PDF Shop Manual Komatsu PW95R-2 Wheeled Excavator - 2 MB
This is the official shop manual for the Komatsu PW95R-2 Wheeled Excavator.
It provides professional technicians with detailed instructions for every aspect of machine service and repair.
The manual includes sections on structure, function, testing, adjusting, and troubleshooting.
With this guide, you can confidently tackle any maintenance or repair task, ensuring the excavator is serviced to factory standards.
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--- Page 3 ---
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle por-
tion.
Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and Assem-
bly section, every part weighing 25 kg or more is
clearly indicated with the symbol
1. If a part cannot be smoothly removed from the ma-
chine by hoisting, the following checks should be
made:
ā¢ Check for removal of all bolts fastening the part 3) Do not sling a heavy load with one rope alone, but
to the relative parts. sling with two or more ropes symmetrically wound
ā¢ Check for any part causing interference with on to the load.
the part to be removed. 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
2. Wire ropes load, which can cause dangerous accidents.
1) Use adequate ropes depending on the weight of 4) Do not sling a heavy load with ropes forming a wide
parts to be hoisted, referring to the table below: hanging angle from the hook.
When hoisting a load with two or more ropes, the
WIRE ROPES force subjected to each rope will increase with the
(Standard Ā«SĀ» or Ā«ZĀ» twist ropes hanging angles.
without galvanizing) The table below shows the variation of allowable
load (kg) when hoisting is made with two ropes,
Rope diameter (mm) Allowable load (tons) each of which is allowed to sling up to 1000 kg ver-
tically, at various handing angles.
10.0 1.0
When two ropes sling a load vertically, up to 2000 kg
11.2 1.4 of total weight can be suspended.
This weight becomes 1000 kg when two ropes
12.5 1.6
make a 120Ā° hanging angle.
14.0 2.2 On the other hand, two ropes are subjected to an ex-
cessive force as large as 4000 kg if they sling a 2000
16.0 2.8
kg load at a lifting angle of 150Ā°.
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 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 hoisting, and a se-
rious accident can result.
PW95R-2 00-7
--- Page 4 ---
CONVERSION TABLE
From liter to U.S. Gall.
1 = 0.2642 U.S. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
From liter to U.K. Gall.
1 = 0.21997 U.K. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
PW95R-2 00-17
--- Page 5 ---
STRUCTURE AND FUNCTION FRONT AXLE
BRAKES
A
1 2 3 a
A
Section A - A
4 5 6 7
8
RKP05381
1. Pin a. From swivel joint (7a Port)
2. Pressure disk
3. Screw
4. Disk
5. Brake disk
6. Bushing
7. Screw
8. Spring
PW95R-2 10-5
--- Page 6 ---
STRUCTURE AND FUNCTION STEERING SYSTEM
STEERING SYSTEM
4 1
3
10
9 T P
a d
5
D
A 2 (P2)
11 6 12
B C
b 7 Y2 Y14 c
R L
P B
T A
Y1 Y13
8
RKP10413
1. Engine DESCRIPTION
2. Pump (P2) ā¢ The steering system is completely hydraulic. The oil
3. Tank required, supplied by the pump (2) driven by the motor
4 Priority valve (1), is sent to the priority valve (4) which functions by
Load Sensing, and sends the necessary quantity of oil
5. Steering unit
to the steering system (5), even when other oleody-
6. Steering wheel namic components supplied by the same circuit are in
7. Swivel joint operation. The oil passes from this group (5) into the
8. ST4 Solenoid valve group: swivel joint (7) and from there into the steering cylin-
ā Y1: Rear steering cut out ders (9) and (10).
ā Y2: Front/rear steering The solenoid valve group (8) can switch the oil flow to
provide three types of steering:
ā Y13: Phase coincidence steering
1 - 2 wheels steering
ā Y14: Crab steering
Steering condition in which the rear axle is ex-
9. Front axle steering cylinder cluded.
10. Rear axle steering cylinder 2 - 2 wheels steering and 2 wheels countersteer-
11. Front axle cylinder piston ing. Steering condition in which rear steering is
12. Rear axle cylinder piston activated and the direction of the rear wheels is
contrary to that of the front wheels.
3 - 4 wheels steering in the same direction. Steer-
ing condition in which rear axle steering is acti-
vated and the direction of the rear wheels agrees
with that of the front wheels.
ā¢ The hydraulic power supplied by the pump (2) is trans-
ferred to cylinders (9) and (10) and transformed into
mechanical steering power.
PW95R-2 10-15
--- Page 7 ---
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (WORK EQUIPMENT)
HYDRAULIC CIRCUIT (WORK EQUIPMENT)
REAR OUTRIGGER AND
FRONT BLADE VERSION 4 OUTRIGGER VERSION
LEFT RIGHT LEFT RIGHT
T P T P T P T P
P1 P2 P1 P2
P2 P1 P2 P1
P1 P2 P2 P1 P1 P2 P2 P1
REAR BLADE VERSION REAR OUTRIGGER VERSION
LEFT RIGHT
T P T P
T P
PA2 P B2 P A7 P B7 PA2 PB2 PA7 PB7
P2 P1 P2
P1 P2 P1
P1 P2 P2 P1
P1 P2
A2 A7 A2 B2 A7 B7 PA2 PB2
B2 B7
PA2 PB2 PA7 PB7
FRONT BLADE FRONT OUTRIGGER
Left Right Left Right
10 2 6 10 2 6
A2 B2
A2 B2 A7 B7
C2 C1 C2 C1 C2 C1 C2 C1
10 2 6
V2 V1 V2 V1 V2 V1 V2 V1 10 2 6
V2 V1 V2 V1
C2 C3 C2 C3
P1 P1 V2 V1 V2 V1
C2 C1 C2 C1
P2 P2
Y12 Y12
C2 C1 C2 C1
C4 C1 C4 C1
V2 V1 V2 V1 V2 V1 V2 V1 Left Right
REAR BLADE
Left Right
C2 C1 C2 C1 C2 C1 C2 C1
REAR OUTRIGGER
Left Right Left Right
REAR OUTRIGGER REAR OUTRIGGER
RKP07193
PW95R-2 10-25
--- Page 8 ---
PAGE INTENTIONALLY
LEFT BLANK
--- Page 9 ---
STRUCTURE AND FUNCTION HYDRAULIC PUMP
a) Action of PC-EPC solenoid
ā¢ The command current from resistor flows to PC-
EPC solenoid (1).
This command current acts on the PC-EPC valve
and outputs the signal pressure.
When this signal pressure is received, the force
pushing piston (2) is changed.
ā¢ On the opposite side to this force pushing piston (2)
is the spring set pressure of springs (4) and (6) and
pump pressure PP pushing spool (3). Spool (3)
stops at a position where the combined force push-
ing spool (3) is balanced, and the pressure (pres-
sure of port C) output from the CP valve.
PW95R-2 10-45
--- Page 10 ---
STRUCTURE AND FUNCTION CONTROL VALVE
a. TC Port - To exchanger
b. TSW Port - To swing motor (S Port)
c. TB Port - To hydraulic tank
d. A1 Port - To swing motor (MA Port)
e. B1 Port - To swing motor (MB Port)
f. A2 Port - See hydraulic circuit
g. B2 Port - See hydraulic circuit
h. A3 Port - To swivel joint (13A Port)
i. B3 Port - To swivel joint (12A Port)
j. A4 Port - To boom cylinder (bottom side)
k. B4 Port - To boom cylinder (head side)
l. A5 Port - To arm cylinder (head side)
m. B5 Port - To arm cylinder (bottom side)
n. A6 Port - To bucket cylinder (head side)
o. B6 Port - To bucket cylinder (bottom side)
p. A7 Port - See hydraulic circuit
q. B7 Port - See hydraulic circuit
r. A8 Port - To boom swing cylinder (head side)
s. B8 Port - To boom swing cylinder (bottom side)
t. A9 Port - To 2-piece boom cylinder (head side)
u. B9 Port - To 2-piece boom cylinder (bottom side)
v. A10 Port - To attachment (L.H. side)
x. B10 Port - To attachment (R.H. side)
y. P2 Port - From priority valve (EF Port)
w. P1 Port - From servocontrol unit (P2 Port) and to pump (PB Port)
aa. PLS Port - To hydraulic pump (PLS Port)
xx. TS Port - To hydraulic tank
Pa. PA1 Port - From L.H. PPC valve (P2 Port)
Pb. PB1 Port - From L.H. PPC valve (P4 Port)
Pc. PA2 Port - See hydraulic circuit
Pd. PB2 Port - See hydraulic circuit
Pe. PA3 Port - From ST3 solenoid valve group (A Port)
Pf. PB3 Port - From ST3 solenoid valve group (B Port)
Pg. PA4 Port - From R.H. PPC valve (P4 Port)
Ph. PB4 Port - From R.H. PPC valve (P2 Port)
Pi. PA5 Port - From L.H. PPC valve (P3 Port)
Pj. PB5 Port - From L.H. PPC valve (P1 Port)
Pk. PA6 Port - From R.H. PPC valve (P3 Port)
Pl. PB6 Port - From R.H. PPC valve (P1 Port)
Pm. PA7 Port - See hydraulic circuit
Pn. PB7 Port - See hydraulic circuit
Po. PA8 Port - From boom swing PPC valve (P1 Port)
Pp. PB8 Port - From boom swing PPC valve (P2 Port)
Pq. PA9 Port - From 2-piece boom PPC valve (P2 Port)
Pr. PB9 Port - From 2-piece boom PPC valve (P1 Port)
Ps. PA10 Port - From OP2 solenoid valve group (B Port)
Pt. PB10 Port - From OP2 solenoid valve group (A Port)
Pu. PDB Port - From PA4 Port
PW95R-2 10-55
--- Page 11 ---
STRUCTURE AND FUNCTION 2-PIECE BOOM VALVE - ATTACHMENT VALVE
1 2
3
5 4
RKP03231
Section N-N
6 7
8
10 9
RKP03241
Section O-O
11
RKP03251
Section P-P
2-PIECE BOOM VALVE ATTACHMENT VALVE
1. Suction valve (A9 Port) 6. Safety valve (R.H. side)
2. Suction valve (B9 Port) 7. Safety valve (L.H. side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve
11. Unload valve
PW95R-2 10-65
--- Page 12 ---
STRUCTURE AND FUNCTION CONTROL VALVE
LS bypass plug
DESCRIPTION
1 - The LS bypass plug releases the residual pressure of the LS pressure PLS.
2 - This makes the pressure-rising speed of the LS pressure PLS more gentle, and with this discarded throttled flow, it
creases a pressure loss in the throttled amount of the spool or shuttle valve and increases the stability to lowering the
effective LS differential pressure.
1 T
b
a
PLS
RKP03010
OPERATION
ā¢ The pressurized oil in the LS circuit PLS flows from the clearance filter a, which is formed by the clearance between
the LS bypass plug (1) and the body, to the tank circuit T through the orifice b.
PW95R-2 10-75
--- Page 13 ---
STRUCTURE AND FUNCTION SWING MOTOR
OPERATION OF THE MODULATING RELIEF VALVE
FUNCTION
ā¢ The relief valve for the swing motor has the prop- Modulating relief valve
erties to suppress the rapid increase of the relief P Normal relief valve
pressure as per shown in the figure right, and serves
P2
to reduce the shock at the time of start and stop of
swing.
P1
P0
t
T
RKP11970
OPERATION
When the circuit pressure is P0 1 2 a 3 4 5
ā¢ The relief valve does not operate.
When the circuit pressure has rapidly increased
ā¢ When the circuit pressure increases to P1, the valve P
(3) starts to open bacause the oil pressure acts on
the difference in area between D1 and D3 (D1>D3),
thus pressing the spring (4). D2 D1 D3
On this occasion, the seat (1) tries to follow the valve
(3) because the pressure acts on the difference in S
area between D1 and D2 (D1<D2).
However, the route that the oil in the chamber a
compressed by the movement of the seat (1) can
flow to the S port has been throttled by the ball (2),
P1
so that the movement of the seat (1) is slower than P2
that of the valve (3).
Therefore, during the time T until the seat (1) makes
contact with the sleeve (5), the relief pressure grad-
ually increases from P1 to P2
S
P2
S RKP11960
PW95R-2 10-85
--- Page 14 ---
PAGE INTENTIONALLY
LEFT BLANK
--- Page 15 ---
STRUCTURE AND FUNCTION PPC VALVES
3. During fine control
(when the lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at Port P1. 5
When this happens, fine control hole f is connected
4
to drain chamber D and the pressure oil at Port P1 is
released.
If the pressure at Port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con- 7 D
trol hole f is shut off from drain chamber D. At almost
the same time, it is connected to pump pressure 2
T
chamber PP, and the pump pressure is supplied un-
til the pressure at Port P1 recovers to a pressure that 1
corresponds to the lever position.
f
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f' in f'
PP
the valve on the side that is not working. The oil P1 P P2
passes through Port P2 and enters chamber B to fill
the chamber with oil. (Fig. 3)
4. At full stroke A Control valve
B
When disc (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut Fig. 3
RKP12861
off from drain chamber D, and is connected with
pump pressure chamber PP. Therefore, the pilot
pressure from the control pump passes through fine
control hole f and flows to chamber A from Port P1,
and pushes the control valve spool.
The oil returning from chamber B passes from Port
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4). 5
4
7 D
2
T
1
f
PP
P1 P P2
A Control valve
B