KOMATSU PC95-1 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:5000007 and up) – PDF DOWNLOAD

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KOMATSU PC95-1 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:5000007 and up)

KOMATSU PC95-1 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:5000007 AND UP) – PDF DOWNLOAD:

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KOMATSU PC95-1 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:5000007 and up)

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
• STRUCTURE AND FUNCTION
  This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
• TESTING AND ADJUSTING
  This sections explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
• DISASSEMBLY AND ASSEMBLY
  This section explains the order to be followed when removing, installing, dissassembling or assembling each component, as well as precautions to be taken for these operations.
• MAINTENANCE STANDARD
  This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

KOMATSU PC95-1 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:5000007 and up)

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

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]