Komatsu PC95-1 Hydraulic Excavator Operation & Maintenance Manual 5000007 and up – PDF DOWNLOAD

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Komatsu PC95-1 Hydraulic Excavator Operation & Maintenance Manual

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Komatsu PC95-1 Hydraulic Excavator Operation & Maintenance Manual

Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Operation & Maintenance Manual
Machine Model: PC95-1
Serial Number: 5000007 and up
Book Code: EEAM004900
Language: English
Pages: 147
File Format: Portable Document Format (PDF)

KOMATSU PC95-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL 5000007 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu PC95-1 Hydraulic Excavator Operation & Maintenance Manual

FOREWORD:

• This manual has been prepared by Komatsu to provide you with all the information you need to operate and maintain your machine in total safety. By complying with the  instructions contained in this manual you will get the best out of your machine and keep it operating at maximum efficiency for many years to come.
•  Make sure that this manual is always readily available to all machine operators and maintenance personnel. Make sure,that they read it carefully. Keep this manual in good condition and where it is easily accessible for rapid consultation (e.g. with the spare parts catalogue). If this manual becomes damaged or lost, request another copy from Komatsu or from your Komatsu dealer.
•  Komatsu machines are constantly being improved. Your machine may therefore differ in some points from ttie illustrations shown in this manual. Consult your Komatsu dealer for the latest information.
•  Make orderly notes immediately any work is done during maintenance checks. This is not only a demonstration of efficient servicing, but also provides a clear record of what work has been done and what still remains to be done at the next service interval. Check the hour counter and the maintenance chart regularly.
•  Your Komatsu dealer has years of experience in dealing with customers’ queries. Do not hesitate to contact your dealer if you need more information. He can help you to get the best out of your machine, and can suggest the most appropriate equipment for a job. You dealer can also provide Technical Assistance for any modifications needed to adapt your machine to comply with safety.
  Your Komatsu dealer also stocks original Komatsu spare parts – the only ones which guarantee safety and interchangeability.
•  Write your machine’s serial numbers on the form provided at the end of this section. Give these details to your dealer whenever you request Technical Assistance or spare parts.

TABLE OF CONTENTS:

Komatsu PC95-1 Hydraulic Excavator Operation & Maintenance Manual

MAIN MENU.......................................................................................  0
CONTENTS........................................................................................ 10
FOREWORD........................................................................................  3
SAFETY INFORMATION..............................................................................  4
INTRODUCTION....................................................................................  6
PERMITTED USES..................................................................................  6
MAIN FEATURES...................................................................................  6
RUNNING IN THE MACHINE..........................................................................  6
LOCATION OF MACHINE COMPONENT IDENTIFICATION PLATES.............................................  8
SERIAL NUMBERS AND ADDRESS OF DEALER............................................................  9
SAFETY AND ACCIDENT PREVENTION.................................................................. 16
	1. SAFETY MEASURES ......................................................................... 17
		1.1 GENERAL PRECAUTIONS ................................................................ 17
		1.2 SAFETY DEVICES ..................................................................... 17
		1.3 PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT ......................................... 17
		1.4 UNAUTHORISED MODIFICATIONS ......................................................... 18
		1.5 LEAVING THE DRIVING SEAT ........................................................... 18
		1.6 ENTERING AND LEAVING THE MACHINE ................................................... 19
		1.7 PREVENTION OF FUEL AND OIL FIRES ................................................... 19
		1.8 PREVENTION OF BURNS AND SCALDING ................................................... 20
		1.9 PREVENTION OF ASBESTOS DUST CONTAMINATION .......................................... 21
		1.10 PREVENTION OF INJURY BY WORK EQUIPMENT ............................................ 21
		1.11 FIRE EXTINGUISHERS AND FIRST AID KIT .............................................. 22
		1.12 PRECAUTIONS REGARDING THE CAB FRAME ............................................... 22
		1.13 PRECAUTIONS REGARDING EQUIPMENT ................................................... 22
PRECAUTIONS..................................................................................... 23
	2. PRECAUTIONS TO BE TAKEN BEFORE STARTING  THE  ENGINE .................................... 24
		2.1 ON-SITE SAFETY ..................................................................... 24
		2.2 FIRE PREVENTION .................................................................... 24
		2.3 PRECAUTIONS REGARDING THE CAB ...................................................... 25
		2.4 VENTILATION OF ENCLOSED AREAS ...................................................... 25
		2.5 CLEANING WINDOWS, MIRRORS AND HEADLIGHTS -  CHECKING  WIPER  BLADES,  LAMPS ........ 25
	3. PRECAUTIONS TO BE TAKEN WHILE WORKING ................................................... 26
		3.1 STARTING THE ENGINE ................................................................ 26
		3.2 CHECKS PRIOR TO REVERSING .......................................................... 26
		3.3 MOVING THE MACHINE ................................................................. 27
		3.4 WORKING ON SLOPES .................................................................. 28
		3.5 PREVENTION OF ELECTROCUTION ........................................................ 29
		3.6 VISIBILITY ......................................................................... 30
		3.7 WORKING ON FROZEN OR SNOW-COVERED  GROUND .......................................... 30
		3.8 PREVENTION OF DAMAGE BY THE EQUIPMENT .............................................. 30
		3.9 WORKING ON LOOSE OR PLOUGHED SOIL .................................................. 30
		3.10 PARKING THE MACHINE ............................................................... 31
	4. TRANSPORTING THE MACHINE ON ANOTHER  VEHICLE ............................................ 32
		4.1 LOADING AND UNLOADING .............................................................. 32
		4.2 THE ROUTE .......................................................................... 32
	5. THE BATTERY ............................................................................. 33
		5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES ........................................... 33
		5.2 STARTING THE ENGINE WITH JUMP LEADS ................................................ 33
	6. PRECAUTIONS FOR EMERGENCY RECOVERY ...................................................... 34
	7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE .............................................. 35
		7.1 WARNING NOTICES .................................................................... 35
		7.2 TOOLS .............................................................................. 35
		7.3 PERSONAL PRECAUTIONS ............................................................... 35
		7.4 EQUIPMENT .......................................................................... 36
		7.5 KEEPING THE MACHINE CLEAN .......................................................... 36
		7.6 RUNNING THE ENGINE DURING MAINTENANCE .............................................. 36
		7.7 RULES FOR REFUELLING AND ADDING OIL ................................................ 37
		7.8 LEVEL OF COOLANT IN THE RADIATOR ................................................... 37
		7.9 USING LAMPS ........................................................................ 38
		7.10 BATTERY AND ALTERNATOR PRECAUTIONS ................................................ 38
		7.11 PRECAUTIONS REGARDING HIGH PRESSURE HOSES ......................................... 39
		7.12 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH  PRESSURE  SYSTEMS ................... 39
		7.13 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING  HIGH  TEMPERATURES  AND  PRESSURES .... 39
		7.14 THE RADIATOR COOLING FAN AND FAN BELT ............................................. 40
	8. SAFETY AND NOISE ABATEMENT NOTICES ...................................................... 41
		8.1 LOCATION OF SAFETY NOTICES ......................................................... 41
		8.2 LOCATION OF NOISE ABATEMENT NOTICES ................................................ 42
TECHNICAL SPECIFICATIONS ....................................................................... 43
	OVERALL DIMENSIONS WITH MONOBLOCK BOOM...................................................... 44
	OVERALL DIMENSIONS WITH ARTICULATED BOOM.................................................... 44
	TECHNICAL SPECIFICATIONS.................................................................... 45
THE MACHINE AND ITS OPERATIONS.................................................................. 46
	9. SAFETY DEVICES .......................................................................... 47
		9.1 EQUIPMENT SAFETY DEVICES ........................................................... 47
	10. GENERAL VIEWS .......................................................................... 48
		10.1 GENERAL VIEW (MONOBLOCK BOOM) ..................................................... 48
		10.2 GENERAL VIEW (ARTICULATED  BOOM) .................................................. 49
		10.3 GENERAL VIEW OF INSIDE OF CAB ..................................................... 50
	11. INSTRUMENTS AND CONTROLS ............................................................... 51
		11.1 INSTRUMENTS, WARNING LIGHTS, AND PUSH-BUTTONS ..................................... 51
			11.1.1  INSTRUMENTS................................................................. 52
			11.1.2 WARNING LIGHTS AND INDICATORS................................................ 52
			11.1.3 PUSH-BUTTONS AND SWITCHES.................................................... 53
		11.2 LOCATION OF MACHINE CONTROLS ...................................................... 56
			11.2.1 MACHINE CONTROLS............................................................. 57
				1 - ARTICULATED BOOM CONTROL PEDAL.............................................. 57
				2 - 3 TRANSLATION AND STEERING LEVER............................................ 57
				4 - BOOM ROTATION PEDAL......................................................... 58
				5 - 6 EQUIPMENT CONTROL LEVERS.................................................. 59
				7 - BLADE CONTROL LEVER......................................................... 61
				8 - ACCELERATOR LEVER........................................................... 61
				9 - SWING LOCK LEVER............................................................ 61
				10 - EQUIPMENT CONTROL LOCK..................................................... 62
				11 - SPEED CONTROL PEDAL........................................................ 63
				12 - WORKING BRAKE.............................................................. 63
	12. FUSES AND RELAYS ....................................................................... 64
		12.1 FUSES ............................................................................. 64
		12.2 RELAYS............................................................................. 66
	13. THE CAB AND DRIVING POSITION ........................................................... 67
		13.1 THE CAB ........................................................................... 67
		13.2 VENTILATION AND HEATING ........................................................... 70
		13.3 THE DRIVING SEAT .................................................................. 71
		13.4 THE SAFETY BELT ................................................................... 72
	14. OPERATING THE MACHINE .................................................................. 73
		14.1 CHECKS PRIOR TO STARTING THE ENGINE ............................................... 73
			14.1.1 VISUAL CHECKS................................................................ 73
			14.1.2 DAILY CHECKS................................................................. 73
			14.1.3 OPERATING CHECKS............................................................. 74
		14.2 STARTING THE ENGINE ............................................................... 75
			14.2.1 STARTING A WARM ENGINE AND STARTING IN WARM WEATHER.......................... 75
			14.2.2 STARTING A COLD ENGINE AND STARTING IN COLD WEATHER.......................... 76
		14.3 WARMING UP THE ENGINE.............................................................. 76
		14.4 WARMING UP THE HYDRAULIC FLUID .................................................... 77
		14.5 MOVING THE MACHlNE ................................................................ 77
			14.5.1 STEERING AND DIRECTION CHANGING.............................................. 78
			14.5.2 NEGOTIATING SLOPES........................................................... 80
			14.5.3 MAXIMUM DEPTH OF WATER....................................................... 81
	15. PARKING THE MACHINE .................................................................... 82
		15.1 PARKING ON LEVEL GROUND ........................................................... 82
		15.2 PARKING ON A SLOPE ................................................................ 83
	16. STOPPING THE ENGINE .................................................................... 84
	17. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE ............................................ 85
		17.1 LOADING AND UNLOADING ............................................................. 85
		17.2 THE ROUTE ......................................................................... 86
	18. COLD WEATHER PRECAUTIONS ............................................................... 87
		18.1 FUEL AND LUBRICANTS ............................................................... 87
		18.2 COOLANT ........................................................................... 87
		18.3 THE BATTERY ....................................................................... 88
		18.4 OTHER PRECAUTIONS ................................................................. 88
		18.5 PRECAUTIONS AT THE END OF A WORKING DAY ........................................... 88
	19. WARM WEATHER PRECAUTIONS ............................................................... 89
	20. USING THE WORK EQUIPMENT ............................................................... 90
		20.1 ORGANISATION OF THE WORK AREA ..................................................... 90
		20.2 POSITIONING THE BUCKET ACCORDING TO THE JOB ....................................... 90
		20.3 POSITIONING THE MACHINE FOR DIGGING ............................................... 91
		20.4 DIGGING METHOD .................................................................... 92
		20.5 CHANGING THE WORK EQUIPMENT ....................................................... 94
			20.5.1 CHANGING THE BUCKET.......................................................... 94
	21. FAULT FINDING .......................................................................... 95
		21.1 RUNNING OUT OF FUEL ............................................................... 95
		21.2 IF THE BATTERY IS FLAT............................................................. 95
			21.2.1 USING JUMP LEADS TO START THE ENGINE......................................... 96
		21.3 OTHER FAULTS....................................................................... 98
			21.3.1 ELECTRICAL SYSTEM............................................................ 98
			21.3.2 ENGINE....................................................................... 99
			21.3.3 HYDRAULIC SYSTEM.............................................................100
MAINTENANCE.....................................................................................101
	22. MAINTENANCE GUIDE ......................................................................102
	23. MAINTENANCE NOTES ......................................................................104
		23.1 ENGINE MAINTENANCE NOTES ..........................................................104
			23.1.1 ENGINE OIL...................................................................104
			23.1.2 COOLING WATER................................................................105
			23.1.3 FUEL.........................................................................105
		23.2 HYDRAULIC SYSTEM MAINTENANCE NOTES ................................................106
		23.3 ELECTRICAL SYSTEM MAINTENANCE NOTES ...............................................106
		23.4 NOTES ON LUBRICATION ..............................................................107
		23.5 PARTS SUBJECT TO RAPID WEAR AND REQUIRING  REGULAR REPLACEMENT ....................107
	24. FUEL, COOLANT, AND LUBRICANTS ..........................................................108
	25. NUT AND BOLT TIGHTENING TORQUES ........................................................110
		25.1 STANDARD TIGHTENING TORQUES .......................................................110
		25.2 SPECIAL TIGHTENING TORQUES ........................................................110
	26. SCHEDULED MAINTENANCE ..................................................................111
		26.1 PRE-STARTING CHECKS ...............................................................115
			26.1.a VARIOUS CHECKS...............................................................115
			26.1.b CHECKING THE COOLANT LEVEL...................................................115
			26.1.c CHECKING THE FUEL LEVEL......................................................116
			26.1.d CHECKING THE ENGINE OIL LEVEL................................................116
			26.1.e CHECKING THE LEVEL OF THE HYDRAULIC FLUID....................................117
			26.1.f CHECKING THE ELECTRICAL SYSTEM...............................................118
			26.1.g DRAINING THE FUEL LINE WATER TRAP............................................118
		26.2 AFTER THE FIRST 50 HOURS ..........................................................119
		26.3 EVERY 50 HOURS ....................................................................119
			26.3.a GREASING THE SWIVEL JOINT....................................................119
			26.3.b CLEANING THE ENGINE AIR FILTER DUST TRAP.....................................119
		26.4 EVERY 100 HOURS ...................................................................120
			26.4.a GREASING THE ARTICULATIONS...................................................120
			26.4.b CLEANING THE MAIN AIR FILTER ELEMENT.........................................124
		26.5 AFTER THE FIRST 250 HOURS .........................................................125
		26.6 EVERY 250 HOURS ...................................................................125
			26.6.a ADJUSTING FAN BELT TENSION...................................................125
			26.6.b CHECKING THE ELECTROLYTE LEVEL IN THE BATTERY................................126
			26.6.c CHECKING THE OIL LEVEL IN THE FINAL DRIVES...................................127
			26.6.d CHECKING THE OIL LEVEL IN THE SWING MOTOR....................................128
			26.6.e CHANGING THE HYDRAULIC SYSTEM FILTER ELEMENT.................................128
			26.6.f CHANGING THE SERVOCONTROL FILTER ELEMENT.....................................130
			26.6.g CHANGING THE ENGINE OIL......................................................130
			26.6.h CHANGING THE ENGINE OIL FILTER...............................................131
		26.7 EVERY 500 HOURS ...................................................................132
			26.7.a CHANGING THE MAIN AIR FILTER ELEMENT.........................................132
			26.7.b DRAINING THE FUEL TANK.......................................................132
			26.7.c CLEANING THE OUTSIDE OF THE RADIATOR.........................................133
			26.7.d CHANGING THE FUEL FILTER AND CLEANING THE FUEL PUMP’S GAUZE FILTER...........133
			26.7.e CHECKING THE GREASE LEVEL IN THE FIFTH WHEEL PINION GEAR.....................135
			26.7.f GREASING THE FIFTH WHEEL.....................................................135
		26.8 EVERY 1000 HOURS ..................................................................136
			26.8.a CHANGING THE AIR FILTER BACKUP ELEMENT.......................................136
		26.9 EVERY 2000 HOURS ..................................................................137
			26.9.a CHANGING THE HYDRAULIC FLUID.................................................137
			26.9.b CHANGING THE FINAL DRIVES OIL................................................138
			26.9.c CHANGING THE SWING MOTOR OIL.................................................139
			26.9.d CHANGING THE GREASE IN THE FIFTH WHEEL PINION GEAR...........................140
			26.9.e CHANGING THE COOLANT.........................................................141
			26.9.f CHECKING ENGINE VALVE CLEARANCE..............................................141
			26.9.g CHECKING THE ALTERNATOR AND STARTER MOTOR....................................141
		26.10 OCCASIONAL MAINTENANCE............................................................142
			26.10.a WASHING OUT THE COOLING SYSTEM..............................................142
			26.10.b ADJUSTING TRACK TENSION.....................................................143
			26.10.c CHECKING THE SECURITY OF THE TRACK SHOES....................................145
	27. EXTENDED PERIODS OF DISUSE .............................................................146
		27.1 PREPARING TO LAY UP THE MACHINE ...................................................146
		27.2 PREPARING THE MACHINE FOR USE......................................................146

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