Komatsu Hydraulic Excavator PC95R Repair Service Manual
Komatsu Hydraulic Excavator PC95R Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC95R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC95R 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: 1,465 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...3
REVISED PAGES...5
SAFETY...7
FOREWORD...9
HOW TO READ THE SHOP MANUAL...10
HOISTING INSTRUCTIONS...11
STANDARD TIGHTENING TORQUE...12
COATING MATERIALS...14
ELECTRIC WIRE CODE...15
WEIGHT TABLE...16
TABLE OF OIL AND COOLANT QUANTITIES...17
CONVERSION TABLE...19
10.STRUCTURE AND FUNCTION...27
P.T.O...28
POWER TRAIN...29
TRACK FRAME...31
IDLER AND RECOIL SPRING...32
CARRIER ROLLER - TRACK ROLLER...33
TRACK SHOE...34
SWING CIRCLE...35
SWING MACHINERY...36
FINAL DRIVE...37
HYDRAULIC DIAGRAM STANDARD...39
HYDRAULIC DIAGRAM WITH 2-PIECE BOOM...41
HYDRAULIC PUMP...42
9-SPOOL CONTROL VALVE (STANDARD)...68
10-SPOOL CONTROL VALVE (STANDARD 2-PIECE BOOM)...70
CONTROL VALVE...72
BLADE VALVE...77
L.H. AND R.H. TRAVEL VALVE BOOM VALVE...78
ARM VALVE BUCKET VALVE...79
BOOM SWING VALVE (2-PIECE BOOM VALVE) ATTACHMENT VALVE...80
CONTROL VALVE...81
SWING MOTOR...98
SWIVEL JOINT...104
TRAVEL MOTOR...106
CYLINDERS...108
2-PIECE BOOM...109
SERVOCONTROL FEED UNIT...110
ACCUMULATOR...115
SHUTTLE VALVE...116
PPC VALVE...117
BOOM AND ARM SAFETY VALVE...127
BLADE SAFETY VALVE...128
2-PIECE BOOM SAFETY VALVE...129
OVERLOAD SENSOR SWITCH...130
SOLENOID VALVES...131
AIR-CONDITIONING UNIT...133
ELECTRICAL DIAGRAM (1/5)...135
ELECTRICAL DIAGRAM (2/5)...137
ELECTRICAL DIAGRAM (3/5)...139
ELECTRICAL DIAGRAM (4/5)...141
ELECTRICAL DIAGRAM (5/5)...143
20.TESTING AND ADJUSTMENTS...145
NORMAL OR STANDARD TECHNICAL DATA...146
SPECIAL TOOLS...160
MEASURING THE ENGINE SPEED...161
ADJUSTING VALVE CLEARANCE...162
MEASURING COMPRESSION PRESSURE...163
TESTING AND ADJUSTING FUEL INJECTION TIMING...164
TESTING AND ADJUSTING FAN BELT TENSION...166
CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT...167
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER...168
ADJUSTING THE SAFETY MICROSWITCH...169
MEASURING THE SWING CIRCLE AXIAL CLEARANCE...170
TESTING AND ADJUSTING TRACK-SHOE TENSION...171
AIR BLEEDING FROM HYDRAULIC CIRCUITS...172
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS...174
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS...175
TESTING AND SETTING OF MAIN VALVES...176
ADJUSTING PC VALVE...178
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE...179
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL FEED UNIT...181
MEASURING PUMPS DELIVERY AND FLOW CONTROL STARTING POINT PUMP P1...182
MEASURING TRAVEL DEVIATION...183
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS...184
MEASURING INNER OIL LEAKAGE OF TRAVEL MOTOR...185
ADJUSTING BOOM AND ARM SAFETY VALVES...186
ADJUSTING 2nd BOOM SAFETY VALVES...187
MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL OVERLOAD OPERATION...188
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR...189
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT...190
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS...192
TESTING THE AIR-CONDITIONING UNIT...199
EMPTYING THE AIR-CONDITIONING UNIT...201
30.REMOVAL AND INSTALLATION...203
HOW TO READ THE MANUAL...205
PRECAUTIONS TO BE TAKEN WHEN WORKING...206
SPECIAL TOOLS...207
STARTER MOTOR...209
ALTERNATOR...210
AIR-CONDITIONING UNIT COMPRESSOR...211
INJECTION PUMP...213
INJECTION NOZZLE...217
THERMOSTAT...218
MUFFLER...219
CYLINDER HEAD...220
SEAT...224
CABIN...225
ENGINE HOOD...228
CONDENSER UNIT...229
FRONT HOOD...231
HEATING FAN UNIT...232
AIR CONIDTIONING FAN UNIT...234
RADIATOR...237
FUEL TANK...239
HYDRAULIC OIL TANK...241
ENGINE-PUMP GROUP...243
PUMP GROUP...246
ENGINE-PUMP COUPLING JOINT...247
GEAR-PUMP...248
SWIVEL JOINT...249
SWING MOTOR...250
SWING MACHINERY...251
CONTROL VALVE...267
REVOLVING FRAME...268
COUNTERWEIGHT...270
SWING CIRCLE...271
TRACK SHOES...272
SPROCKET ASSEMBLY...273
FINAL DRIVE...274
IDLER AND RECOIL SPRING ASSEMBLY...287
IDLER...288
RECOIL SPRING GROUP AND CYLINDER...289
TRACK ROLLER...290
CARRIER ROLLER...291
R.H. PPC VALVE (BOOM-BUCKET)...292
L.H. PPC VALVE (ARM-SWING)...294
BLADE PPC VALVE...296
TRAVEL PEDAL CONTROL...297
BOOM SWING PEDAL CONTROL...298
1st BOOM PEDAL CONTROL...299
BOOM CYLINDER (For 1-piece boom)...300
BOOM CYLINDER (For 2-piece boom)...301
2nd BOOM CYLINDERS...303
ARM CYLINDER...305
BUCKET CYLINDER...306
BOOM SWING CYLINDER...307
BLADE CYLINDER...308
WORK EQUIPMENT CYLINDERS...309
WORK EQUIPMENT (For 1-piece boom)...314
WORK EQUIPMENT (For 2-piece boom)...315
BUCKET...317
ARM...318
2nd BOOM...321
BOOM (For 1-piece boom)...323
BOOM (For 2-piece boom)...324
SWING SUPPORT...326
BLADE...327
40.STANDARD MAINTENANCE...329
P.T.O...330
SWING CIRCLE...331
TRACK FRAME...332
IDLER...333
CARRIER ROLLER...334
TRACK ROLLER...335
TRACK SHOE...336
SPROCKET...337
SWING MACHINERY...338
FINAL DRIVE...340
HYDRAULIC PUMP...341
CONTROL VALVE...342
SWING MOTOR...351
SWIVEL JOINT...352
TRAVEL MOTOR...353
SERVOCONTROL FEED UNIT...355
PPC VALVES...356
SAFETY VALVE...358
CYLINDERS...360
WORK EQUIPMENT...362
MAIN MENU...0
COVER...1
1.1 FORWORD...4
1.2 INFORMATION ON SAFETY...5
1.3 INTRODUCTION...7
1.3.1 INTENDED USES...7
1.3.2 IMPROPER OR UNAUTHORIZED USE...7
1.3.3 MAIN CHARACTERISTICS...8
1.3.4 RUNNING-IN...8
1.4 PRODUCT IDENTIFICATION...9
1.4.1 MACHINE SERIAL NUMBER...9
1.4.2 MACHINE IDENTIFICATION PLATE...9
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL...10
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...10
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...11
1.4.6 CAB SERIAL NUMBER...11
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS...12
CONTENTS...13
SAFETY AND ACCIDENT PREVENTION...20
2.1 SAFETY PLATES...21
2.1.1 POSITION OF THE SAFETY PLATES...21
2.1.2 POSITION OF THE PICTOGRAMS...37
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS...38
2.1.4 VIBRATIONS TO WHICH THE OPERTOR IS SUBJECTED...40
2.2 GENERAL PRECAUTIONS...41
2.2.1 GENERAL SAFETY RULES...41
2.2.2 SAFETY DEVICES AND GUARDS...41
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...41
2.2.4 UNATHORIZED MODIFICATIONS...42
2.2.5 LEAVING THE OPERATOR'S SEAT...42
2.2.6 GETTING ON AND OFF THE MACHINE...43
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...43
2.2.8 PREVENTING BURNS...44
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...44
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...45
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...45
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE...45
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...45
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...46
2.3.1 SAFETY ON THE WORK SITE...46
2.3.2 FIRE PREVENTION...46
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...46
2.3.4 ROOM VENTILATION...47
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...47
2.3.6 CLEANING THE WINDOWS AND THE REAR VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES...47
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...48
2.4.1 STARTING THE ENGINE...48
2.4.2 CHECK THE DIRECTIONS BEFORE STARTING THE MACHINE...48
2.4.3 CHECKS FOR TRAVELING IN REVERSE...48
2.4.4 MOVING THE MACHINE...49
2.4.5 MOVING ON SLOPES...50
2.4.6 WORKING ON SLOPES...51
2.4.7 UNAUTHORIZED OPERATIONS...51
2.4.8 PREVENTING ELECTROCUTION...52
2.4.9 VISIBILITY...53
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES...53
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...53
2.4.12 WORKING ON LOOSE GROUND...53
2.4.13 PARKING THE MACHINE...54
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...55
2.5.1 LOADING AND UNLOADING THE MACHINE...55
2.5.2 SHIPPING...55
2.6 BATTERY...56
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES...56
2.6.2 STARTING WITH BOOSTER CABLES...56
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...57
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...58
2.8.1 WARNING PLATES...58
2.8.2 TOOLS...58
2.8.3 PERSONNEL...59
2.8.4 EQUIPMENT...59
2.8.5 WORKING UNDER THE MACHINE...59
2.8.6 KEEPING THE MACHINE CLEAN...59
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...60
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...60
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...60
2.8.10 RULES FOR REFUELLING AND ADDING OIL...61
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...61
2.8.12 USING LAMPS...61
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...62
2.8.14 PRECAUTIONS CONCERNING THE STARTER...62
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES...63
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS...63
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...63
2.8.18 COOLING FAN AND FAN BELT...64
2.8.19 WASTE MATERIALS...64
DESCRIPTION AND USE OF THE MACHINE...66
3.1 SAFETY LOCKS...67
3.1.1 MACHINE LOCKS...67
3.2 GENERAL VIEWS...68
3.2.1 FRONT GENERAL VIEW (MONOBOOM)...68
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)...69
3.2.3 CAB INSIDE GENERAL VIEW...70
3.3 INSTRUMENTS AND CONTROLS...72
3.3.1 INSTRUMENTS, WARNING LIGHTS AND PUSH BUTTONS...72
3.3.2 MACHINE CONTROLS...81
3.4 FUSES AND RELAYS...92
3.4.1 CENTRAL UNIT FUSES AND RELAYS...92
3.4.1.1 CENTRAL UNIT FUSES...93
3.4.1.2 CENTRAL UNIT RELAYS...94
3.4.2 ENGINE LINE FUSES AND RELAYS...95
3.4.2.1 ENGINE LINE FUSES...95
3.4.2.2 ENGINE LINE RELAYS...96
3.5 GUARDS AND DRIVER'S SEAT...97
3.5.1 ENGINE HOOD...97
3.5.2 SIDE COVER...97
3.5.3 CAB...98
3.5.4 VENTILATION AND HEATING...102
3.5.5 SEAT...103
3.5.6 SAFETY BELT...104
3.5.7 EMERGENCY EXIT...104
3.5.8 TECHNICAL DOCUMENTATION CASE...105
3.5.9 FIRE EXTINGUISHER...105
3.5.10 FIRST AID KIT...105
3.6 USE OF THE MACHINE...106
3.6.1 CHECKS BEFORE STARTING THE ENGINE...106
3.6.1.1 VISUAL CHECKS...106
3.6.1.2 DAILY CHECKS...106
3.6.1.3 OPERATIONAL CHECKS...107
3.6.2 STARTING THE ENGINE...108
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...108
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...109
3.6.3 WARMING THE ENGINE...110
3.6.4 HEATING THE HYDRAULIC OIL...110
3.6.5 HOW TO MOVE THE MACHINE...110
