Komatsu PC95-1 Excavator Manual
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
SHOP
MANUAL
HYDRAULIC EXCAVATOR
PC95 -1
SERIAL NUMBER
WEBMPC9500
5000007 and up
TEMAS - GALLARATE (VA) ITALY (6916GB-07/96)
This shop manual may contain attachments and optional equipment that are not
avaiable in your area.
Please consult your local FKI distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC95-1 mount the 1004-4 engine.
For detail of the engine, see the 1000 Series Engine Shop Manual.
HYDRAULIC EXCAVATOR
PC95- 1
SERIAL NUMBER
5000007 and up
FKI FAI KOMATSU INDUSTRIES S.p.A.
SEDE LEGALE: 36025 NOVENTA VICENTINA (VI) ITALY • tel. 0444/760033 • tlx. 480264 • fax 0444/861569
UFFICI E STABILIMENTO: 35042 ESTE (PD) ITALY • tel. 0429/600601 • tlx. 431396 • fax 0429/601000
SHOP
MANUAL
WEBMPC9500
CONTENTS
00-2
No. of page
10 STRUCTURE AND FUNCTION .............................................. 10-1
20 TESTING AND ADJUSTING ................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ........................................... 30-1
40 MAINTENANCE STANDARD ............................................... 40-1
Pages having no marks are those previously revised
or made additions
00-2-1
Mark Indication Action required
C Page to be newly Add
c Page to be replaced
Replace
( ) Page to be delete
Discard
LIST OF REVISED PAGES
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac-
tions be taken to these pages according to table
below.
Mark Page
Time of
revision
Mark Page
Time of
revision
Mark Page
Time of
revision
Mark Page
Time of
revision
Mark Page
Time of
revision
00-1
00-2
00-2-1
00-2-2
00-3
00-4
00-5
00-6
00-7
00-8
00-9
00-10
00-11
00-12
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
10-19
10-20
10-21
10-22
10-23
10-24
10-25
10-26
10-27
10-28
10-29
10-30
10-31
10-32
10-33
10-34
10-35
10-36
10-37
10-38
10-39
10-40
10-41
10-42
10-43
10-45
10-47
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16
20-17
20-19
20-21
20-22
20-23
20-24
20-25
20-26
20-27
20-28
20-29
20-30
20-31
20-32
20-33
20-34
20-35
20-36
20-37
20-38
20-39
20-40
20-41
20-42
20-43
20-44
20-45
20-46
20-47
20-48
20-49
20-50
20-51
20-52
20-53
20-54
20-55
20-56
20-57
20-58
20-59
20-60
20-61
20-62
20-63
20-65
20-66
20-67
20-69
20-70
20-71
20-72
20-73
20-74
20-75
20-76
20-77
20-78
20-79
20-80
20-81
20-82
20-83
20-84
20-85
20-86
20-87
30-1
30-2
30-3
30-4
30-5
30-6
30-7
30-8
30-9
30-10
30-11
30-12
30-13
30-14
30-15
30-16
30-17
30-18
30-19
30-20
30-21
30-22
30-23
30-24
30-25
30-26
30-27
30-28
30-29
30-40
30-41
30-42
30-43
30-44
30-45
30-46
30-47
30-48
30-49
30-50
30-51
30-52
30-53
30-54
30-55
30-56
30-57
30-58
30-59
30-60
30-61
30-62
30-63
30-64
30-65
30-66
30-67
30-68
30-69
00-2-2
Mark Page
Time of
revision
Mark Page
Time of
revision
Mark Page
Time of
revision
Mark Page
Time of
revision
Mark Page Time of
revision
30-70
30-71
30-72
30-73
30-74
30-75
30-76
30-77
30-78
30-79
30-80
30-81
30-82
30-83
30-84
30-85
30-86
30-87
30-88
30-89
30-90
30-91
30-92
30-93
30-94
30-95
30-96
30-97
30-98
30-99
30-100
30-101
30-102
30-103
30-104
30-105
30-106
30-107
30-108
30-109
30-110
30-111
30-112
30-113
30-114
30-115
30-116
30-117
30-118
30-119
30-120
30-121
30-122
30-123
30-124
30-125
30-126
30-127
30-128
30-129
30-130
30-131
30-132
30-133
30-134
30-135
30-136
40-1
40-2
40-3
40-4
40-5
40-6
40-7
40-8
40-9
40-10
40-11
40-12
40-13
40-14
40-15
40-16
40-17
40-18
40-19
40-20
40-21
40-22
40-23
40-24
40-25
40-26
40-27
40-28
40-29
GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
. Always wear safety glasses when hitting parts
with a hammer.
. Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the cor-
rect way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the tracks
to prevent the machine from moving.
8. Before starting work, lower blade, bucket or any
other work equipment to the ground. If this is
not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before start-
ing work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.
00-3
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by FKI and describe in this manual are both effective
and safe methods of operation. Some of these operations require the use of tools specially designed by
FKI for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this man-
ual. The cautions accompanying these symbols should always be carefully followed. If any danger arises
or may possibly arise, first consider safety, and take necessary steps to face.
SAFETY
13. Before starting work, remove the leads from the
battery. Always remove the lead from the negative
( – ) terminal first.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
When installing hoses and wires, be sure that
they will not be damaged by conctat with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.
24. Take sure when removing or installing tracks.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
00-4
00-5
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate 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 under-
standing 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.
NOTICE
The specifications contained in this shop manual are subject to change at any time without any notice.
Contact your FKI distributor for the latest information.
VOLUMES
Shop manual are issued as a guide to carry out re-
pairs. These various volumes are designed to avoid
duplicating the same information.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will
be sent to FKI distributors.
Get the most up-to-date information before you start
any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show you how to read the
page number.
Example
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num-
ber.
Fle as in the example.
Example:
10-4
10-4-1
10-4-2
10-5
] Added pages
REVISED EDITION MARK
(123 ....)
When a manual is revised, an edition mark is re-
corded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF RE-
VISED PAGES between the title page and SAFETY
page.
SYMBOLS
In order to make the shop manual greatly chelpful,
important points about safety and quality are marked
with the following symbols.
Symbol Item Remarks
Safety
Special safety precautions are ne-
cessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under inter-
nal pressure.
Caution
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems.
Caution necessary when selecting
hoisting wire, or when working
posture is important, etc.
Tightening
torque
Parts that require special attention
for the tightening torque during as-
sembly.
Coat
Parts to be coated with adhesives
and lubricants etc.
Oil, water
Places where oil, water or fuel
must be added, and their quantity.
Drain
Places where oil or water must be
drained, and quantity to be
drained.
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
00-6
Item number (10. Structure and
Function)
Consecutive page number for each
item.
10 - 3
Heavy parts (25 kg or more) must be lifted
with a hoist etc.
In the Disassembly and Assembly, section,
every part weighing 25 kg or more is clearly in-
dicated with the symbol
1. If a part cannot be smoothly removed from the
machine by hoisting, the following checks should
be made:
. Check for removal of all bolts fastening the part
to the relative parts.
. Check for any part causing interference with
the part to be removed.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table be-
low:
WIRE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
Rope diameter (mm) Allowable load (tons)
10
11.2
12.5
14
16
18
20
22.4
30
40
50
60
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
The allowable load value is estimated to be
one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of the
hook.Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-
ing, and a serious accident can result.
Hooks have maximum strenght at the middle
portion.
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the
rope, or slipping of the rope from its original
winding position on the load, which can
cause dangerous accidents.
4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles.
The table below shows the variation of allow-
able load (kg) when hoisting is made with two
ropes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
make a 120º hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150º.
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
00-7
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$41.99
Viewed 20 Times Today
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$41.99
Complete service repair manual for the Komatsu PC95-1 Excavator s/n 5000007 and up. No shipping involved, get it right away!
This shop manual contains all the information needed to perform service and repairs on the excavator. It is useful for both professional mechanics and DIY enthusiasts. Save money and fix the machine yourself!
Why get grease all over your expensive paper manual while you are working? Just print out the section you need and dispose of it when you are done. Alternatively, print entire manuals and place them in 3-ring binders for reference. These manuals are in Adobe Acrobat format and will work on a PC or Mac.
If you need a specific service manual, we most likely have it available. Just message us for assistance.
Instant delivery means no waiting for a CD to arrive via snail mail. Get it now!
*Note: High-speed internet users only. Some of the files are too large for dial-up users. If you are on dial-up, please message us first, and we will see if the file is small enough to download via a dial-up connection.
