Komatsu PC95R-2 Hydraulic Excavator Shop Manual SN 21D5210001, 21D5220001 and up – PDF DOWNLOAD

Description

Komatsu PC95R-2 Hydraulic Excavator Shop Manual

FILE DETAILS:

Komatsu PC95R-2 Hydraulic Excavator Shop Manual 

Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC95R-2
Serial Number: 21D5210001 and up, 21D5220001 and up
Book Code: WEBM001702
Language: English
Pages: 366
File Format: Portable Document Format (PDF)

KOMATSU PC95R-2 HYDRAULIC EXCAVATOR SHOP MANUAL SN 21D5210001, 21D5220001 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC95R-2 Hydraulic Excavator Shop Manual 

FOREWORD:

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

10.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.
20.TESTING AND ADJUSTING:
This section 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 thissection.
30.DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
40.MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu PC95R-2 Hydraulic Excavator Shop Manual 

COVER.........................................................................  1
	CONTENTS..................................................................  3
	REVISED PAGES.............................................................  5
	SAFETY....................................................................  7
	FOREWORD..................................................................  9
	HOW TO READ THE SHOP MANUAL............................................... 10
	HOISTING INSTRUCTIONS..................................................... 11
	STANDARD TIGHTENING TORQUE................................................ 12
	COATING MATERIALS......................................................... 14
	ELECTRIC WIRE CODE........................................................ 15
	WEIGHT TABLE.............................................................. 16
	TABLE OF OIL AND COOLANT QUANTITIES....................................... 17
	CONVERSION TABLE.......................................................... 19
	10.STRUCTURE AND FUNCTION................................................. 27
		P.T.O................................................................. 28
		POWER TRAIN........................................................... 29
		TRACK FRAME........................................................... 31
		IDLER AND RECOIL SPRING............................................... 32
		CARRIER ROLLER - TRACK ROLLER......................................... 33
		TRACK SHOE............................................................ 34
		SWING CIRCLE.......................................................... 35
		SWING MACHINERY....................................................... 36
		FINAL DRIVE........................................................... 37
		HYDRAULIC DIAGRAM STANDARD............................................ 39
		HYDRAULIC DIAGRAM WITH 2-PIECE BOOM................................... 41
		HYDRAULIC PUMP........................................................ 42
		9-SPOOL CONTROL VALVE (STANDARD)...................................... 68
		10-SPOOL CONTROL VALVE (STANDARD 2-PIECE BOOM)........................ 70
		CONTROL VALVE......................................................... 72
		BLADE VALVE........................................................... 77
		L.H. AND R.H. TRAVEL VALVE BOOM VALVE................................. 78
		ARM VALVE BUCKET VALVE................................................ 79
		BOOM SWING VALVE (2-PIECE BOOM VALVE) ATTACHMENT VALVE................ 80
		CONTROL VALVE......................................................... 81
		SWING MOTOR........................................................... 98
		SWIVEL JOINT..........................................................104
		TRAVEL MOTOR..........................................................106
		CYLINDERS.............................................................108
		2-PIECE BOOM..........................................................109
		SERVOCONTROL FEED UNIT................................................110
		ACCUMULATOR...........................................................115
		SHUTTLE VALVE.........................................................116
		PPC VALVE.............................................................117
		BOOM AND ARM SAFETY VALVE.............................................127
		BLADE SAFETY VALVE....................................................128
		2-PIECE BOOM SAFETY VALVE.............................................129
		OVERLOAD SENSOR SWITCH................................................130
		SOLENOID VALVES.......................................................131
		AIR-CONDITIONING UNIT.................................................133
		ELECTRICAL DIAGRAM (1/5)..............................................135
		ELECTRICAL DIAGRAM (2/5)..............................................137
		ELECTRICAL DIAGRAM (3/5)..............................................139
		ELECTRICAL DIAGRAM (4/5)..............................................141
		ELECTRICAL DIAGRAM (5/5)..............................................143
	20.TESTING AND ADJUSTMENTS................................................145
		NORMAL OR STANDARD TECHNICAL DATA.....................................146
		SPECIAL TOOLS.........................................................160
		MEASURING THE ENGINE SPEED............................................161
		ADJUSTING VALVE CLEARANCE.............................................162
		MEASURING COMPRESSION PRESSURE........................................163
		TESTING AND ADJUSTING FUEL INJECTION TIMING...........................164
		TESTING AND ADJUSTING FAN BELT TENSION................................166
		CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT.......................167
		ADJUSTING THE STROKE OF THE ACCELERATOR LEVER.........................168
		ADJUSTING THE SAFETY MICROSWITCH......................................169
		MEASURING THE SWING CIRCLE AXIAL CLEARANCE............................170
		TESTING AND ADJUSTING TRACK-SHOE TENSION..............................171
		AIR BLEEDING FROM HYDRAULIC CIRCUITS..................................172
		RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS.........................174
		CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS............175
		TESTING AND SETTING OF MAIN VALVES....................................176
		ADJUSTING PC VALVE....................................................178
		MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE.............179
		CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL FEED UNIT........181
		MEASURING PUMPS DELIVERY AND FLOW CONTROL STARTING POINT PUMP P1......182
		MEASURING TRAVEL DEVIATION............................................183
		ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS......................184
		MEASURING INNER OIL LEAKAGE OF TRAVEL MOTOR...........................185
		ADJUSTING BOOM AND ARM SAFETY VALVES..................................186
		ADJUSTING 2nd BOOM SAFETY VALVES......................................187
		MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL OVERLOAD OPERATION....188
		MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR...............189
		CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT.........................190
		ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS............................192
		TESTING THE AIR-CONDITIONING UNIT.....................................199
		EMPTYING THE AIR-CONDITIONING UNIT....................................201
	30.REMOVAL AND INSTALLATION...............................................203
		HOW TO READ THE MANUAL................................................205
		PRECAUTIONS TO BE TAKEN WHEN WORKING..................................206
		SPECIAL TOOLS.........................................................207
		STARTER MOTOR.........................................................209
		ALTERNATOR............................................................210
		AIR-CONDITIONING UNIT COMPRESSOR......................................211
		INJECTION PUMP........................................................213
		INJECTION NOZZLE......................................................217
		THERMOSTAT............................................................218
		MUFFLER...............................................................219
		CYLINDER HEAD.........................................................220
		SEAT..................................................................224
		CABIN.................................................................225
		ENGINE HOOD...........................................................228
		CONDENSER UNIT........................................................229
		FRONT HOOD............................................................231
		HEATING FAN UNIT......................................................232
		AIR CONIDTIONING FAN UNIT.............................................234
		RADIATOR..............................................................237
		FUEL TANK.............................................................239
		HYDRAULIC OIL TANK....................................................241
		ENGINE-PUMP GROUP.....................................................243
		PUMP GROUP............................................................246
		ENGINE-PUMP COUPLING JOINT............................................247
		GEAR-PUMP.............................................................248
		SWIVEL JOINT..........................................................249
		SWING MOTOR...........................................................250
		SWING MACHINERY.......................................................251
		CONTROL VALVE.........................................................267
		REVOLVING FRAME.......................................................268
		COUNTERWEIGHT.........................................................270
		SWING CIRCLE..........................................................271
		TRACK SHOES...........................................................272
		SPROCKET ASSEMBLY.....................................................273
		FINAL DRIVE...........................................................274
		IDLER AND RECOIL SPRING ASSEMBLY......................................287
		IDLER.................................................................288
		RECOIL SPRING GROUP AND CYLINDER......................................289
		TRACK ROLLER..........................................................290
		CARRIER ROLLER........................................................291
		R.H. PPC VALVE (BOOM-BUCKET)..........................................292
		L.H. PPC VALVE (ARM-SWING)............................................294
		BLADE PPC VALVE.......................................................296
		TRAVEL PEDAL CONTROL..................................................297
		BOOM SWING PEDAL CONTROL..............................................298
		1st BOOM PEDAL CONTROL................................................299
		BOOM CYLINDER (For 1-piece boom)......................................300
		BOOM CYLINDER (For 2-piece boom)......................................301
		2nd BOOM CYLINDERS....................................................303
		ARM CYLINDER..........................................................305
		BUCKET CYLINDER.......................................................306
		BOOM SWING CYLINDER...................................................307
		BLADE CYLINDER........................................................308
		WORK EQUIPMENT CYLINDERS..............................................309
		WORK EQUIPMENT (For 1-piece boom).....................................314
		WORK EQUIPMENT (For 2-piece boom).....................................315
		BUCKET................................................................317
		ARM...................................................................318
		2nd BOOM..............................................................321
		BOOM (For 1-piece boom)...............................................323
		BOOM (For 2-piece boom)...............................................324
		SWING SUPPORT.........................................................326
		BLADE.................................................................327
	40.STANDARD MAINTENANCE...................................................329
		P.T.O.................................................................330
		SWING CIRCLE..........................................................331
		TRACK FRAME...........................................................332
		IDLER.................................................................333
		CARRIER ROLLER........................................................334
		TRACK ROLLER..........................................................335
		TRACK SHOE............................................................336
		SPROCKET..............................................................337
		SWING MACHINERY.......................................................338
		FINAL DRIVE...........................................................340
		HYDRAULIC PUMP........................................................341
		CONTROL VALVE.........................................................342
		SWING MOTOR...........................................................351
		SWIVEL JOINT..........................................................352
		TRAVEL MOTOR..........................................................353
		SERVOCONTROL FEED UNIT................................................355
		PPC VALVES............................................................356
		SAFETY VALVE..........................................................358
		CYLINDERS.............................................................360
		WORK EQUIPMENT........................................................362

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]