Komatsu PC95R-2 Hydraulic Excavator Operation & Maintenance Manual SN 21D5200001 and up – PDF DOWNLOAD

Description

Komatsu PC95R-2 Hydraulic Excavator Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu PC95R-2 Hydraulic Excavator Operation & Maintenance Manual 

MAIN MENU...............................................................................................  0
COVER...................................................................................................  1
1.1  FORWORD............................................................................................  4
1.2  INFORMATION ON SAFETY..............................................................................  5
1.3  INTRODUCTION.......................................................................................  7
	1.3.1  INTENDED USES................................................................................  7
	1.3.2  IMPROPER OR UNAUTHORIZED USE.................................................................  7
	1.3.3  MAIN CHARACTERISTICS.........................................................................  8
	1.3.4  RUNNING-IN...................................................................................  8
1.4  PRODUCT IDENTIFICATION.............................................................................  9
	1.4.1  MACHINE SERIAL NUMBER........................................................................  9
	1.4.2  MACHINE IDENTIFICATION PLATE.................................................................  9
	1.4.3  ENGINE SERIAL NUMBER AND EMISSION LABEL...................................................... 10
	1.4.4  TRAVEL REDUCTION GEAR SERIAL NUMBER.......................................................... 10
	1.4.5  SWING REDUCTION GEAR SERIAL NUMBER........................................................... 11
	1.4.6  CAB SERIAL NUMBER............................................................................ 11
	1.4.7  SERIAL NUMBERS AND DEALER'S ADDRESS.......................................................... 12
CONTENTS................................................................................................ 13
SAFETY AND ACCIDENT PREVENTION.......................................................................... 20
	2.1  SAFETY PLATES.................................................................................. 21
		2.1.1  POSITION OF THE SAFETY PLATES............................................................ 21
		2.1.2 POSITION OF THE PICTOGRAMS................................................................ 37
		2.1.3  PICTOGRAMS AND RELEVANT MEANINGS......................................................... 38
		2.1.4 VIBRATIONS TO WHICH THE OPERTOR IS SUBJECTED.............................................. 40
	2.2  GENERAL PRECAUTIONS............................................................................ 41
		2.2.1 GENERAL SAFETY RULES...................................................................... 41
		2.2.2  SAFETY DEVICES AND GUARDS................................................................ 41
		2.2.3  CLOTHING AND PERSONAL PROTECTION ITEMS................................................... 41
		2.2.4  UNATHORIZED MODIFICATIONS................................................................ 42
		2.2.5  LEAVING THE OPERATOR'S SEAT.............................................................. 42
		2.2.6  GETTING ON AND OFF THE MACHINE........................................................... 43
		2.2.7  PREVENTING FIRES DUE TO FUEL AND OIL..................................................... 43
		2.2.8  PREVENTING BURNS......................................................................... 44
		2.2.9  PREVENTING DAMAGE DUE TO ASBESTOS POWDER................................................. 44
		2.2.10  PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT.......................................... 45
		2.2.11  FIRE EXTINGUISHERS AND FIRST AID KIT.................................................... 45
		2.2.12  PRECAUTIONS CONCERNING THE CAB STRUCTURE................................................ 45
		2.2.13  PRECAUTIONS CONCERNING THE EQUIPMENT.................................................... 45
	2.3  PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE............................................. 46
		2.3.1  SAFETY ON THE WORK SITE.................................................................. 46
		2.3.2  FIRE PREVENTION.......................................................................... 46
		2.3.3  PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB........................................... 46
		2.3.4  ROOM VENTILATION......................................................................... 47
		2.3.5  PRECAUTIONS TO BE TAKEN FOR THE LIGHTS................................................... 47
		2.3.6  CLEANING THE WINDOWS AND THE REAR VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES.... 47
	2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................ 48
		2.4.1  STARTING THE ENGINE...................................................................... 48
		2.4.2  CHECK THE DIRECTIONS BEFORE STARTING THE MACHINE......................................... 48
		2.4.3  CHECKS FOR TRAVELING IN REVERSE.......................................................... 48
		2.4.4  MOVING THE MACHINE....................................................................... 49
		2.4.5  MOVING ON SLOPES......................................................................... 50
		2.4.6  WORKING ON SLOPES........................................................................ 51
		2.4.7  UNAUTHORIZED OPERATIONS.................................................................. 51
		2.4.8  PREVENTING ELECTROCUTION................................................................. 52
		2.4.9  VISIBILITY............................................................................... 53
		2.4.10  WORKING ON ICY OR SNOW-COVERED SURFACES................................................. 53
		2.4.11  PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT.......................................... 53
		2.4.12  WORKING ON LOOSE GROUND................................................................. 53
		2.4.13  PARKING THE MACHINE..................................................................... 54
	2.5  TRANSPORTING THE MACHINE ON OTHER VEHICLES..................................................... 55
		2.5.1  LOADING AND UNLOADING THE MACHINE........................................................ 55
		2.5.2  SHIPPING................................................................................. 55
	2.6  BATTERY........................................................................................ 56
		2.6.1  SAFETY PRECAUTIONS FOR WORK ON BATTERIES................................................. 56
		2.6.2  STARTING WITH BOOSTER CABLES............................................................. 56
	2.7  PRECAUTIONS FOR EMERGENCY RECOVERY............................................................. 57
	2.8  PRECAUTIONS TO BE TAKEN DURING MAINTENANCE..................................................... 58
		2.8.1  WARNING PLATES........................................................................... 58
		2.8.2  TOOLS.................................................................................... 58
		2.8.3  PERSONNEL................................................................................ 59
		2.8.4  EQUIPMENT................................................................................ 59
		2.8.5  WORKING UNDER THE MACHINE................................................................ 59
		2.8.6  KEEPING THE MACHINE CLEAN................................................................ 59
		2.8.7  USE OF THE ENGINE DURING MAINTENANCE..................................................... 60
		2.8.8  PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY.............................. 60
		2.8.9  STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION.............. 60
		2.8.10  RULES FOR REFUELLING AND ADDING OIL..................................................... 61
		2.8.11  CHECKING THE COOLANT LEVEL IN THE RADIATOR.............................................. 61
		2.8.12  USING LAMPS............................................................................. 61
		2.8.13  PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR................................... 62
		2.8.14  PRECAUTIONS CONCERNING THE STARTER...................................................... 62
		2.8.15  PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES.............................................. 63
		2.8.16  PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS........................... 63
		2.8.17  PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES.............. 63
		2.8.18  COOLING FAN AND FAN BELT................................................................ 64
		2.8.19  WASTE MATERIALS......................................................................... 64
DESCRIPTION AND USE OF THE MACHINE...................................................................... 66
	3.1  SAFETY LOCKS................................................................................... 67
		3.1.1  MACHINE LOCKS............................................................................ 67
	3.2  GENERAL VIEWS.................................................................................. 68
		3.2.1  FRONT GENERAL VIEW (MONOBOOM)............................................................ 68
		3.2.2  FRONT GENERAL VIEW (TWO-PIECE BOOM)...................................................... 69
		3.2.3  CAB INSIDE GENERAL VIEW.................................................................. 70
	3.3  INSTRUMENTS AND CONTROLS....................................................................... 72
		3.3.1  INSTRUMENTS, WARNING LIGHTS AND PUSH BUTTONS............................................. 72
		3.3.2  MACHINE CONTROLS......................................................................... 81
	3.4  FUSES AND RELAYS............................................................................... 92
		3.4.1  CENTRAL UNIT FUSES AND RELAYS............................................................ 92
			3.4.1.1  CENTRAL UNIT FUSES................................................................. 93
			3.4.1.2  CENTRAL UNIT RELAYS................................................................ 94
		3.4.2  ENGINE LINE FUSES AND RELAYS............................................................. 95
			3.4.2.1  ENGINE LINE FUSES.................................................................. 95
			3.4.2.2  ENGINE LINE RELAYS................................................................. 96
	3.5  GUARDS AND DRIVER'S SEAT....................................................................... 97
		3.5.1  ENGINE HOOD.............................................................................. 97
		3.5.2  SIDE COVER............................................................................... 97
		3.5.3  CAB...................................................................................... 98
		3.5.4  VENTILATION AND HEATING..................................................................102
		3.5.5  SEAT.....................................................................................103
		3.5.6  SAFETY BELT..............................................................................104
		3.5.7  EMERGENCY EXIT...........................................................................104
		3.5.8  TECHNICAL DOCUMENTATION CASE.............................................................105
		3.5.9  FIRE EXTINGUISHER........................................................................105
		3.5.10  FIRST AID KIT...........................................................................105
	3.6  USE OF THE MACHINE.............................................................................106
		3.6.1  CHECKS BEFORE STARTING THE ENGINE........................................................106
			3.6.1.1  VISUAL CHECKS......................................................................106
			3.6.1.2  DAILY CHECKS.......................................................................106
			3.6.1.3  OPERATIONAL CHECKS.................................................................107
		3.6.2  STARTING THE ENGINE......................................................................108
			3.6.2.1  STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES.................................108
			3.6.2.2  STARTING WITH COLD ENGINE OR IN COLD CLIMATES......................................109
		3.6.3  WARMING THE ENGINE.......................................................................110
		3.6.4  HEATING THE HYDRAULIC OIL................................................................110
		3.6.5  HOW TO MOVE THE MACHINE..................................................................110
			3.6.5.1  STEERING (CHANGING DIRECTION)......................................................112
			3.6.5.2  MOVING ON SLOPES...................................................................113
			3.6.5.3  MAXIMUM IMMERSION DEPTH............................................................114
	3.7  PARKING THE MACHINE............................................................................115
		3.7.1  PARKING ON LEVEL GROUND..................................................................115
		3.7.2  PARKING ON SLOPES........................................................................116
	3.8  STOPPING THE ENGINE............................................................................117
	3.9  TRANSPORTING THE MACHINE ON OTHER VEHICLES.....................................................118
		3.9.1  LOADING AND UNLOADING THE MACHINE........................................................118
		3.9.2  TRANSPORT................................................................................119
	3.10  PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....................................................120
		3.10.1  FUEL AND LUBRICANTS.....................................................................120
		3.10.2  COOLANT.................................................................................120
		3.10.3  BATTERY.................................................................................121
		3.10.4  OTHER PRECAUTIONS.......................................................................121
		3.10.5  PRECAUTIONS TO BE TAKEN AT THE END OF WORK..............................................121
	3.11  PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....................................................122
	3.12  USING THE WORK EQUIPMENT......................................................................123
		3.12.1  ORGANIZING THE WORK AREA................................................................123
		3.12.2  POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT..........................123
		3.12.3  POSITIONING THE MACHINE FOR DIGGING OPERATIONS..........................................124
		3.12.4  DIGGING METHOD..........................................................................125
		3.12.5  CHANGING THE BUCKET.....................................................................126
	3.13  LONG PERIODS OF INACTIVITY....................................................................127
		3.13.1  BEFORE THE PERIOD OF INACTIVITY.........................................................127
		3.13.2  DURING THE PERIOD OF INACTIVITY.........................................................128
		3.13.3  AFTER THE PERIOD OF INACTIVITY..........................................................128
	3.14  TROUBLESHOOTING...............................................................................129
		3.14.1  HOW TO REMOVE THE MACHINE...............................................................129
		3.14.2  IF THE FUEL HAS BEEN COMPLETELY DEPLETED................................................129
		3.14.3  IF THE BATTERY IS DEPLETED..............................................................130
			3.14.3.1  STARTING WITH BOOSTER CABLES......................................................131
		3.14.4   OTHER TROUBLES.........................................................................132
			3.14.4.1  ELECTRICAL CIRCUIT................................................................132
			3.14.4.2  HYDRAULIC SYSTEM..................................................................133
			3.14.4.3  ENGINE............................................................................134
MAINTENANCE.............................................................................................136
	4.1  GUIDE TO MAINTENANCE...........................................................................137
	4.2  MAINTENANCE NOTES..............................................................................139
		4.2.1  NOTES REGARDING THE ENGINE...............................................................139
			4.2.1.1  ENGINE OIL.........................................................................139
			4.2.1.2  COOLANT............................................................................139
			4.2.1.3  FUEL...............................................................................140
		4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM......................................................140
		4.2.3  NOTES REGARDING THE ELECTRICAL SYSTEM....................................................141
		4.2.4  NOTES REGARDING LUBRICATION..............................................................141
		4.2.5  PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....................................142
	4.3  FUEL, COOLANT AND LUBRICANTS...................................................................143
	4.4 NUT AND BOLT TIGHTENING TORQUES.................................................................147
		4.4.1  STANDARD TIGHTENING TORQUES..............................................................147
		4.4.2  SPECIFIC TIGHTENING TORQUES..............................................................147
	4.5  LUBRICATION....................................................................................148
		4.5.1  LUBRICATION DIAGRAM......................................................................148
	4.6  PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY......................................149
		4.6.1  CRITICAL PARTS FOR SAFETY................................................................150
	4.7  MAINTENANCE PLAN...............................................................................153
		4.7.1  WHEN REQUIRED............................................................................156
			4.7.1.a  CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTIRIDGE..........................156
			4.7.1.b  CHECKING AND CLEANING THE CAB AIR FILTER...........................................157
			4.7.1.c  WASHING THE COOLANT CIRCUIT........................................................158
			4.7.1.d  CLEANING THE WATER SEPARATOR.......................................................159
			4.7.1.e  CHECKING THE STEEL TRACK TENSION...................................................160
			4.7.1.f  CHECKING THE SHOE FASTENING........................................................162
		4.7.2  MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER............................163
			4.7.2. a  CHANGING THE HYDRAULIC OIL FILTER.................................................163
			4.7.2.b  CHANGING THE HYDRAULIC OIL.........................................................163
		4.7.3  CHECKS BEFORE STARTING...................................................................164
			4.7.3.a  VARIOUS CHECKS.....................................................................164
			4.7.3.b  CHECKINGTHE COOLANT LEVEL..........................................................164
			4.7.3.c  CHECKING THE FUEL LEVEL............................................................165
			4.7.3.d  CHECKING THE ENGINE OIL LEVEL......................................................165
			4.7.3.e  CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRUIT.....................................166
			4.7.3.f  DRAINING THE WATER SEPARATOR.......................................................167
		4.7.4  MAINTENANCE EVERY 10 HOURS OF OPERATION..................................................168
			4.7.4.a  LUBRICATING THE JOINTS.............................................................168
		4.7.5  MAINTENANCE EVERY 50 HOURS OF OPERATION..................................................171
			4.7.5.a CHECKING THE RADIATOR FLUID LEVEL...................................................171
			4.7.5.b  LUBRICATING THE SWING JOINT........................................................171
			4.7.5. c  CHECKING THE ELECTRICAL SYSTEM....................................................172
		4.7.6  MAINTENANCE EVERY 100 HOURS OF OPERATION.................................................173
			4.7.6.a  LUBRICATING THE BALL-BEARING RING..................................................173
		4.7.7  MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION.......................................174
		4.7.8  MAINTENANCE EVERY 250 HOURS OF OPERATION.................................................174
			4.7.8.a  ADJUSTING THE FAN BELT TENSION.....................................................174
			4.7.8.b  CHECKING THE BATTERY ELECTROLYTE LEVEL.............................................175
			4.7.8.c  CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS...............................175
			4.7.8.d  CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR.................................176
		4.7.9  MAINTENANCE EVERY 500 HOURS OF OPERATION.................................................177
			4.7.9.a  CHANGING THE HYDRAULIC SYSTEM OIL FILTER...........................................177
			4.7.9.b  CHANGING THE SERVO CONTROL FILTER..................................................178
			4.7.9.c  CHANGING THE ENGINE OIL............................................................179
			4.7.9.d  CHANGING THE ENGINE OIL FILTER.....................................................180
			4.7.9.e  CHANGING THE FUEL FILTER...........................................................181
			4.7.9.f  DRAINING THE FUEL TANK.............................................................182
			4.7.9.g  CLEANING THE OUTSIDE OF THE RADIATORS..............................................182
			4.7.9.h  CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL..............................183
		4.7.10  MAINTENANCE EVERY 1000 HOURS OF OPERATION...............................................184
			4.7.10.a  CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE.................................184
		4.7.11  MAINTENANCE EVERY 2000 HOURS OF OPERATION...............................................185
			4.7.11.a  CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....................................185
			4.7.11.b  CHANGING THE OIL IN THE SWING REDUCTION GEAR......................................186
			4.7.11.c  CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER.................187
			4.7.11.d  CHANGING THE COOLANT..............................................................190
			4.7.11.e  CHANGING THE BALL-BEARING RING PINOIN LUBRICANT...................................191
			4.7.11.f  CHECKING THE ALTERNATOR AND THE STARTER...........................................191
TECHNICAL DATA..........................................................................................192
	5.1  TECHNICAL DATA.................................................................................193
		5.1.1  STANDARD OVERALL DIMENSIONS..............................................................193
		5.1.2  TECHNICAL CHARACTERISTICS................................................................194
		5.1.3  LIFTING CAPACITIES.......................................................................195
			5.1.3.1  LIFTING CAPACITY TABLE.............................................................195
			5.1.3.2  LIFTING CAPACITY WITH RAISED BLADE.................................................196
			5.1.3.3  LIFTING CAPACITY WITH LOWERED BLADE................................................197
AUTHORIZED OPTIONAL EQUIPMENT...........................................................................198
	6.1  AUTHORIZED OPTIONAL EQUIPMENT..................................................................199
		6.1.1  PRECAUTIONS REGARDING SAFETY.............................................................199
		6.1.2  PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT......................................200
		6.1.3  CHARACTERISTICS OF THE OPTIONAL EQUIPMENT................................................201
	6.2  ARRANGEMENT FOR THE INSTALLATION OF THE DEMOILITION HAMMER.....................................202
		6.2.1  DESCRIPTION AND OPERATION................................................................202
		6.2.2  USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....................................202
		6.2.3  INSTALLATING AND REMOVING THE DEMOLITION HAMMER..........................................206
			6.2.3.1  INSTALLING THE HAMMER..............................................................206
			6.2.3.2  REMOVING THE HAMMER................................................................207
		6.2.4  MAINTENANCE..............................................................................207
	6.3  CLAMSHELL BUCKET...............................................................................208
		6.3.1  DESCRIPTION AND OPERATION................................................................208
		6.3.2  INSTALLING THE CLAMSHELL BUCKET..........................................................209
		6.3.3  MAINTENANCE..............................................................................211

KOMATSU PC95R-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN 21D5200001 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC95R-2 Hydraulic Excavator Operation & Maintenance Manual 

FOREWORD:

This manual is provided by Komatsu in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time. The operation manual, together with the parts book, is an integral part of the machine and must accompany it, even when it is resold, until the machines.

• The manual must be handled with the greatest care and always kept on board the machine, so that it can be consulted at any moment; it must be placed in the appropriate compartment behind the seat, where also the ownership documents and the logbook are usually kept.
• This manual must be given to the persons who use the machine and carry out the routine maintenance operations; they must read the contents carefully more than once, in such a way as to clearly understand what are the correct operating conditions and the dangerous conditions that must be avoided. In case of loss or damage of this manual, request a new copy to Komatsu or your Komatsu Dealer.
•  Komatsu machines are constantly being improved in order to increase their efficiency and reliability; this manual sums up all the information regarding the most recent techniques applied at the moment in which the machine is marketed.
• For any further or updated information, contact your Komatsu Dealer. Punctual periodic annotations regarding the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval. Therefore, consult the hour meter and the maintenance plan frequently. Over the years Komatsu Dealers have gathered considerable experience in customer service.
• If more information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the best performance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules.
• Furthermore, Komatsu Dealers also ensure their assistance for the supply of Komatsu genuine spare parts, which alone guarantee safety and interchangeability.  The table included in this manual must be filled in with the machine data, which are the data that must always be indicated to the Dealer when requiring assistance and ordering spare parts.

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]