)
Codes
Vehicle Code:
930E-4
👋 Introduction
Market Position
Vehicle Class:
Heavy Duty Mining Truck
Industry Segment:
Large Capacity Off-Highway Haulage
Target Application:
Large-scale mining operations, quarrying, heavy construction
Competitive Analysis
Primary Competitors:
Caterpillar 797 Series, Hitachi EH Series, Liebherr T Series
Key Features
Payload Capacity:
230-250 US Ton (approximately)
Engine Type:
Tiered, high-horsepower diesel
Transmission Type:
AC Electric Drive System
Propulsion System:
Electric motors driving rear wheels
Fuel Efficiency:
Optimized for large payload and long haul cycles
Operator Comfort:
Advanced cabin design and suspension
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Yes
Maintenance:
Included
Assembly:
Included
Disassembly:
Included
Servicing:
Included
Page Count
Estimated Page Count:
Varies (typically 1000+ pages for this class of equipment)
Manual Type
Type:
Service Shop Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul procedures
Powertrain:
Transmission, drive axles, differentials, hydraulic systems
Braking System:
Service, adjustment, component replacement
Electrical System:
Wiring diagrams, component testing, troubleshooting
Hydraulic System:
Pump, valve, cylinder repair and testing, fluid specifications
Suspension System:
Component identification, service procedures
Steering System:
Components, troubleshooting, adjustments
Body And Chassis:
Frame, dump body, cab, lubrication points
Cooling System:
Radiator, fan, coolant specifications and service
Fuel System:
Tank, lines, filters, engine fueling
Air Intake And Exhaust:
Filters, turbocharger, mufflers
Operator Station:
Controls, instrumentation, cab components
Procedures Included
Routine Maintenance:
Greasing, fluid checks, filter replacement
Troubleshooting:
Diagnostic flowcharts, symptom-based guides
Component Replacement:
Detailed step-by-step instructions for all major components
Overhaul Procedures:
Engine, transmission, hydraulic cylinder rebuilds
Calibration:
Sensors, control modules
Adjustment Procedures:
Brakes, clutch, steering linkages
Diagnostic Testing:
Electrical system diagnostics, hydraulic pressure tests
Installation Procedures:
Major component installations
Technical Depth
Depth:
Deep, comprehensive
Diagnostic Capability:
Advanced diagnostics, fault code interpretation
Rebuild Detail:
Complete engine, transmission, and hydraulic system rebuilds
Schematics:
Detailed electrical and hydraulic schematics
Torque Specifications:
All critical fastener torque values
Clearances:
Component and bearing clearances
Special Tools:
Identification and usage of specialized tools
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content
Viewing Requirements:
Adobe Acrobat Reader or compatible PDF viewer
Print Quality
Printability:
Printable for hard copy reference
Binding Type
Binding Type Physical:
N/A (Digital Format)
Paper Type
Paper Type Physical:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Manufacturer:
Cummins
Engine Model:
QSK60
Engine Configuration:
V16, Turbocharged, Aftercooled
Displacement:
1483 cu in (24.3 Liters)
Performance
Gross Horsepower Rating:
Approximately 2300-2400 HP (May vary by specific configuration)
Peak Torque:
High torque output for heavy hauling
Fuel System
Fuel Type:
Diesel
Injection System:
High-pressure common rail (Cummins先進システム)
Fuel Filter Part Numbers:
Refer to specific engine service manual or manual sections
Cooling System
Cooling System Capacity:
Large capacity, multi-circuit
Emission Controls
Emission Standards:
Compliant with relevant emissions regulations for heavy-duty off-road equipment
🔧 Transmission
Standard
Type:
AC Electric Drive (Proprietary Komatsu System)
Optional
Options Available:
N/A (Electric drive is standard for this model)
Features
Drive Motors:
High-torque AC electric motors driving rear wheels
Power Generation:
Engine directly coupled to generator
Regenerative Braking:
Integrated into electric drive system
Control System:
Advanced electronic control module for power distribution and traction
Fluid Specifications
Electric Drive Fluid:
Specialized synthetic lubricant for drive motors and gearboxes (refer to manual for specific type and part number)
📐 Dimensions
Exterior
Length:
Approx. 28-30 ft (8.5-9.1 m)
Width:
Approx. 22-24 ft (6.7-7.3 m)
Height:
Approx. 15-17 ft (4.6-5.2 m)
Wheelbase:
Approx. 15-17 ft (4.6-5.2 m)
Ground Clearance:
Variable based on suspension settings and load
Cargo
Body Capacity Struck:
Approx. 210 cu yd (160 cu m)
Body Capacity Heaped:
Approx. 268 cu yd (205 cu m)
Weights
Operating Weight:
Approx. 300,000 - 350,000 lbs (136,000 - 159,000 kg)
Payload Capacity:
230-250 US Tons (209-227 Metric Tons)
Gvwr:
Approx. 580,000 - 620,000 lbs (263,000 - 281,000 kg)
🛡️ Safety Features
Ratings
Rollover Protection:
ROPS (Roll-Over Protective Structure) standard in cab
Fire Suppression:
Optional fire suppression systems available
Active Features
Automatic Braking:
Integrated into electric drive system for controlled stops
Traction Control:
Advanced traction control managed by electric drive system
Speed Governor:
Electronically controlled speed limitation
Passive Features
Cab Structure:
Reinforced operator cab for protection
Seatbelts:
Heavy-duty operator seatbelts
Visibility:
Large windows, optional work lights, rearview cameras
💡 Technology Features
Infotainment
Operator Interface:
Advanced digital display for system monitoring, diagnostics, and machine parameters.
Driver Assistance
Payload Monitoring:
Integrated payload monitoring system for optimizing loads.
Gradeability Control:
Electronically managed to optimize hauling on inclines.
Connectivity
Telematics:
Komatsu KOMTRAX or similar telematics system for remote monitoring, fleet management, and predictive maintenance.
Propulsion Technology
Electric Drive Benefits:
Improved fuel efficiency, reduced emissions, enhanced torque, and simpler powertrain compared to traditional mechanical transmissions.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Based on operating hours, typically 250-500 hours; consult manual for exact intervals and oil analysis recommendations.
Hydraulic Oil Change:
Based on operating hours and oil analysis; consult manual.
Filter Replacement:
Fuel, oil, air, and hydraulic filters typically replaced at engine oil change intervals or as per manual.
Greasing Schedule:
Daily, weekly, and monthly points as specified in the manual.
Fluid Specifications
Engine Oil Grade:
Refer to manual for specific SAE viscosity grade (e.g., SAE 15W-40 API CK-4 or CJ-4 compliant).
Engine Oil Capacity:
High capacity, requires specific oil type.
Hydraulic Fluid Type:
High-performance hydraulic oil, ISO VG 46 or similar; consult manual for exact specification and brand.
Coolant Type:
Heavy-duty engine coolant (e.g., ELC - Extended Life Coolant), typically a 50/50 mix with de-ionized water.
Transmission Fluid Type:
Specialized synthetic lubricant for AC electric drive system - consult manual for exact part number and specifications.
Known Issues
Common Wear Items:
Brake components, tires, hydraulic hoses, electrical connectors due to heavy-duty operation.
Preventative Maintenance Importance:
Crucial for uptime and preventing costly failures in harsh mining environments.
Troubleshooting Tips
Diagnostic Tools Required:
Komatsu proprietary diagnostic software and hardware interfaces are often necessary.
📚 Vehicle History
Brand Heritage
Brand Focus:
Komatsu is a globally recognized manufacturer of construction and mining equipment, known for innovation and durability.
Model Evolution
Predecessor Models:
Komatsu 930E, 930E-2, 930E-3 series
Key Advancements In 4 Series:
Refinements in engine efficiency, electric drive system performance, and updated operator interface.
Production
Production Period:
Ongoing (specific start year for -4 series not explicitly stated but follows previous generations)
Manufacturing Location:
Various Komatsu facilities globally, often with specialized assembly plants for large mining equipment.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Komatsu mining equipment is consistently recognized for reliability and performance in demanding applications.
Ratings
Operational Efficiency Ratings:
Designed for high operational efficiency and low cost per ton hauled.
Certifications
Manufacturing Standards:
Manufactured to ISO 9001 and other relevant quality management standards.
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