KOMATSU PC95-1 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:5005145 and up) KOMATSU PC95 1 – PDF DOWNLOAD

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KOMATSU PC95-1 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:5005145 and up) KOMATSU PC95 1

KOMATSU PC95-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:5005145 AND UP) KOMATSU PC95 1 – PDF DOWNLOAD:

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KOMATSU PC95-1 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:5005145 and up) KOMATSU PC95 1

• 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:5005145 and up) KOMATSU PC95 1

MAIN MENU..................................................................................  0
FOREWORD...................................................................................  3
SAFETY INFORMATION.........................................................................  5
INTRODUCTION...............................................................................  7
	PERMITTED USES.........................................................................  7
	MAIN FEATURES..........................................................................  7
	RUNNING IN THE MACHINE.................................................................  7
	SUMMARY OF PICTOGRAMS..................................................................  9
	LOCATION OF MACHINE COMPONENT IDENTIFICATION PLATES.................................... 12
	SERIAL NUMBERS AND ADDRESS OF DEALER................................................... 13
	POSITION AND CONTENTS OF <<CE>> PLATE.................................................. 14
CONTENTS................................................................................... 15
SAFETY AND ACCIDENT PREVENTION............................................................. 23
	1. SAFETY MEASURES..................................................................... 24
		1.1 GENERAL PRECAUTIONS............................................................ 24
		1.2 SAFETY DEVICES................................................................. 24
		1.3 PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT..................................... 24
		1.4 UNAUTHORISED MODIFICATIONS..................................................... 25
		1.5 LEAVING THE DRIVING SEAT....................................................... 25
		1.6 ENTERING AND LEAVING THE MACHINE............................................... 26
		1.7 PREVENTION OF FUEL AND OIL FIRES............................................... 26
		1.8 PREVENTION OF BURNS AND SCALDING............................................... 27
		1.9 PREVENTION OF ASBESTOS DUST CONTAMINATION...................................... 28
		1.10 PREVENTION OF INJURY BY WORK EQUIPMENT........................................ 28
		1.11 FIRE EXTINGUISHERS AND FIRST AID KIT.......................................... 29
		1.12 PRECAUTIONS REGARDING THE CAB FRAME........................................... 29
		1.13 PRECAUTIONS REGARDING EQUIPMENT............................................... 29
PRECAUTIONS................................................................................ 31
	2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE.................................. 32
		2.1 ON-SITE SAFETY................................................................. 32
		2.2 FIRE PREVENTION................................................................ 32
		2.3 PRECAUTIONS REGARDING THE CAB.................................................. 33
		2.4 VENTILATION OF ENCLOSED AREAS.................................................. 33
		2.5 CLEANING WINDOWS, MIRRORS AND HEADLIGHTS - CHECKING WIPER BLADES, LAMPS........ 33
	3. PRECAUTIONS TO BE TAKEN WHILE WORKING............................................... 34
		3.1 STARTING THE ENGINE............................................................ 34
		3.2 CHECKS PRIOR TO REVERSING...................................................... 34
		3.3 MOVING THE MACHINE............................................................. 35
		3.4 WORKING ON SLOPES.............................................................. 36
		3.5 PREVENTION OF ELECTROCUTION.................................................... 37
		3.6 VISIBILITY..................................................................... 38
		3.7 WORKING ON FROZEN OR SNOW-COVERED GROUND....................................... 38
		3.8 PREVENTION OF DAMAGE BY THE EQUIPMENT.......................................... 38
		3.9 WORKING ON LOOSE OR PLOUGHED SOIL.............................................. 38
		3.10 PARKING THE MACHINE........................................................... 39
	4. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE......................................... 40
		4.1 LOADING AND UNLOADING.......................................................... 40
		4.2 THE ROUTE...................................................................... 40
	5. THE BATTERY......................................................................... 41
		5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....................................... 41
		5.2 STARTING THE ENGINE WITH JUMP LEADS............................................ 41
	6. PRECAUTIONS FOR EMERGENCY RECOVERY.................................................. 42
	7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE.......................................... 43
		7.1 WARNING NOTICES................................................................ 43
		7.2 TOOLS.......................................................................... 43
		7.3 PERSONAL PRECAUTIONS........................................................... 44
		7.4 EQUIPMENT...................................................................... 44
		7.5 KEEPING THE MACHINE CLEAN...................................................... 44
		7.6 RUNNING THE ENGINE DURING MAINTENANCE.......................................... 45
		7.7 RULES FOR REFUELLING AND ADDING OIL............................................ 45
		7.8 LEVEL OF COOLANT IN THE RADIATOR............................................... 46
		7.9 USING LAMPS.................................................................... 46
		7.10 BATTERY AND ALTERNATOR PRECAUTIONS............................................ 46
		7.11 PRECAUTIONS REGARDING HIGH PRESSURE HOSES..................................... 47
		7.12 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS................. 47
		7.13 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES.... 48
		7.14 THE RADIATOR COOLING FAN AND FAN BELT......................................... 48
	8. SAFETY AND NOISE ABATEMENT NOTICES.................................................. 49
		8.1 LOCATION OF SAFETY NOTICES..................................................... 49
		8.2 LOCATION OF NOISE ABATEMENT NOTICES............................................ 50
	9. VIBRATIONS TO WHICH THE USER IS SUBJECTED........................................... 50
TECHNICAL SPECIFICATIONS................................................................... 51
	10.TECHNICAL SPECIFICATIONS............................................................ 52
		10.1 OVERALL DIMENSIONS............................................................ 52
		10.2 TECHNICAL SPECIFICATIONS...................................................... 53
		10.3 LIFTING CAPACITY.............................................................. 53
			10.3.1 LIFTING CAPACITY TABLE.................................................. 54
			10.3.2 LIFTING CAPACITY WITH MONOBLOCK BOOM.................................... 56
			10.3.3 LIFTING CAPACITY WITH ARTICULATED BOOM.................................. 57
THE MACHINE AND ITS OPERATIONS............................................................. 59
	11. SAFETY DEVICES..................................................................... 60
		11.1 EQUIPMENT SAFETY DEVICES...................................................... 60
	12. GENERAL VIEWS...................................................................... 61
		12.1 GENERAL VIEW (MONOBLOCK BOOM)................................................. 61
		12.2 GENERAL VIEW (ARTICULATED BOOM)............................................... 62
		12.3 GENERAL VIEW OF INSIDE OF CAB................................................. 63
	13. INSTRUMENTS AND CONTROLS........................................................... 64
		13.1 INSTRUMENTS, WARNING LIGHTS, AND PUSH-BUTTONS................................. 64
			13.1.1 INSTRUMENTS............................................................. 66
			13.1.2 WARNING LIGHTS AND INDICATORS........................................... 66
			13.1.3 PUSH-BUTTONS AND SWITCHES............................................... 67
			13.1.4 ELECTRICAL ACCESSORIES.................................................. 70
		13.2 LOCATION OF MACHINE CONTROLS.................................................. 71
			13.2.1 MACHINE CONTROLS........................................................ 72
				1 - ARTICULATED BOOM CONTROL PEDAL......................................... 72
				2 - 3 TRANSLATION AND STEERING LEVER....................................... 72
				4 - BOOM ROTATION PEDAL.................................................... 73
				5 - 6 EQUIPMENT CONTROL LEVERS............................................. 74
				7 - BLADE CONTROL LEVER.................................................... 76
				8 - ACCELERATOR LEVER...................................................... 76
				9 - SWING LOCK LEVER....................................................... 77
				10 - EQUIPMENT CONTROL LOCK................................................ 78
				11 - WORKING BRAKE......................................................... 79
	14. FUSES AND RELAYS................................................................... 80
		14.1 FUSES......................................................................... 80
		14.2 RELAYS........................................................................ 82
	15. THE CAB AND DRIVING POSITION....................................................... 83
		15.1 THE CAB....................................................................... 83
		15.2 VENTILATION AND HEATING....................................................... 86
		15.3 THE DRIVING SEAT.............................................................. 87
		15.4 THE SAFETY BELT............................................................... 88
		15.5 EMERGENCY EXIT................................................................ 89
		15.6 FIRE EXTINGUISHERS............................................................ 89
		15.7 FIRST AID KIT................................................................. 90
		15.8 TECHNICAL DOCUMENTATION....................................................... 90
	16. OPERATING THE MACHINE.............................................................. 91
		16.1 CHECKS PRIOR TO STARTING THE ENGINE........................................... 91
			16.1.1 VISUAL CHECKS........................................................... 91
			16.1.2 DAILY CHECKS............................................................ 91
			16.1.3 OPERATING CHECKS........................................................ 92
		16.2 STARTING THE ENGINE........................................................... 93
			16.2.1 STARTING A WARM ENGINE AND STARTING IN WARM WEATHER..................... 93
			16.2.2 STARTING A COLD ENGINE AND STARTING IN COLD WEATHER..................... 94
		16.3 WARMING UP THE ENGINE......................................................... 94
		16.4 WARMING UP THE HYDRAULIC FLUID................................................ 95
		16.5 MOVING THE MACHINE............................................................ 95
			16.5.1 STEERING AND DIRECTION CHANGING......................................... 96
			16.5.2 NEGOTIATING SLOPES...................................................... 98
			16.5.3 MAXIMUM DEPTH OF WATER.................................................. 99
	17. PARKING THE MACHINE................................................................100
		17.1 PARKING ON LEVEL GROUND.......................................................100
		17.2 PARKING ON A SLOPE............................................................101
	18. STOPPING THE ENGINE................................................................102
	19. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE........................................102
		19.1 LOADING AND UNLOADING.........................................................102
		19.2 THE ROUTE.....................................................................104
	20. COLD WEATHER PRECAUTIONS...........................................................105
		20.1 FUEL AND LUBRICANTS...........................................................105
		20.2 COOLANT.......................................................................105
		20.3 THE BATTERY...................................................................106
		20.4 OTHER PRECAUTIONS.............................................................106
		20.5 PRECAUTIONS AT THE END OF A WORKING DAY.......................................106
	21. WARM WEATHER PRECAUTIONS...........................................................107
	22. USING THE WORK EQUIPMENT...........................................................108
		22.1 ORGANISATION OF THE WORK AREA.................................................108
		22.2 POSITIONING THE BUCKET ACCORDING TO THE JOB...................................108
		22.3 POSITIONING THE MACHINE FOR DIGGING...........................................109
		22.4 DIGGING METHOD................................................................110
		22.5 CHANGING THE WORK EQUIPMENT...................................................112
			22.5.1 CHANGING THE BUCKET.....................................................112
	23. FAULT FINDING......................................................................113
		23.1 RUNNING OUT OF FUEL...........................................................113
		23.2 IF THE BATTERY IS FLAT........................................................113
			23.2.1 USING JUMP LEADS TO START THE ENGINE....................................114
		23.3 OTHER FAULTS..................................................................116
			23.3.1 ELECTRICAL SYSTEM.......................................................116
			23.3.2 ENGINE..................................................................117
			23.3.3 HYDRAULIC SYSTEM........................................................118
MAINTENANCE................................................................................119
	24. MAINTENANCE GUIDE..................................................................120
	25. MAINTENANCE NOTES..................................................................122
		25.1 ENGINE MAINTENANCE NOTES......................................................122
			25.1.1 ENGINE OIL..............................................................122
			25.1.2 COOLING WATER...........................................................123
			25.1.3 FUEL....................................................................123
		25.2 HYDRAULIC SYSTEM MAINTENANCE NOTES............................................124
		25.3 ELECTRICAL SYSTEM MAINTENANCE NOTES...........................................124
		25.4 NOTES ON LUBRICATION..........................................................125
		25.5 PARTS SUBJECT TO RAPID WEAR AND REQUIRING REGULAR REPLACEMENT.................125
	26. FUEL, COOLANT, AND LUBRICANTS......................................................126
	27. NUT AND BOLT TIGHTENING TORQUES....................................................128
		27.1 STANDARD TIGHTENING TORQUES...................................................128
		27.2 SPECIAL TIGHTENING TORQUES....................................................128
	28. LUBRICATION........................................................................129
		28.1 LUBRICATION CHART.............................................................129
	29. SCHEDULED MAINTENANCE..............................................................130
		29.1 PRE-STARTING CHECKS...........................................................133
			29.1.a VARIOUS CHECKS..........................................................133
			29.1.b CHECKING THE COOLANT LEVEL..............................................133
			29.1.c CHECKING THE FUEL LEVEL.................................................134
			29.1.d CHECKING THE ENGINE OIL LEVEL...........................................134
			29.1.e CHECKING THE LEVEL OF THE HYDRAULIC FLUID...............................135
			29.1.f CHECKING THE ELECTRICAL SYSTEM..........................................136
			29.1.g DRAINING THE FUEL LINE WATER TRAP.......................................136
		29.2 AFTER THE FIRST 50 HOURS......................................................137
		29.3 EVERY 50 HOURS................................................................137
			29.3.a GREASING THE SWIVEL JOINT...............................................137
			29.3.b CLEANING THE ENGINE AIR FILTER DUST TRAP................................137
		29.4 EVERY 100 HOURS...............................................................138
			29.4.a GREASING THE ARTICULATIONS..............................................138
			29.4.b CLEANING THE MAIN AIR FILTER ELEMENT....................................141
			29.4.c GREASING THE FIFTH WHEEL................................................142
			29.4.d LUBRICATION OF THE OVERLOAD DEVICE CAM..................................142
		29.5 AFTER THE FIRST 250 HOURS.....................................................142
		29.6 EVERY 250 HOURS...............................................................143
			29.6.a ADJUSTING FAN BELT TENSION..............................................143
			29.6.b CHECKING THE ELECTROLYTE LEVEL IN THE BATTERY...........................143
			29.6.c CHECKING THE OIL LEVEL IN THE FINAL DRIVES..............................144
			29.6.d CHECKING THE OIL LEVEL IN THE SWING MOTOR...............................145
			29.6.e CHANGING THE HYDRAULIC SYSTEM FILTER ELEMENT............................145
			29.6.f CHANGING THE SERVOCONTROL FILTER ELEMENT................................146
			29.6.g CHANGING THE ENGINE OIL.................................................147
			29.6.h CHANGING THE ENGINE OIL FILTER..........................................148
		29.7 EVERY 500 HOURS...............................................................149
			29.7.a CHANGING THE MAIN AIR FILTER ELEMENT....................................149
			29.7.b DRAINING THE FUEL TANK..................................................149
			29.7.c CLEANING THE OUTSIDE OF THE RADIATOR....................................150
			29.7.d CHANGING THE FUEL FILTER AND CLEANING THE FUEL PUMP’S GAUZE FILTER......150
			29.7.e CHECKING THE GREASE LEVEL IN THE FIFTH WHEEL PINION GEAR................152
		29.8 EVERY 1000 HOURS..............................................................153
			29.8.a CHANGING THE AIR FILTER BACKUP ELEMENT..................................153
		29.9 EVERY 2000 HOURS..............................................................154
			29.9.a CHANGING THE HYDRAULIC FLUID............................................154
			29.9.b CHANGING THE FINAL DRIVES OIL...........................................156
			29.9.c CHANGING THE SWING MOTOR OIL............................................156
			29.9.d CHANGING THE GREASE IN THE FIFTH WHEEL PINION GEAR......................158
			29.9.e CHANGING THE COOLANT....................................................159
			29.9.f CHECKING ENGINE VALVE CLEARANCE.........................................160
			29.9.g CHECKING THE ALTERNATOR AND STARTER MOTOR...............................160
		29.10 OCCASIONAL MAINTENANCE.......................................................161
			29.10.a WASHING OUT THE COOLING SYSTEM.........................................161
			29.10.b ADJUSTING TRACK TENSION................................................162
			29.10.c CHECKING THE SECURITY OF THE TRACK SHOES...............................164
	30. EXTENDED PERIODS OF DISUSE.........................................................165
		30.1 PREPARING TO LAY UP THE MACHINE...............................................165
		30.2 PREPARING THE MACHINE FOR USE.................................................166
AUTHORISED OPTIONAL EQUIPMENT..............................................................167
	31. AUTHORISED OPTIONAL EQUIPMENT......................................................168
		31.1 OPTIONAL EQUIPMENT CHARACTERISTICS............................................168
	32. DEMOLITION HAMMER..................................................................169
		32.1 DESCRIPTION AND OPERATION.....................................................169
		32.2 FITTING AND REMOVING THE DEMOLITION HAMMER....................................169
			32.2.1 FITTING THE DEMOLITION HAMMER...........................................169
			32.2.2 REMOVING THE DEMOLITION HAMMER..........................................172
	33. CLAMSHELL BUCKET...................................................................173
		33.1 DESCRIPTION AND OPERATION.....................................................173
		33.2 FITTING THE CLAMSHELL BUCKET..................................................174

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