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Komatsu PW95R-2 Hydraulic Excavator Service Repair Manual SN21D02100001 and Up PDF
Komatsu PW95R-2 Hydraulic Excavator Service Repair Manual SN21D02100001 and Up PDF
No. of page
PW95R-2
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility 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 Komatsu Utility 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
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the wheels
fully BEFORE operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read 8. Before starting work, lower outrigger, bucket or
all the precautions written on the decals which any other work equipment to the ground. If this
are suck on the machine. is not possible, use blocks to prevent the work
2. When carrying out any operation, always wear equipment from falling down. In addition, be sure
safety shoes and helmet. Do not wear loose work to lock all the control levers and hang warning
clothes, or clothes with buttons missing. sign on them.
. Always wear safety glasses when hitting parts 9. When disassembling or assembling, support the
with a hammer. machine with blocks, jacks or stands before start-
. Always wear safety glasses when grinding ing work.
parts with a grinder, etc.
10. Remove all mud and oil from the steps or other
3. If welding repairs are needed, always have a places used to get on and off the machine. Always
trained, experienced welder carry out the work. use the handrails, ladders or steps when getting
When carrying out welding work, always wear on or off the machine.
welding gloves, apron, glasses, cap and other Never jump on or off the machine.
clothes suited for welding work. If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before 11. When removing the oil filler cap, drain plug or hy-
starting work, hang UNDER REPAIR signs on draulic pressure measuring plugs, loosen them
the controls in the operator's compartment. slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the cor- Before disconnecting or removing components of
rect way to use them. the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
6. Decide a place in the repair workshop to keep cuit.
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep 12. The water and oil in the circuits are not hot when
the work area clean and make sure that there is the engine in stopped, so be careful not to get
no dirt or oil on the floor. burned.
Smoke only in the areas provided for smoking. Wait for the oil water to cool before carrying out
Never smoke while working. any work on the cooling water circuits.
PW95R-2 00-3
13. Before starting work, remove the leads from the 19. Be sure to assemble all parts again in their origi-
battery. Always remove the lead from the negative nal places. Replace any damage parts with new
( ± ) terminal first. parts.
14. When raising heavy components, use a hoist or . When installing hoses and wires, be sure that
crane. Check that the wire rope, chains and hooks they will not be damaged by contact with other
parts when the machine is being operated.
are free from damage.
Always use lifting equipment which has ample ca- 20. When installing high pressure hoses, make sure
pacity. Install the lifting equipment at the correct that they are not twisted. Damaged tubes are dan-
places. gerous, so be extremely careful when installing
Use a hoist or crane and operate slowly to prevent tubes for high pressure circuits. Also, check that
the component from hitting any other part. connecting parts are correctly tightened.
Do not work with any part still raised by the hoist
or crane. 21. When assembling or installing parts, always use
specified tightening torques.
15. When removing covers which are under internal When installing the parts which vibrate violently or
pressure or under pressure from a spring, always rotate at high speed, be particulary careful to
leave two bolts in position on opposite sides. check that they are correctly installed.
Slowly release the pressure, then slowly loosen
the bolts to remove. 22. When aligning two holes, never insert your fingers
or hand.
16. When removing components, be careful not to
break or damage the wiring. 23. When measuring hydraulic pressure, check that
Damage wiring may cause electrical fires. the measuring tool is correctly assembled before
taking any measurement.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, 24. Take sure when removing or installing tracks of in
wipe it up immediately. particular rubber tracks. When removing the
Fuel or oil on the floor can cause you to slip, or track, the track separates suddenly, so never let
can even start fires. anyone stand at either end of the wheel.
00-4 PW95R-2
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.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your Komatsu Utility distributor for the latest information.
PW95R-2 00-5
HOW TO READ THE SHOP MANUAL
VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.
REVISIONS
Revised pages are shown on the LIST OF RE-
VISED PAGES between the title page and SAFETY
page.
00-6 PW95R-2
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
WIRE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
4) Do not sling a heavy load with ropes forming a
Rope diameter (mm) Allowable load (tons) wide hanging angle from the hook.
When hoisting a load with two or more ropes,
10 1.0 the force subjected to each rope will increase
with the hanging angles.
11.2 1.4 The table below shows the variation of allow-
able load (kg) when hoisting is made with two
12.5 1.6 ropes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
14 2.2 When two ropes sling a load vertically, up to
16 2.8 2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
18 3.6 make a 120ë hanging angle.
On the other hand, two ropes are subjected to
20 4.4 an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150ë.
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0
PW95R-2 00-7
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of «Dis-
assembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
. Nm (Newton meter): 1 Nm = 0.102 kgm
00-8 PW95R-2
STANDARD TIGHTENING TORQUE
Sealing
Superficie surface
di tenuta
PW95R-2 00-9
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
00-10 PW95R-2
ELECTRIC WIRE CODE
PW95R-2 00-11
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model PW95R-2
From serial no. 21D0200001
Engine assembly 350
Radiator - exchanger 37
Hydraulic tank (without hydraulic oil) 62
Fuel tank (without fuel) 43
Revolving frame 1110
Counterweigh 1150
Swing circle 124
Swing machinery assembly 87
Main hydraulic pump ± Gear pump 97
Cabin 220
Seat 32
Seat support 14.5
Platform 51
Control valve 60
Track frame assembly 1380
Front axle 380
Rear axle + transmission 436
Travel motor 49
Wheel 8.25 - 20 79
Swivel joint 54
Axle locking cylinder 32x2
Swing bracket 230
Engine hood 36
Front hood 27
Boom 300
1st boom 292
2nd boom 195
Arm (L=1600) 134
Arm (L=1850) 155
Arm (L=2300) 198
Blade 210
Outrigger 76x2
Bracket 29x2
Outrigger support 128
Boom cylinder 117
2-piece boom cylinder 58x2
Arm cylinder 100
Bucket cylinder 89
Boom swing cylinder 90
Blade cylinder 64
Work equipment (1-piece boom version) (Bucket L=800 - Arm L=1850) 1110
Work equipment (2-piece boom version) (Bucket L=800 - Arm L=1850) 1650
00-12 PW95R-2
TABLE OF OIL AND COOLANT QUANTITIES
SAE 10W
SAE 20W-20
SAE 30
OIL
Crankcase sump 12.5 12.5
. API CD SAE 40
SAE 15W-30
SAE 15W-40
OIL
Hydraulic system SAE 10W 170 74
. API CD
Front axle: 9.0 9.0
. differential
. final drive (each) OIL 0.8 0.8
. UTTO
Rear axle FLUID 9.0 9.0
. differential
. final drive (each) 0.8 0.8
Swing OIL
SAE 80W/90 4 4
machinery . API GL5
]
Fuel tank GASOIL 125 ±
ASTM D975 N. 2
WATER+
18 ±
ANTI-FREEZE
PERMANENT
18 ±
LIQUID
] ASTM D975 N. 1
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
PW95R-2 00-13
STRUCTURE AND FUNCTION
PW95R-2 10-1
P.T.O.
1 2 3
6 5 4 RKP05340
1. Damper
2. Disc
3. Flywheel
4. Dowel
5. Hub
6. Pump
10-2 PW95R-2
POWER TRAIN
REDUCTION RATIO
Fronte macchina
Front of machine 10
Z=34 8
Z=70
Z=14
Z=27
Z=9
7 2
5
3
4
Z=51
Z=39
Z=86
Z=19
6
Z=70
Z=14
Z=27
Z=9 Z=34
9
11
RKP05680
PW95R-2 10-3
FRONT AXLE
DIFFERENTIAL
1 2 3 4 5
8 7 6
11 12
9 10
16 15 14 13
RKP05390
10-4 PW95R-2
BRAKES
A
1 2 3 a
A
Section
SezioneAA±-AA
4 5 6 7
RKP05380
PW95R-2 10-5
FINAL REDUCTION
4 5 6 7 8 9 10
11
1 2 3
12
13
14
16 15
23 22 21 20 19 18 17 RKP05370
10-6 PW95R-2
STEERING CYLINDER
A A
a 2 b
Section
Sezione B
B ±- B
B
3 4 Section AA-±AA
Sezione
RKP05320
1. Steering cylinder
2. Sensor
3. Nut
4. Pin cotter
a. Port b - From swivel joint (1a Port)
b. Port a - From ST4 solenoid valve group (T Port)
PW95R-2 10-7
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