Description

Komatsu PC95R-2 Workshop Manual – What You Get on the Bench

Komatsu PC95R-2 Workshop Manual – 338 pages of factory-engineered procedures meant to be followed, not skimmed. I’ve seen too many guys lose a swing motor because they pulled torque specs from a forum. This thing hands you the exact numbers Komatsu wrote on the line. Sheet metal, hoisting instructions, standard tightening torque – page 1 of the TOC tells you where it lives. You want to tighten a cylinder head bolt? You want to set the PC valve? This book has the step, the tool, and the sequence.

Standard Tightening Torque – Why You Need the OEM Spec

Section 10 in the TOC lists “STANDARD TIGHTENING TORQUE” and “COATING MATERIALS.” That’s where you find the base numbers for nuts, bolts, and flanges before you touch anything that sees hydraulic pressure. Aftermarket books give you a generic chart; Komatsu gives you the thread pitch, grade, and torque in ft-lbs for every fastener on the machine. If you’re pulling the final drive or the swivel joint, you look here first. Skipping it means leaks, stripped threads, or worse – a joint that comes loose under load.

Does This Manual Cover the Fuel System?

Yes, but not in a separate chapter – it’s folded into the testing sections. Under “20.TESTING AND ADJUSTMENTS” you get “MEASURING COMPRESSION PRESSURE,” “TESTING AND ADJUSTING FUEL INJECTION TIMING,” and “ADJUSTING VALVE CLEARANCE.” No, it won’t walk you through a full fuel pump rebuild, but it shows the timing procedure and the nozzle specs. For an injection pump overhaul, go to section 30 “DISASSEMBLY AND ASSEMBLY” and look for “INJECTION PUMP” and “INJECTION NOZZLE.” The manual treats the injection pump as a unit replacement – you pull it, install it, set the timing from the marks. That’s the factory approach, and it’s reliable.

7 Areas of Disassembly and Assembly

Section 30 covers major component work. You get the starter, alternator, injection pump, cylinder head, pump group, swivel joint, swing motor, control valve, track shoes, sprocket, final drive, idler, recoil spring, rollers, PPC valves, travel pedal, cylinders, and all the work equipment. The manual uses exploded diagrams and step sequences – not just pictures, but the order you break and rebuild. For example, the “CYLINDER HEAD” entry includes the head bolt tightening sequence and the torque value. That’s the stuff that keeps the head gasket from blowing after fifty hours.

Get the Right Hydraulic Pressure Settings

The testing section has a list of “SPECIAL TOOLS” you’ll need for measuring pressures. You see “CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS,” “TESTING AND SETTING OF MAIN VALVES,” and “ADJUSTING PC VALVE.” If you’ve got a PC95R-2 that’s sluggish, you don’t guess the relief valve setting – you go to the LS‑PC valve subsection. The manual gives you the pilot pressure spec, the main relief setting, and the adjustment method. You can’t fake hydraulics. You need the number, and this manual has it.

Valve Clearance Adjustment: Factory Procedure

Under “ADJUSTING VALVE CLEARANCE” the manual lists the cold clearance for intake and exhaust valves. You use a feeler gauge – no shortcuts. The section also includes “MEASURING COMPRESSION PRESSURE” right after, which tells you what to look for if the valve adjustment doesn’t fix the performance. You get the compression pressure in psi (Imperial units, as we use in North America).

Source Validity – OEM vs Aftermarket

This is a Komatsu factory document, printed from the original digital master. The cover says “SHOP MANUAL,” and the serial number range is PC95R-2 21D5200330 and up. Aftermarket manuals commonly renumber pages or leave out the safety section. This one includes every page of the original – the SAFETY foreword, the HOISTING INSTRUCTIONS, the ELECTRIC WIRE CODE. That last piece is critical when you’re chasing a short in the solenoid valve group. You trace wires using the diagram in the manual, not a photocopy that lost the color coding.

I’ve been doing this for 28 years. When I see a technician reach for an aftermarket manual, I ask them why they enjoy wasting four hours on a misprint. Genuine Komatsu documentation has the revised pages list – “LIST OF REVISED PAGES” – so you know you’re working from the latest spec. Aftermarket shops ignore that part.

FAQ

Does this manual cover the fuel injection pump rebuild?

It covers removal, installation, and timing adjustment. The manual treats the injection pump as a sealed unit – you replace it, not rebuild it internally. For internal overhaul, you’d need a dedicated injection pump manual.

What torque values are listed?

The standard tightening torque table covers common fasteners. For specific components like the cylinder head, the manual gives the torque sequence and value in the disassembly section. The table is not generic; it’s Komatsu’s own spec.

Is this the same manual the dealer uses?

Yes. The dealer shop manual is the same document. This is the factory PDF, not a scan or reprint. The TOC and content are identical to what Komatsu supplies to their service centers.

Can I use this for a PC95R-1?

No. This manual is specifically for the PC95R-2 with serial number 21D5200330 and up. The PC95R-1 uses a different engine and hydraulic system. Using this manual on a different model risk component damage or incorrect adjustments.

Related Manuals

• KOMATSU PC95R-2 Hydraulic Excavator Shop Manual
• Komatsu PC95R-2 Hydraulic Excavator Operation & Maintenance Manual
• Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual

For general background on gearboxes used in heavy equipment, see Manual Transmission and Manual Transmission.

When you need the real data – not a third-party interpretation – access the Factory Manual from AutoRepairManuals. You get the 338-page PDF, the torque specs that matter, and the confidence that every adjustment matches what Komatsu certified. No guessing. No aftermarket shortcuts. Just the file you can trust on the bench.