Description

FKI FAI Komatsu Industries S.p.a PC95-1 Workshop Manual

If you are digging into a FKI FAI Komatsu Industries S.p.a PC95-1 hydraulic excavator and don’t have the factory workshop manual, you are working blind. I have seen more than a few aftermarket guides—they skip the critical steps and get the pressures wrong. This 315-page OEM document comes straight from the Italian factory (TEMAS-Gallarate, July 1996). It covers serial numbers 5000007 and up. The manual is built for a tech who wants to get the job done once, without chasing leaks or stripped threads.

Structure and Function: Inside the PC95-1 Hydraulics

Section 10 of this Workshop Manual (starting page 10-1) digs into every hydraulic component. You get the full breakdown of the main hydraulic pump, pump drive, summation horsepower control, and the 3-circuit control valve. Want to understand the Valve body for the swing motor or the center swivel joint? It is all there. The manual includes hydraulic circuit diagrams and exploded views of the final drive, track frame, idler and recoil spring, carrier and track rollers. If you need to know which port on the control valve does what, flip to the CONTROL VALVE (Ports) and CONTROL VALVE (Valve) sections. This is not a generic overview—it is the actual factory data used to build the machine.

Testing and Adjustments: 15+ Pages of Hydraulic Diagnostics

Section 20 is where you will spend most of your time. It starts with normal technical data and the equipment you need for testing. There are specific procedures for measuring engine speed, adjusting valve clearance, checking compression pressure, and bleeding air from the pumps and circuits. One of the most useful parts is the checklist for checking and regulating pressure in the hydraulic circuits. If you have a swing motor that drifts or a travel motor that pulls to one side, the manual gives you step-by-step tests: measuring travel deviation, testing for internal oil leakage, and adjusting the main safety valve of pump P4. The troubleshooting section is thorough—it lists failure modes and causes for everything from excessive travel deviation to abnormal noises in the pumps. You get a table of tests to run before you start tearing things apart.

Valve Clearance and PPC Adjustments – The Right Way

Adjusting PPC valves is something many guys mess up because they rely on feel rather than the factory clearance spec. The manual dedicates a full subsection to adjusting PPC valves clearance and centering the stroke of the blade control lever. It also covers the safety microswitch adjustment—skip that and you could have a machine that starts in gear. For the 2nd boom safety valves, there is a specific adjustment procedure to control closing speed. These tolerances matter. I have seen 10-ton excavators drop a load because someone guessed at the valve setting. Use the factory data.

3 Reasons to Choose OEM Documentation Over Aftermarket

Aftermarket manuals often copy the electrical diagrams but leave out the hydraulic circuit diagram (Engine Line, Solenoid Valve, Light Line) that this manual includes. They also tend to omit the exact torque values for the swing motor relief valve or the travel motor acceleration valve. The PC95-1 has a summation horsepower control system that interacts with the 3-circuit control valve—only the OEM manual shows how to check the intervention point. The pressure settings for the servocontrol supply units are critical, and the aftermarket stuff usually just says “adjust to spec” without telling you which port to measure. This manual gives you the actual test points.

Real-World Use Case: Diagnosing Swing Motor Drift

You are on a job site and the swing motor creeps when you release the PPC lever. The troubleshooting section (starting page 20-30) walks you through measuring internal oil leakages in the swing motor, checking the swing motor braking circuit selector valve, and testing the accumulator. It also has a dedicated analysis of hydraulic drifts with specific tests for the boom, arm, bucket, and blade. The manual tells you to check the swing circle axial clearance first—most guys jump straight to the motor rebuild and waste a day. This book saves you that time.

Maintenance Standards and Disassembly

Section 30 covers disassembly and assembly for the major components. Section 40 has the maintenance standard—wear limits, clearance specs, and rejection criteria. If you need to know the maximum allowable slop in the track roller or the idler recoil spring free length, it is in there. The manual also includes the full electrical circuit diagrams for the engine line, solenoid valve, and light line. That’s three separate diagrams, not one generic schematic.

Frequently Asked Questions

Does this manual cover the 1004-4 engine?

The manual states that the PC95-1 mounts the 1004-4 engine, but it refers you to the separate 1000 Series Engine Shop Manual for detailed engine service data. This manual covers the excavator chassis and hydraulics, not the engine overhaul.

What serial numbers does this manual apply to?

5000007 and up.

Are the torque values given in imperial units?

The manual provides torque values in metric units (Nm). You will need a conversion chart or a digital torque wrench that reads both. I always keep a conversion card in my box. The specs are factory-original, so they are reliable.

Can I use this manual for a PC95-2 or later model?

No. This manual is specifically for the PC95-1. The hydraulic system changed in later models—different pump drives and control valves. Using the wrong torque specs can crack a housing or blow a seal. Stick to the exact model.

Access the Factory Manual now and get the full 315 pages of structure, function, testing, and adjustments. No generic PDF—this is the OEM file from FKI FAI Komatsu Industries S.p.a. Pair it with related manuals like Manuel d’Atelier Tracteurs Ferguson TEF20 for the tractor side, or the IKA Workshop Manual Motor TORNADO Errata Sheet for engine corrections, and the Lister Petter TS, TR, TX Workshop Manual Edition 12 for auxiliary engine work. For broader transmission knowledge, see the Manual Transmission and Manual Transmission pages on Wikipedia. Stop guessing and start working with verified factory data.