KOMATSU PC95-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN: 5001617 & UP) – PDF DOWNLOAD

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KOMATSU PC95-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN: 5001617 & UP)

KOMATSU PC95-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN: 5001617 & UP) – PDF DOWNLOAD:

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KOMATSU PC95-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN: 5001617 & UP)

• This manual has been prepared by FKI S.p.A. 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.
• This operator’s manual, together with the spare parts catalogue, are essential items of machine equipment and must accompany the machine throughout its working life, even if the machine is sold to new owners. Keep this manual in a convenient place on board the machine where it can be consulted quickly and easily. We recommend that you keep it in the document pocket behind the seat, together with the documents of ownership and registration.
• Make sure that this manual is always readily available to all machine operators and maintenance personnel who must read it carefully and understand how to operate and maintain the machine and what hazards must be avoided. If this manual becomes damaged or lost, request another copy from FKI or from your FKI dealer. FKI machines are constantly being improved in terms of efficiency and reliability.
• This manual describes the machine as first sold. Consult your FKI dealer for information on technical changes. 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 FKI 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 FKI dealer also stocks original FKI 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 (SN: 5001617 & UP)

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
		1.11 FIRE EXTINGUISHERS AND FIRST AID KIT .............................................. 27
		1.12 PRECAUTIONS REGARDING THE CAB FRAME ............................................... 27
		1.13 PRECAUTIONS REGARDING EQUIPMENT ................................................... 27
PRECAUTIONS..................................................................................... 28
	2. PRECAUTIONS TO BE TAKEN BEFORE STARTING  THE  ENGINE .................................... 29
		2.1 ON-SITE SAFETY ..................................................................... 29
		2.2 FIRE PREVENTION .................................................................... 29
		2.3 PRECAUTIONS REGARDING THE CAB ...................................................... 30
		2.4 VENTILATION OF ENCLOSED AREAS ...................................................... 30
		2.5 CLEANING WINDOWS, MIRRORS AND HEADLIGHTS -  CHECKING  WIPER  BLADES,  LAMPS ........ 30
	3. PRECAUTIONS TO BE TAKEN WHILE WORKING ................................................... 31
		3.1 STARTING THE ENGINE ................................................................ 31
		3.2 CHECKS PRIOR TO REVERSING .......................................................... 31
		3.3 MOVING THE MACHINE ................................................................. 32
		3.4 WORKING ON SLOPES .................................................................. 33
		3.5 PREVENTION OF ELECTROCUTION ........................................................ 34
		3.6 VISIBILITY ......................................................................... 35
		3.7 WORKING ON FROZEN OR SNOW-COVERED GROUND ........................................... 35
		3.8 PREVENTION OF DAMAGE BY THE EQUIPMENT .............................................. 35
		3.9 WORKING ON LOOSE OR PLOUGHED SOIL .................................................. 35
		3.10 PARKING THE MACHINE ............................................................... 36
	4. TRANSPORTING THE MACHINE ON ANOTHER  VEHICLE ............................................ 37
		4.1 LOADING AND UNLOADING .............................................................. 37
		4.2 THE ROUTE .......................................................................... 37
	5. THE BATTERY ............................................................................. 38
		5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES ........................................... 38
		5.2 STARTING THE ENGINE WITH JUMP LEADS ................................................ 38
	6. PRECAUTIONS FOR EMERGENCY RECOVERY ...................................................... 39
	7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE .............................................. 40
		7.1 WARNING NOTICES .................................................................... 40
		7.2 TOOLS .............................................................................. 40
		7.3 PERSONAL PRECAUTIONS ............................................................... 41
		7.4 EQUIPMENT .......................................................................... 41
		7.5 KEEPING THE MACHINE CLEAN .......................................................... 41
		7.6 RUNNING THE ENGINE DURING MAINTENANCE .............................................. 42
		7.7 RULES FOR REFUELLING AND ADDING OIL ................................................ 42
		7.8 LEVEL OF COOLANT IN THE RADIATOR ................................................... 43
		7.9 USING LAMPS ........................................................................ 43
		7.10 BATTERY AND ALTERNATOR PRECAUTIONS ................................................ 43
		7.11 PRECAUTIONS REGARDING HIGH PRESSURE HOSES ......................................... 44
		7.12 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH  PRESSURE  SYSTEMS ................... 44
		7.13 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING  HIGH  TEMPERATURES  AND  PRESSURES .... 45
		7.14 THE RADIATOR COOLING FAN AND FAN BELT ............................................. 45
	8. SAFETY AND NOISE ABATEMENT NOTICES ...................................................... 46
		8.1 LOCATION OF SAFETY NOTICES ......................................................... 46
		8.2 LOCATION OF NOISE ABATEMENT NOTICES ................................................ 47
	9. VIBRATIONS TO WHICH THE USER IS SUBJECTED................................................ 47
TECHNICAL SPECIFICATIONS........................................................................ 48
	10. TECHNICAL SPECIFICATIONS ............................................................... 49
		10.1 OVERALL DIMENSIONS ................................................................ 49
		10.2 TECHNICAL SPECIFICATIONS .......................................................... 50
		10.3 LIFTING CAPACITY .................................................................. 50
			10.3.1 LIFTING CAPACITY WITH MONOBLOCK BOOM......................................... 51
			10.3.2 LIFTING CAPACITY WITH ARTICULATED BOOM ...................................... 52
THE MACHINE AND ITS OPERATIONS.................................................................. 53
	11. SAFETY DEVICES ......................................................................... 54
		11.1 EQUIPMENT SAFETY DEVICES .......................................................... 54
	12. GENERAL VIEWS .......................................................................... 55
		12.1 GENERAL VIEW (MONOBLOCK BOOM) ..................................................... 55
		12.2 GENERAL VIEW (ARTICULATED BOOM) ................................................... 56
		12.3 GENERAL VIEW OF INSIDE OF CAB ..................................................... 57
	13. INSTRUMENTS AND CONTROLS ............................................................... 58
		13.1 INSTRUMENTS, WARNING LIGHTS, AND PUSH-BUTTONS ..................................... 58
			13.1.1 INSTRUMENTS ................................................................. 60
			13.1.2 WARNING LIGHTS AND INDICATORS ............................................... 60
			13.1.3 PUSH-BUTTONS AND SWITCHES ................................................... 61
			13.1.4 ELECTRICAL ACCESSORIES ...................................................... 63
		13.2 LOCATION OF MACHINE CONTROLS ...................................................... 65
			13.2.1 MACHINE CONTROLS ............................................................ 66
				1 - ARTICULATED BOOM CONTROL PEDAL ............................................. 66
				2 - 3 TRANSLATION AND STEERING LEVER ........................................... 66
				4 - BOOM ROTATION PEDAL ........................................................ 67
				5 - 6 EQUIPMENT CONTROL LEVERS ................................................. 68
				7 - BLADE CONTROL LEVER ........................................................ 70
				8 - ACCELERATOR LEVER .......................................................... 70
				9 - SWING LOCK LEVER ........................................................... 71
				10 - EQUIPMENT CONTROL LOCK .................................................... 72
				11 - SPEED CONTROL PEDAL ....................................................... 72
				12 - WORKING BRAKE ............................................................. 73
	14. FUSES AND RELAYS ....................................................................... 74
		14.1 FUSES ............................................................................. 74
		14.2 RELAYS ............................................................................ 76
	15. THE CAB AND DRIVING POSITION ........................................................... 77
		15.1 THE CAB ........................................................................... 77
		15.2 VENTILATION AND HEATING ........................................................... 80
		15.3 THE DRIVING SEAT .................................................................. 81
		15.4 THE SAFETY BELT ................................................................... 82
		15.5 EMERGENCY EXIT .................................................................... 83
		15.6 FIRE EXTINGUISHERS  ............................................................... 83
		15.7 FIRST AID KIT ..................................................................... 84
		15.8 TECHNICAL DOCUMENTATION ........................................................... 84
	16. OPERATING THE MACHINE .................................................................. 85
		16.1 CHECKS PRIOR TO STARTING THE ENGINE ............................................... 85
			16.1.1 VISUAL CHECKS ............................................................... 85
			16.1.2 DAILY CHECKS ................................................................ 85
			16.1.3 OPERATING CHECKS ............................................................ 86
		16.2 STARTING THE ENGINE ............................................................... 87
			16.2.1 STARTING A WARM ENGINE AND STARTING IN WARM WEATHER ......................... 87
			16.2.2 STARTING A COLD ENGINE AND STARTING IN COLD WEATHER ......................... 88
		16.3 WARMING UP THE ENGINE ............................................................. 88
		16.4 WARMING UP THE HYDRAULIC FLUID .................................................... 89
		16.5 MOVING THE MACHINE ................................................................ 89
			16.5.1 STEERING AND DIRECTION CHANGING ............................................. 90
			16.5.2 NEGOTIATING SLOPES .......................................................... 92
			16.5.3 MAXIMUM DEPTH OF WATER ...................................................... 93
	17. PARKING THE MACHINE .................................................................... 94
		17.1 PARKING ON LEVEL GROUND ........................................................... 94
		17.2 PARKING ON A SLOPE ................................................................ 95
	18. STOPPING THE ENGINE .................................................................... 96
	19. TRANSPORTING THE MACHINE ON ANOTHER  VEHICLE............................................ 96
		19.1 LOADING AND UNLOADING ............................................................. 96
		19.2 THE ROUTE ......................................................................... 98
	20. COLD WEATHER PRECAUTIONS ............................................................... 99
		20.1 FUEL AND LUBRICANTS ............................................................... 99
		20.2 COOLANT ........................................................................... 99
		20.3 THE BATTERY .......................................................................100
		20.4 OTHER PRECAUTIONS .................................................................100
		20.5 PRECAUTIONS AT THE END OF A WORKING DAY ...........................................100
	21. WARM WEATHER PRECAUTIONS ...............................................................101
	22. USING THE WORK EQUIPMENT ...............................................................102
		22.1 ORGANISATION OF THE WORK AREA .....................................................102
		22.2 POSITIONING THE BUCKET ACCORDING TO THE JOB .......................................102
		22.3 POSITIONING THE MACHINE FOR DIGGING ...............................................103
		22.4 DIGGING METHOD ....................................................................104
		22.5 CHANGING THE WORK EQUIPMENT .......................................................106
			22.5.1 CHANGING THE BUCKET .........................................................106
	23. FAULT FINDING ..........................................................................107
		23.1 RUNNING OUT OF FUEL ...............................................................107
		23.2 IF THE BATTERY IS FLAT ............................................................107
			23.2.1 USING JUMP LEADS TO START THE ENGINE ........................................108
		23.3 OTHER FAULTS.......................................................................110
			23.3.1 ELECTRICAL SYSTEM............................................................110
			23.3.2 ENGINE ......................................................................111
			23.3.3 HYDRAULIC SYSTEM ............................................................112
MAINTENANCE.....................................................................................113
	24. MAINTENANCE GUIDE ......................................................................114
	25. MAINTENANCE NOTES ......................................................................116
		25.1 ENGINE MAINTENANCE NOTES ..........................................................116
			25.1.1 ENGINE OIL ..................................................................116
			25.1.2 COOLING WATER ...............................................................117
			25.1.3 FUEL ........................................................................117
		25.2 HYDRAULIC SYSTEM MAINTENANCE NOTES ................................................118
		25.3 ELECTRICAL SYSTEM MAINTENANCE NOTES ...............................................118
		25.4 NOTES ON LUBRICATION ..............................................................119
		25.5 PARTS SUBJECT TO RAPID WEAR AND REQUIRING  REGULAR  REPLACEMENT ...................119
	26. FUEL, COOLANT, AND LUBRICANTS ..........................................................120
	27. NUT AND BOLT TIGHTENING TORQUES ........................................................122
		27.1 STANDARD TIGHTENING TORQUES .......................................................122
		27.2 SPECIAL TIGHTENING TORQUES ........................................................122
	28. LUBRICATION ............................................................................123
		28.1 LUBRICATION CHART .................................................................123
	29. SCHEDULED MAINTENANCE...................................................................124
		29.1 PRE-STARTING CHECKS ...............................................................127
			29.1.a VARIOUS CHECKS ..............................................................127
			29.1.b CHECKING THE COOLANT LEVEL ..................................................127
			29.1.c CHECKING THE FUEL LEVEL .....................................................128
			29.1.d CHECKING THE ENGINE OIL LEVEL ...............................................128
			29.1.e CHECKING THE LEVEL OF THE HYDRAULIC FLUID....................................129
			29.1.f  CHECKING THE ELECTRICAL SYSTEM .............................................130
			29.1.g DRAINING THE FUEL LINE WATER TRAP ...........................................130
		29.2 AFTER THE FIRST 50 HOURS ..........................................................131
		29.3 EVERY 50 HOURS.....................................................................131
			29.3.a GREASING THE SWIVEL JOINT....................................................131
			29.3.b CLEANING THE ENGINE AIR FILTER DUST TRAP.....................................131
		29.4 EVERY 100 HOURS....................................................................132
			29.4.a GREASING THE ARTICULATIONS...................................................132
			29.4.b CLEANING.....................................................................135
			29.4.c GREASING THE FIFTH WHEEL.....................................................136
			29.4.d LUBRICATION OF THE OVERLOAD DEVICE CAM.......................................136
		29.5 AFTER THE FIRST 250 HOURS..........................................................136
		29.6 EVERY 250 HOURS....................................................................137
			29.6.a ADJUSTING FAN BELT TENSION...................................................137
			29.6.b CHECKING THE ELECTROLYTE LEVEL IN THE BATTERY................................137
			29.6.c CHECKING THE OIL LEVEL IN THE F..............................................138
			29.6.d CHECKING THE OIL LEVEL IN THE SWING..........................................139
			29.6.e CHANGING THE HYDRAULIC SYSTEM FILTER ELEMENT.................................139
			29.6.f CHANGING THE SERVOCONTROL FILTER ELEMENT.....................................140
			29.6.g CHANGING THE ENGINE OIL......................................................141
			29.6.h CHANGING THE ENGINE OIL FILTER...............................................142
		29.7 EVERY 500 HOURS....................................................................143
			29.7.a CHANGING THE MAIN AIR FILTER ELEMENT.........................................143
			29.7.b DRAINING THE FUEL TANK.......................................................143
			29.7.c CLEANING THE OUTSIDE OF THE RADIATOR.........................................144
			29.7.d CHANGING THE FUEL FILTER AND CLEANING THE FUEL PUMP’S GAUZE FILTER...........144
			29.7.e CHECKING THE GREASE LEVEL IN THE FIFTH WHEEL PINION GEAR.....................146
		29.8 EVERY 1000 HOURS...................................................................147
			29.8.a CHANGING THE AIR FILTER BACKUP ELEMENT.......................................147
		29.9 EVERY 2000 HOURS...................................................................148
			29.9.a CHANGING THE HYDRAULIC FLUID.................................................148
			29.9.b CHANGING THE FINAL DRIVES OIL................................................150
			29.9.c CHANGING THE SWING MOTOR OIL.................................................150
			29.9.d CHANGING THE GREASE IN THE FIFTH WHEEL PINION GEAR...........................152
			29.9.e CHANGING THE COOLANT.........................................................153
			29.9.f CHECKING ENGINE VALVE CLEARANCE..............................................154
			29.9.g CHECKING THE ALTERNATOR AND STARTER MOTOR....................................154
		29.10 OCCASIONAL MAINTENANCE............................................................155
			29.10.a WASHING OUT THE COOLING SYSTEM..............................................155
			29.10.b ADJUSTING TRACK TENSION.....................................................156
			29.10.c CHECKING THE SECURITY OF THE TRACK SHOES....................................158
	30. EXTENDED PERIODS OF DISUSE .............................................................159
		30.1 PREPARING TO LAY UP THE MACHINE ...................................................159
		30.2 PREPARING THE MACHINE FOR USE .....................................................160
AUTHORISED OPTIONAL EQUIPMENT...................................................................161
	31. AUTHORISED OPTIONAL EQUIPMENT ..........................................................162
		31.1 OPTIONAL EQUIPMENT CHARACTERISTICS.................................................162
	32. DEMOLITION HAMMER ......................................................................163
		32.1 DESCRIPTION AND OPERATION .........................................................163
		32.2 FITTING AND REMOVING THE DEMOLITION HAMMER ........................................163
			32.2.1 FITTING THE DEMOLITION HAMMER ...............................................163
			32.2.2 REMOVING THE DEMOLITION HAMMER ..............................................166
	33. CLAMSHELL BUCKET........................................................................167
		33.1 DESCRIPTION AND OPERATION..........................................................167
		33.2 FITTING THE CLAMSHELL BUCKET ......................................................168

PLEASE NOTE:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]