Komatsu Hydraulic Excavator PC95 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC95, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC95 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 810 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
MAIN MENU...0
COVER PAGE...1
CONTENTS...3
10 STRUCTURE AND FUNCTION...16
P.T.O...17
POWER TRAIN...18
FINAL DRIVE - SPROCKET...19
TRACK FRAME...20
IDLER AND RECOIL SPRING...21
CARRIER ROLLER...22
TRACK ROLLER...22
TRACK SHOE...23
SWING CIRCLE...24
SWING MACHINERY...25
CHECK VALVE AND OIL COOLER SAFETY BY-PASS...26
HYDRAULIC CIRCUIT DIAGRAM...27
MAIN HYDRAULIC PUMP...28
PUMP DRIVE...29
SUMMATION HORSEPOWER CONTROL...30
3 CIRCUIT CONTROL VALVE...33
MODE-SYSTEM...35
AUXILIARY PUMP...36
CONTROL VALVE (Ports)...37
CONTROL VALVE (Valve)...39
SWING MOTOR...40
SWING MOTOR RELIEF VALVE...41
CENTER SWIVEL JOINT...42
TRAVEL MOTOR...43
TRAVEL ACCELERATION VALVE...44
SERVOCONTROL FEED UNIT...45
SWING MOTOR BRAKING CIRCUIT SELECTOR VALVE...47
ACCUMULATOR...48
R.H. PPC VALVE...49
L.H. PPC VALVE...50
TRAVEL PPC VALVE...51
2nd BOOM PPC VALVE...52
BOOM SWING PPC VALVE...53
BLADE PPC VALVE...54
BLADE SAFETY VALVE...55
SOLENOID VALVES...56
ELECTRICAL CIRCUIT DIAGRAM (Engine Line)...58
ELECTRICAL CIRCUIT DIAGRAM (Solenoid Valve)...60
ELECTRICAL CIRCUIT DIAGRAM (Light Line)...62
20 TESTING AND ADJUSTMENTS...64
NORMAL OR STANDARD TECHNICAL DATA...65
EQUIPMENT FOR TESTING, ADJUSTING, AND IDENTIFYING FAULTS...82
MEASURING THE ENGINE SPEED...84
VALVE CLEARANCE ADJUSTMENT...85
MEASUREMENT OF COMPRESSION PRESSURE...86
CHECKING AND TIGHTENING THE FAN-BELT...87
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER...88
ADJUSTING PPC VALVES CLEARANCE...89
ADJUSTING THE SAFETY MICROSWITCH...91
CENTRING THE STROKE OF THE BLADE CONTROL LEVER...91
MEASURING THE SWING CIRCLE AXIAL CLEARANCE...92
TESTING AND ADJUSTING TRACK-SHOE TENSION...93
BLEEDING AIR - RELEASING RESIDUAL PRESSURE...94
Bleeding air from pumps P1 and P2...94
Bleeding air from the PPC valves circuit...94
Bleeding air from the cylinders...95
Releasing residual pressure from the circuits...95
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS...96
CHECKING THE INTERVENTION POINT OF THE SUMMATION HORSEPOWER CONTROL...102
CHECKING THE INITIAL HORSEPOWER CONTROL POINT FOR THE 3-CIRCUIT CONTROL VALVE...103
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL SUPPLY UNITS...104
ADJUSTING THE MAIN SAFETY VALVE OF PUMP P4...105
MEASURING PUMP DELIVERY...106
MEASURING TRAVEL DEVIATION...107
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS...108
CHECKING THE CORRECT FUNCTIONING OF THE TRAVEL ACCELERATION VALVE...110
TESTING FOR INTERNAL OIL LEAKAGE IN THE TRAVEL MOTORS...111
ADJUSTING BOOM AND ARM SAFETY VALVES...112
ADJUSTING 2nd BOOM SAFETY VALVES...113
MEASURING THE INITIAL INTERVENTION POINT OF THE OVERLOAD SENSOR...114
ADJUSTING THE VALVE THAT CONTROLS THE CLOSING SPEED OF THE 2nd BOOM...115
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR...116
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT...117
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS...119
1. Boom test...119
2. Arm test...119
3. Testing the functionality of the boom and arm safety valve...120
4. 2nd boom test...121
5. Testing the functionality of the 2nd boom safety valves...122
6. Bucket test...122
7. Boom swing test...123
8. Blade test...123
9. Swing motor test...124
10. Testing the travel motors...125
TROUBLESHOOTING...128
PROCEDURES TO FOLLOW WHILE TROUBLESHOOTING...129
RULES TO BE OBSERVED WHEN WORKING ON HYDRAULIC CIRCUITS OR EQUIPMENT...130
TABLE OF FAILURE MODES AND CAUSES TESTS TO BE CARRIED OUT BEFORE TROUBLESHOOTING...132
EXCESSIVE TRAVEL DEVIATION...133
THE MACHINE DEVIATES EXCESSIVELY AT THE COMMENCEMENT OF TRAVEL...137
WORK EQUIPMENT, REVOLVING FRAME SWING AND TRAVEL ARE SLOW OR WITHOUT POWER...138
WORK EQUIPMENT, REVOLVING FRAME SWING AND TRAVEL MECHANISMS FUNCTION INTERMITTENTLY...139
THE REVOLVING FRAME SWING SPEED IS SLOW IN BOTH DIRECTIONS...140
THE REVOLVING FRAME SWING SPEED IS SLOW IN ONE DIRECTION, AND DOES NOT BRAKE PROPERLY ON THAT SIDE...141
DIFFICULTIES WITH RAISING OR LOWERING THE BOOM...142
EXCESSIVE RESPONSE TIME FOR THE BOOM, ARM AND BUCKET...143
BOOM SLOW TO RISE - ARM SLOW TO CLOSE...145
THE SERVOCONTROL SUPPLY GROUP DOES NOT FUNCTION OR THE PRESSURE IS UNSTABLE ...146
THE CONTROL LEVERS MOVE, BUT EQUIPMENT MOVEMENTS ARE INCOMPLETE OR HAVE NO EFFECT...147
SPEEDS DO NOT CHANGE IF THE WORKING MODE SELECTOR IS POSITIONED ON E...149
ABNORMAL NOISES IN THE PUMPS...149
ENGINE LOSES POWER OR STALLS DURING WORK...150
30 DISASSEMBLY AND ASSEMBLY...151
HOW TO READ THE MANUAL...153
PRECAUTIONS TO BE TAKEN WHEN WORKING...154
SPECIAL TOOLS...155
STARTER MOTOR...157
REMOVAL AND INSTALLATION...157
ALTERNATOR...158
REMOVAL AND INSTALLATION...158
NOZZLE HOLDER...159
REMOVAL AND INSTALLATION...159
AIR FILTER GROUP...160
REMOVAL AND INSTALLATION...160
MUFFLER...161
REMOVAL...161
INSTALLATION...162
ENGINE HOOD...163
REMOVAL AND INSTALLATION...163
FIXED HOOD...164
REMOVAL...164
INSTALLATION...165
SEAT...166
REMOVAL AND INSTALLATION...166
CABIN...167
REMOVAL AND INSTALLATION...167
COUNTERWEIGHT...168
REMOVAL AND INSTALLATION...168
RADIATOR...169
REMOVAL AND INSTALLATION...169
HYDRAULIC OIL COOLER...170
REMOVAL AND INSTALLATION...170
HEATING FAN...171
REMOVAL...171
INSTALLATION...172
FUEL TANK...173
REMOVAL AND INSTALLATION...173
HYDRAULIC OIL TANK...174
REMOVAL AND INSTALLATION...174
ENGINE-PUMP GROUP...175
REMOVAL...175
INSTALLATION...177
PUMP GROUP...178
REMOVAL AND INSTALLATION...178
HYDRAULIC PUMP...179
DISASSEMBLY...179
ASSEMBLY...186
GEAR-PUMP...192
REMOVAL AND INSTALLATION...192
DISASSEMBLY...193
ASSEMBLY...196
ENGINE-PUMP COUPLING JOINT...201
REMOVAL AND INSTALLATION...201
SWIVEL JOINT...202
REMOVAL AND INSTALLATION...202
SWING MOTOR...203
REMOVAL AND INSTALLATION...203
SWING MACHINERY...204
REMOVAL AND INSTALLATION...204
DISASSEMBLY...205
ASSEMBLY...213
REVOLVING FRAME...224
REMOVAL...224
INSTALLATION...225
SWING CIRCLE...226
REMOVAL AND INSTALLATION...226
TRAVEL MOTOR...227
REMOVAL AND INSTALLATION...227
TRACK SHOES...228
REMOVAL AND INSTALLATION...228
SPROCKET...229
REMOVAL AND INSTALLATION...229
FINAL DRIVE...230
REMOVAL AND INSTALLATION...230
DISASSEMBLY...231
ASSEMBLY...237
IDLER AND RECOIL SPRING...247
REMOVAL AND INSTALLATION...247
IDLER...248
DISASSEMBLY AND ASSEMBLY...248
RECOIL SPRING AND CYLINDER...249
DISASSEMBLY AND ASSEMBLY...249
TRACK ROLLER...250
REMOVAL AND INSTALLATION...250
CARRIER ROLLER...251
REMOVAL AND INSTALLATION...251
R.H. PPC VALVE (BOOM - BUCKET)...252
REMOVAL AND INSTALLATION...252
L.H. PPC VALVE (ARM-SWING)...253
REMOVAL AND INSTALLATION...253
BLADE PPC VALVE...254
REMOVAL AND INSTALLATION...254
PPC VALVE (For travel, boom swing, 2-piece boom)...255
REMOVAL AND INSTALLATION...255
SERVOCONTROL FEED UNIT...256
REMOVAL AND INSTALLATION...256
CONTROL VALVE...257
REMOVAL AND INSTALLATION...257
BOOM CYLINDER...258
REMOVAL AND INSTALLATION...258
BOOM CYLINDER (For 2-piece boom)...259
REMOVAL...259
INSTALLATION...260
2-PIECE BOOM CYLINDER...261
REMOVAL...261
INSTALLATION...262
ARM CYLINDER...263
REMOVAL AND INSTALLATION...263
BUCKET CYLINDER...264
REMOVAL AND INSTALLATION...264
BOOM SWING CYLINDER...265
REMOVAL AND INSTALLATION...265
BLADE CYLINDER...266
REMOVAL AND INSTALLATION...266
WORK EQUIPMENT CYLINDERS...267
DISASSEMBLY...267
ASSEMBLY...268
OVERLOAD SENSOR...272
REMOVAL AND INSTALLATION...272
WORK EQUIPMENT (For the boom)...273
REMOVAL AND INSTALLATION...273
WORK EQUIPMENT (2-piece boom version)...274
REMOVAL...274
INSTALLATION...275
BUCKET...276
REMOVAL AND INSTALLATION...276
ARM...277
REMOVAL...277
INSTALLATION...279
2-PIECE BOOM...280
REMOVAL...280
INSTALLATION...281
BOOM...282
REMOVAL AND INSTALLATION...282
BOOM (2-piece boom version)...283
REMOVAL...283
INSTALLATION...284
SWING BRACKET...285
REMOVAL AND INSTALLATION...285
BLADE...286
REMOVAL AND INSTALLATION...286
40 MAINTENANCE STANDARD...287
P.T.O...288
TRAVEL MACHINERY...289
SPROCKET...290
TRACK FRAME AND RECOIL SPRING...291
IDLER...292
CARRIER ROLLER...293
TRACK ROLLER...294
TRACK SHOE...295
SWING CIRCLE...296
SWING MACHINERY...297
CHECK VALVE AND OIL COOLER SAFETY BY-PASS...298
PUMP DRIVE...299
SUMMATION HORSEPOWER CONTROL - MODE SYSTEM...300
AUXILIARY PUMP...301
CONTROL VALVE...302
SWING MOTOR RELIEF VALVE...303
TRAVEL MOTOR...304
SERVOCONTROL FEED UNIT...305
L.H. AND R.H. PPC VALVE...306
2nd BOOM, R.H. TRAVEL, L.H. TRAVEL AND BOOM SWING PPC VALVE...307
BLADE PPC VALVE...308
BLADE SAFETY VALVE...309
CYLINDERS...310
WORK EQUIPMENT (1 - piece boom)...312
WORK EQUIPMENT (2 - piece boom)...314
MAIN MENU...0
CONTENTS ...14
FOREWORD...2
SAFETY INFORMATION ...4
INTRODUCTION ...6
PERMITTED USES ...6
MAIN FEATURES ...6
RUNNING IN THE MACHINE ...6
SUMMARY OF PICTOGRAMS ...8
LOCATION OF MACHINE COMPONENT IDENTIFICATION PLATES ...11
SERIAL NUMBERS AND ADDRESS OF DEALER ...12
POSITION AND CONTENTS OF <<CE>> PLATE ...13
SAFETY AND ACCIDENT PREVENTION...21
1. SAFETY MEASURES ...22
1.1 GENERAL PRECAUTIONS ...22
1.2 SAFETY DEVICES ...22
1.3 PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT ...22
1.4 UNAUTHORISED MODIFICATIONS ...23
1.5 LEAVING THE DRIVING SEAT ...23
1.6 ENTERING AND LEAVING THE MACHINE ...24
1.7 PREVENTION OF FUEL AND OIL FIRES ...24
1.8 PREVENTION OF BURNS AND SCALDING ...25
1.9 PREVENTION OF ASBESTOS DUST CONTAMINATION ...26
1.10 PREVENTION OF INJURY BY WORK EQUIPMENT ...26
