Komatsu printed WEBMPW9500 as the factory shop manual for its PW95-1 hydraulic excavator, and this 440-page Komatsu PW95-1 shop manual PDF is that book, reproduced in full. Hydraulic schematics trace oil from the main pump through the control valve, swing motor relief valve and PPC circuits, while wiring diagrams map harness routing across the electrical system. Testing and Adjusting takes a solid share of the book and walks you through engine speed, valve clearance, compression pressure, steering and travel motor checks; the Maintenance Standard section then sets wear limits for work equipment cylinders, axles and swing machinery. Confirm main pump output at 28 cc/rev maximum displacement, with the check valve rated at 2 bar and the by-pass valve at 3 bar. One wrong relief setting means a second teardown. Once bought, the file is yours: search the text, jump between bookmarked sections, and keep it for as long as the PW95-1 stays in your fleet.
What's Inside This Komatsu PW95-1 Manual
| System | Pages | Key Topics |
|---|---|---|
| Structure and Function | 17-77 | Power Train, Transmission, Front Axle Differential, Rear Axle Differential, Steering System, Main Hydraulic Pump |
| Disassembly and Assembly | 78-92 | Starter Motor, Alternator, Nozzle Holder, Air Filter Group, Muffler, Engine Hood, Fixed Hood |
| Testing and Adjusting | 93-111 | Engine Speed, Valve Clearance, Compression Pressure, Hydraulic Circuits, Steering System, Travel Motor |
| Power Train and Axles | 112-119 | P.T.O., Transmission, Differential, Axles, Steering Cylinder |
| Braking and Swing Systems | 120-123 | Parking Brake, Swing Circle, Swing Machinery, Check Valve, Oil Cooler Safety By-Pass |
| Hydraulic System Components | 124-138 | Pump Drive, Summation Horsepower Control, Mode-System, Auxiliary Pump, Control Valve, Swing Motor Relief Valve |
| Travel and Steering Components | 139-144 | Travel Motor, Travel Motor Brake Valves, Servocontrol Feed Unit, Axle Locking Valve, PPC Valves |
| Testing and Adjustments | 145-172 | Checking Wear in the Brake Disks, Adjusting the Parking Brake, Checking the Hydraulic Travel System, Analysis of the Causes of Hydraulic Drifts |
| Troubleshooting | 173-224 | Troubleshooting the Electrical System, Troubleshooting the Hydraulic System |
| Disassembly and Assembly | 225-345 | Starter Motor, Hydraulic Pump, Swing Machinery, Travel Motor, Steering Unit, Axle-Locking Cylinder |
| Complete Front Axle | 346-382 | Complete Rear Axle |
| Work Equipment Cylinders | 383-405 | Removal of Arm, Removal of Boom, Blade and Outriggers |
| Maintenance Standard | 406-440 | Transmission, Steering Cylinder, Swing Circle, Boom Swing PPC Valve, Outrigger and Blade PPC Valves, Axle Locking Cylinder |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Current rating for 0.35 nominal number wire | 3.5 A | |
| Current rating for 0.5 nominal number wire | 6 A | p. 14 |
| Check valve (4) rated pressure | 2 bar | p. 37 |
| By-pass valve (3) rated pressure | 3 bar | p. 37 |
| Main hydraulic pump max. unitary displacement | 28 cc/rev | p. 39 |
| Main hydraulic pump max. power at 2000 rpm | 44 kW | p. 39 |
| Axle locking valve pilot pressure | 3 bar | p. 70 |
| Steering system cap torque | 50 ± 10 Nm | p. 138 |
| Articulation rotation torque | 15-17 Nm | p. 411 |
| Servocontrol pressure | 35 ± 3.5 bar | p. 96 |
| Safety screws torque | 10 ± 1 kgm (98 ± 9.8 Nm) | p. 386 |
| Flange blocking screws torque | 5 ± 0.5 kgm (49 ± 5 Nm) | p. 387 |
Komatsu PW95-1 Common Problems This Manual Covers
Komatsu PW95-1 work equipment, revolving frame swing and travel mechanisms all function intermittently during operation
Check that servocontrol pressure holds steady at 35 ± 3.5 bar using the chart on page 200, and verify accumulator pre-load at 12 ± 1 bar; recharge or replace the accumulator if it is low. Bleed air from the servocontrol circuits, test solenoid valve EV4, then check for seized control valve spools. Never open hydraulic components for internal inspection in dust, rain or wind (page 175).
Manual Section: Hydraulic System Troubleshooting p. 200Swing motor and swing machinery check: revolving frame swing speed is slow in both directions
Verify the secondary valve adjustment at 190/160 ± 5 bar following page 201, and confirm servocontrol pressure reaches the swing machinery brake. Measure swing motor leakage; above 1300 cc/min, replace the motor. Check the 3rd section main safety valve setting of 200 ± 5 bar. If still slow, invert P2 and P3 deliveries on the control valve to check pump P3.
Manual Section: Hydraulic System Troubleshooting p. 201Revolving frame swing slow in one direction and not braking properly on that side
Check whether the fault switches sides when you invert the tubes on the control valve (page 202); if it does, invert the anticavitation valves on the control valve: if the fault remains, repair or replace the control valve; if it goes away, replace the anticavitation valves. If inverting the tubes does not move the fault, measure swing motor drainage against the 1300 cc/min maximum, and check the secondary valve settings on the motor.
Manual Section: Hydraulic System Troubleshooting p. 202Transmission does not change up from 1st to 2nd gear with the reverser lever push-button
Check for 12V at the lower coil 65 of EV3 following page 182, then confirm fuse F5 in fuse box A is intact. Test the reverser lever push-button, step-by-step relay 44 and relay 47. Verify accessory control box 88 works and has continuity to speed surveyor 80; replace whichever part fails or restore the open circuit.
Manual Section: Transmission Troubleshooting p. 182Four-wheel steering fails to engage when 4-wheel mode is selected on steering selector (60)
Check for voltage at selector 60 following page 192, and with the machine stationary confirm the selector switches. Test the diodes with push-button 59, check continuity through sliding joint position 4 to jack 1 of the relay box, and test relay 81 and fuse FS3. Then check relay 84 and voltage at solenoid EV10; repair or replace EV10 if defective.
Manual Section: Steering System Troubleshooting p. 192Low braking pressure warning light comes on above or below the correct residual brake pressure
Verify there are no leaks in the brake lines before testing, as page 144 requires. Apply the working brake engagement button repeatedly, counting actions while watching gauge E2. The warning light should come on at 90 ± 2 bar residual pressure after at least 15 actions; otherwise adjust pressure switch (18). If the light comes on while bleeding, stop and recharge the accumulators (page 146).
Manual Section: Travel and Steering Components p. 144Frequently Asked Questions
What is the standard engine valve clearance on the Komatsu PW95-1?
The standard valve clearance for the engine when cold is 0.20 mm for intake valves and 0.45 mm for exhaust valves. p. 114
What is the specified hydraulic oil tank capacity for the Komatsu PW95-1?
The specified capacity for the hydraulic system is 148 liters, with a refill capacity of 82 liters. p. 16
What is the procedure for bleeding air from the hydraulic pumps P1 and P2?
After draining the tank or removing pumps, remove the plug (1) from the pump body (2), fill the tank to the plug hole level, replace the plug (30 Nm), and continue filling to the maximum level. p. 122
What is the standard tightening torque for the arm cylinder flange retaining screws on the Komatsu PW95-1?
The flange retaining screws for the arm cylinder should be tightened to 5 ± 0.5 kgm (49 ± 5 Nm). p. 387
What exactly do I receive with this Komatsu PW95-1 Shop Manual?
You download the Shop Manual yourself: 440 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Does this Komatsu PW95-1 manual allow printing?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
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