Komatsu PW95R-2 Hydraulic Excavator Operation & Maintenance Manual SN 21D0220354 And Up – PDF DOWNLOAD

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Komatsu PW95R-2 Hydraulic Excavator Operation & Maintenance Manual

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Komatsu PW95R-2 Hydraulic Excavator Operation & Maintenance Manual

Model Specification: KOMATSU PW95R-2 Hydraulic Excavator
Language: English
File Format: PDF
Total Pages: 238
Requirements: Adobe PDF Reader
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KOMATSU PW95R-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN 21D0220354 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu PW95R-2 Hydraulic Excavator Operation & Maintenance Manual

FOREWORD:

• This manual is supplied by Komatsu in order to provide 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 spare parts catalog, is an integral part of the machine and must accompany it, even when it is resold, until its final disposal.
• 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, where also the ownership documents and the logbook are usually kept.
• This manual must be given to the persons who have to 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, request a new copy to Komatsu or to your Komatsu Distributor.
• The illustrations contained in this manual may represent machine configurations that are available on request. Komatsu machines are constantly 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 updated information, contact your Komatsu Distributor.
• 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, it is advisable to consult either the hour meter and the maintenance plan frequently.
• Over the years Komatsu Distributors have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu Distributor: 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 Distributors 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 Dsrtibutor when requiring assistance and ordering spare parts.

TABLE OF CONTENTS:

Komatsu PW95R-2 Hydraulic Excavator Operation & Maintenance Manual

MAIN MENU.......................................................................................................  0
COVER...........................................................................................................  1
1. FORWARD......................................................................................................  4
2. SAFETY INFORMATION...........................................................................................  5
3. INTRODUCTION.................................................................................................  6
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................  7
5. CONTENTS.....................................................................................................  8
SAFETY.......................................................................................................... 12
	6. GENERAL PRECAUTIONS...................................................................................... 13
	7. PRECAUTIONS DURING OPERATION............................................................................. 18
		7.1 BEFORE STARTING ENGINE.............................................................................. 18
		7.2 AFTER STARTING ENGINE............................................................................... 20
		7.3 TRANSPORTATION...................................................................................... 26
		7.4 BATTERY............................................................................................. 27
		7.5 TOWING.............................................................................................. 29
	8. PRECAUTIONS FOR MAINTENANCE.............................................................................. 30
		8.1 BEFORE CARRYING OUT MAINTENANCE..................................................................... 30
		8.2 DURING MAINTENANCE.................................................................................. 34
	9. POSITION FOR ATTACHING SAFETY LABELS..................................................................... 39
		9.1 POSITION FOR ATTACHING SAFETY LABELS................................................................ 39
OPERATION....................................................................................................... 42
	10. GENERAL VIEW............................................................................................ 43
		10.1 GENERAL VIEW OF MACHINE............................................................................ 43
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................................ 44
	11. EXPLANATION OF COMPONENTS............................................................................... 47
		11.1 FRONT PANEL (METERS, LAMPS, SWITCHES).............................................................. 48
		11.2 SWITCHES........................................................................................... 61
		11.3 CONTROL LEVERS, PEDALS............................................................................. 64
		11.4 FUSE BOX........................................................................................... 71
		11.5 POWER PICKUP CONNECTORS............................................................................ 72
		11.6 GREASE PUMP HOLDER................................................................................. 73
		11.7 SHOVEL HOLDER...................................................................................... 73
		11.8 DOOR-OPEN LOCK (MACHINES EQUIPPED WITH CAB)........................................................ 73
		11.9 SASH GLASS INTERMEDIATE LOCK (MACHINES EQUIPPED WITH CAB).......................................... 74
		11.10 CAP WITH LOCK (VANDALISM -PROOF MACHINES)......................................................... 74
		11.11 HOT AND COOL BOX (MACHINES EQUIPPED WITH CAB)..................................................... 75
		11.12 DOOR POCKET (MACHINES EQUIPPED WITH CAB).......................................................... 75
		11.13 ASHTRAY (MACHINES EQUIPPED WITH CAB).............................................................. 75
		11.14 TOOL BOX.......................................................................................... 75
		11.15 USING CAR RADIO (MACHINES EQUIPPED WITH CAB, CAB RADIO)........................................... 76
		11.16 HANDLING AIR CONDITIONER (MACHINES EQUIPPED WITH CAB)............................................. 80
		11.17 HANDLING HEATER (MACHINES EQUIPPED WITH CAB)...................................................... 84
	12. OPERATION............................................................................................... 85
		12.1 CHECK BEFORE STARTING ENGINE....................................................................... 85
		12.2 STARTING ENGINE.................................................................................... 97
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................................103
		12.4 MOVING MACHINE.....................................................................................105
		12.5 SHIFTING GEAR......................................................................................106
		12.6 SHIFTING BETWEEN FORWARD AND REVERSE...............................................................107
		12.7 STEERING MACHINE...................................................................................108
		12.8 STOPPING MACHINE...................................................................................110
		12.9 PRECAUTIONS FOR OPERATION..........................................................................111
		12.10 PARKING MACHINE...................................................................................113
		12.11 CHECK AFTER FINISHING WORK........................................................................114
		12.12 STOPPING ENGINE...................................................................................115
		12.13 CHECK AFTER STOPPING ENGINE.......................................................................116
		12.14 LOCKING...........................................................................................116
		12.15 WORK POSSIBLE USING BULLDOZER.....................................................................117
		12.16 ADJUSTING POSTURE OF WORK EQUIPMENT...............................................................118
		12.17 TIPS FOR LONGER UNDERCARRIAGE LIFE................................................................121
	13. TRANSPORTATION..........................................................................................124
		13.1 LOADING, UNLOADING WORK............................................................................124
		13.2 PRECAUTIONS FOR LOADING AND SECURING THE MACHINE...................................................125
		13.3 PRECAUTIONS FOR TRANSPORTATION.....................................................................126
		13.4 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT...........................................................126
		13.5 REMOVING CAB (MACHINES EQUIPPED WITH CAB)..........................................................126
		13.6 LIFTING THE MACHINE................................................................................127
	14. COLD WEATHER OPERATION..................................................................................130
		14.1 PRECAUTIONS FOR LOW TEMPERATURE....................................................................130
		14.2 AFTER COMPLETION OF WORK...........................................................................132
		14.3 AFTER COLD WEATHER.................................................................................132
	15. LONG-TERM STORAGE.......................................................................................133
		15.1 BEFORE STORAGE.....................................................................................133
		15.2 DURING STORAGE.....................................................................................133
		15.3 AFTER STORAGE......................................................................................133
	16. TROUBLESHOOTING.........................................................................................134
		16.1 AFTER RUNNING OUT OF FUEL..........................................................................134
		16.2 IF BATTERY IS DISCHARGED...........................................................................134
		16.3 OTHER TROUBLE......................................................................................137
MAINTENANCE.....................................................................................................142
	17. GUIDES TO MAINTENANCE...................................................................................142
	18. OUTLINES OF SERVICE.....................................................................................146
		18.1 OUTLINE OF OIL, FUEL, COOLANT......................................................................146
		18.2 RELATING TO ELECTRIC SYSTEM........................................................................148
	19. WEAR PARTS LIST.........................................................................................149
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................................151
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................................................155
		21.1 INTRODUCTION OF NECESSARY TOOLS....................................................................155
		21.2 TORQUE LIST........................................................................................156
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................................................157
	23. MAINTENANCE SCHEDULE CHART..............................................................................159
	24. SERVICE PROCEDURE.......................................................................................162
		24.1 WHEN REQUIRED......................................................................................162
			CLEAN INSIDE OF COOLING SYSTEM......................................................................162
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT........................................................166
			CHECK TRACK TENSION.................................................................................168
			CHECK AND TIGHTEN TRACK SHOE BOLTS..................................................................170
			CHECK ELECTRICAL INTAKE AIR HEATER..................................................................170
			REVERSE AND REPLACE THE END BITS AND CUTTING EDGES..................................................171
			CLEAN, CHECK RADIATOR FINS..........................................................................173
			ADJUST IDLER CLEARANCE..............................................................................174
			 ADJUSTING TENSION OF CENTER BRACE (POWER TILT, POWER PITCH DOZER ONLY).............................175
			CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINES EQUIPPED WITH CAB).................176
			CHECK, ADJUST AIR CONDITIONER (MACHINES EQUIPPED WITH CAB)..........................................177
			GREASE DOOR HINGE (MACHINES EQUIPPED WITH CAB)......................................................177
			CHECK DOOR LOCK STRIKER (MACHINES EQUIPPED WITH CAB)................................................177
			REPLACE DOOR DAMPER (MACHINES EQUIPPED WITH CAB)....................................................178
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (MACHINES EQUIPPED WITH CAB).............................178
			BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER (POWER TILT, POWER PITCH DOZER ONLY)................178
			REPLACE WIPER BLADE (MACHINES EQUIPPED WITH CAB)....................................................179
			CHECK IDLER OIL LEVEL, ADD OIL......................................................................180
			CHECK OIL LEVEL IN DAMPER CASE, ADD AND CHANGE OIL..................................................181
		24.2 CHECK BEFORE STARTING..............................................................................183
			CHECK COOLANT LEVEL, ADD WATER......................................................................183
			CHECKING WITH MACHINE MONITOR (MONITOR PANEL SPECIFICATION).........................................183
			CHECK FUEL LEVEL, ADD FUEL (MONITOR PANEL SPECIFICATION)............................................184
			CHECK FUEL LEVEL, ADD FUEL (GAUGE PANEL SPECIFICATION)..............................................184
			CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL..........................................................185
			CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL........................................................185
			CHECK BRAKE PEDAL TRAVEL............................................................................186
			CHECK DUST INDICATOR................................................................................186
			CHECK THAT LAMPS LIGHT UP...........................................................................186
			CHECK HORN SOUND....................................................................................186
			CHECK BACKUP ALARM SOUND (OPTION)...................................................................187
			CHECK SEAT BELT FOR WEAR OR DAMAGE (OPTION).........................................................187
			CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER........................................187
		24.3 EVERY 50 HOURS SERVICE.............................................................................188
			DRAIN WATER, SEDIMENT FROM FUEL TANK................................................................188
		24.4 EVERY 250 HOURS SERVICE............................................................................189
			LUBRICATING.........................................................................................189
				(POWER TILT DOZER)..............................................................................189
					LIFT CYLINDER SUPPORT YOKE (4 PLACES).......................................................189
					LIFT CYLINDER SUPPORT SHAFT (2 PLACES)......................................................189
					LIFT CYLINDER BALL JOINT (2 PLACES).........................................................189
					TILT CYLINDER BALL JOINT (1 PLACE)..........................................................189
					TILT BRACE BALL JOINT (1 PLACE).............................................................189
					BRACE BALL JOINT (2 PLACES).................................................................189
					TILT BRACE THREAD (1 PLACE) (SCREW-ADJUSTABLE)..............................................189
				(POWER TILT-POWER PITCH DOZER)..................................................................190
					LIFT CYLINDER SUPPORT YOKE (4 PLACES).......................................................190
					LIFT CYLINDER SUPPORT SHAFT (2 PLACES)......................................................190
					LIFT CYLINDER BALL JOINT (2 PLACES).........................................................190
					TILT CYLINDER BALL JOINT (1 PLACE)..........................................................190
					PITCH CYLINDER BALL JOINT (1 PLACE).........................................................190
					BRACE BALL JOINT (2 PLACES).................................................................190
				ANGLEDOZER......................................................................................191
					LIFT CYLINDER SUPPORT YOKE (4 PLACES).......................................................191
					LIFT CYLINDER SUPPORT SHAFT (2 PLACES)......................................................191
					LIFT CYLINDER BALL JOINT (2 PLACES).........................................................191
					TILT BRACE BALL JOINT (2 PLACES)............................................................191
					TILT BRACE THREAD (2 PLACES)................................................................191
				GREASE EQUALIZER BAR SIDE PIN (4 PLACES)........................................................192
				GREASE EQUALIZER BAR CENTER PIN (1 PLACE).......................................................192
				CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....................................................193
				CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL......................................................193
				CHECK LEVEL OF BATTERY ELECTROLYTE..............................................................194
				CHECK FAN BELT TENSION, ADJUST..................................................................195
				DRAIN WATER AND SEDIMENT FROM FUEL FILTER.......................................................196
				CHECK, CLEAN ADDITIONAL FUEL STRAINER...........................................................196
				REPLACE POWER TRAIN OIL FILTER ELEMENT..........................................................197
				CHECK BRAKE PERFORMANCE.........................................................................198
		24.5 EVERY 500 HOURS SERVICE............................................................................199
			REPLACE FUEL FILTER CARTRIDGE.......................................................................199
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...................................201
		24.6 EVERY 1000 HOURS SERVICE...........................................................................203
			CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER)....203
			CHANGE OIL IN FINAL DRIVE CASE (TRANSMISSION).......................................................205
			CLEAN BREATHER (1 PLACE)............................................................................206
			GREASE UNIVERSAL JOINT (2 PLACES)...................................................................206
			REPLACE CORROSION RESISTOR CARTRIDGE (D65P ONLY)....................................................207
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER (D65P ONLY)..............................................207
			CHECK PLAY OF TURBOCHARGER ROTOR (D65P ONLY)........................................................207
			CHECK FOR LOOSE ROPS MOUNT BOLTS....................................................................207
		24.7 EVERY 2000 HOURS SERVICE...........................................................................208
			CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT..................................208
			CLEAN, CHECK TURBOCHARGER (D65P ONLY)...............................................................210
			CLEAN ENGINE BREATHER ELEMENT.......................................................................210
			CHECK VIBRATION DAMPER..............................................................................210
			CHECK ALTERNATOR, STARTING MOTOR....................................................................210
			CHECK ENGINE VALVE CLEARANCE, ADJUST................................................................210
		24.8 EVERY 4000 HOURS SERVICE...........................................................................211
			CHECK WATER PUMP....................................................................................211
SPECIFICATIONS..................................................................................................212
	25. SPECIFICATIONS..........................................................................................213
OPTIONS, ATTACHMENTS............................................................................................218
	26. GENERAL PRECAUTIONS.....................................................................................219
		26.1 PRECAUTIONS RELATED TO SAFETY......................................................................219
	27. USING SEAT BELT.........................................................................................220
		27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER..............................................220
		27.2 ADJUST THE BELT LENGTH IN THE FOLLOWING MANNER.....................................................221
	28. HANDLING DELUXE SEAT....................................................................................222
	29. HANDLING ACCUMULATOR....................................................................................224
		29.1 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR.............224
	30. EQUIPPING THE FIRE EXTINGUISHER AND THE FIRST-AID KIT...................................................225

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]