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Webm001802 PW95R-2
Webm001802 PW95R-2
CONTENTS
Page
10 STRUCTURE AND FUNCTION........................................................................................ 10-1
PW95R-2 00-1
PAGE INTENTIONALLY
LEFT BLANK
REVISED PAGES
PW95R-2 00-2-1
REVISED PAGES
00-2-2 PW95R-2
SAFETY
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 to
fully BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not
on the machine. possible, use blocks to prevent the work equipment
2. When carrying out any operation, always wear safe- from falling down. In addition, be sure to lock all the
ty shoes and helmet. Do not wear loose work control levers and hang warning sign on them.
clothes, or clothes with buttons missing. 9. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts machine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding 10. Remove all mud and oil from the steps or other plac-
parts with a grinder, etc. es used to get on and off the machine. Always use
3. If welding repairs are needed, always have a the handrails, ladders or steps when getting on or off
trained, experienced welder carry out the work. the machine.
When carrying out welding work, always wear weld- Never jump on or off the machine.
ing gloves, apron, glasses, cap and other clothes If it is impossible to use the handrails, ladders or
suited for welding work. steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure
before starting. Always inform your fellow workers 11. When removing the oil filler cap, drain plug or hy-
before starting any step of the operation. Before draulic pressure measuring plugs, loosen them
starting work, hang UNDER REPAIR signs on the slowly to prevent the oil from spurting out.
controls in the operator’s compartment. Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit, first
5. Keep all tools in good condition and learn the correct
remove the pressure completely from the circuit.
way to use them.
12. The water and oil in the circuits are not hot when the
6. Decide a place in the repair workshop to keep tools
engine in stopped, so be careful not to get burned.
and removed parts. Always keep the tools and parts
Wait for the oil water to cool before carrying out any
in their correct places. Always keep the work area
work on the cooling water circuits.
clean and make sure that there is no dirt or oil on the
floor. 13. Before starting work, remove the leads from the bat-
Smoke only in the areas provided for smoking. Nev- tery. Always remove the lead from the negative ( – )
er smoke while working. terminal first.
PW95R-2 00-3
SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places. 20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent that they are not twisted. Damaged tubes are dan-
the component from hitting any other part. gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or tubes for high pressure circuits. Also, check that
crane. connecting parts are correctly tightened.
15. When removing covers which are under internal 21. When assembling or installing parts, always use
pressure or under pressure from a spring, always specified tightening torques.
leave two bolts in position on opposite sides. Slowly When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to rotate at high speed, be particulary careful to check
remove. that they are correctly installed.
16. When removing components, be careful not to 22. When aligning two holes, never insert your fingers
break or damage the wiring. or hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill- measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline
when washing electrical parts.
00-4 PW95R-2
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
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 work-
shop.
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 no-
tice.
Contact your Komatsu Utility distributor for the latest information.
PW95R-2 00-5
HOW TO READ THE SHOP MANUAL
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-6 PW95R-2
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
PW95R-2 00-7
STANDARD TIGHTENING TORQUE
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
22 27 8±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
1” - 14 30 8.2–9.2 80–90
2” - 12 57 20.4–24.4 200–240
PW95R-2 00-9
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.
Alternative product to 242; oil tolerant and so can used on lightly lubricated sur-
Loctite 243
faces without prior use of activator.
Adhesives Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-10 PW95R-2
ELECTRIC WIRE CODE
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
70 – – – 13.6 192
PW95R-2 00-11
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model PW95R-2
Engine assembly 350
Radiator - exchanger 37
Hydraulic tank (without hydraulic oil) 62
Fuel tank (without fuel) 43
Revolving frame 1110
Counterweight 1150
Swing circle 124
Swing motor 87
Main 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
Arm (L=1600) 134
Arm (L=1850) 155
Armo (L=2300) 198
Blade 210
Outrigger 76x2
Bracket 29x2
Equipment plate 128
Boom cylinder 117
2nd boom cylinder 58x2
Arm cylinder 100
Bucket cylinder 89
Boom swing cylinder 90
Blade cylinder 64
Equipment assy. (with 2-piece boom) (bucket L=800 - arm L= 1850) 1110
Equipment assy. (with 2-piece boom) (bucket L=800 - arm L= 1850) 1650
00-12 PW95R-2
TABLE OF OIL AND COOLANT QUANTITIES
SAE 10W
SAE 30
OIL
Crankcase sump SAE 40 12.5 12.5
• API CD
SAE 15W-30
SAE 5W-30
SAE 10W
OIL
Hydraulic circuit 170 74
• API CD
SAE 5W-30
Hydraulic circuit
with biodegradable 170 74
oil
Front axle
9.0 9.0
• Differential
OIL
Swing machinery SAE 85W-90 4 4
• API GL5
✽
Fuel tank FUEL 125 –
ASTM D975 N.2
Engine coolant
system PERMANENT
18 –
LIQUID
Crankcase sump
✽ ASTM D975 N.1
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: Military Specification
CCMC: Common Market Constructors Committe
PW95R-2 00-13
TABLE OF OIL AND COOLANT QUANTITIES
00-14 PW95R-2
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The conversion table in this section is provided to enable simple conversion of figures.
For details of the method of using the conversion table, see the example given below.
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PW95R-2 00-15
CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-16 PW95R-2
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-18 PW95R-2
CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
PW95R-2 00-19
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 PW95R-2
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
PW95R-2 00-21
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
00-22 PW95R-2
STRUCTURE AND FUNCTION
PW95R-2 10-1
STRUCTURE AND FUNCTION P.T.O.
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
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
Transmission Differential Planetary Axle Total
High speed 1.31 29.71
3.78 6.00 22.68
Low speed 4.53 102.74
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
RKP05681
PW95R-2 10-3
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
DIFFERENTIAL
1 2 3 4 5
8 7 6
11 12
9 10
16 15 14 13
RKP05390
10-4 PW95R-2
STRUCTURE AND FUNCTION FRONT AXLE
BRAKES
A
1 2 3 a
A
Section A - A
4 5 6 7
RKP05381
PW95R-2 10-5
STRUCTURE AND FUNCTION FRONT AXLE
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
STRUCTURE AND FUNCTION FRONT AXLE
STEERING CYLINDER
A A
a 2 b
Section B - B
3 4 Section A - A
RKP05321
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
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
B
B
1 2 A 3
5
6
4
7
a b 10 9 8
Section B - B RKP05302
10-8 PW95R-2
STRUCTURE AND FUNCTION TRANSMISSION
1 2 3 4
5
6
19
18
17
16 15
9
14
13 12 11 10
RKP05271
SectionA - A
PW95R-2 10-9
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
DIFFERENTIA
1 2 3 4 5
8 7 6
11 12
9 10
16 15 14 13
RKP05290
10-10 PW95R-2
STRUCTURE AND FUNCTION REAR AXLE
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
PW95R-2 10-11
STRUCTURE AND FUNCTION REAR AXLE
STEERING CYLINDER
A A
a 2 b
2
3 4 Section A - A Section B - B
RKP05331
1. Steering cylinder
2. Sensor
3. Nut
4. Pin cotter
a. d Port - From ST4 solenoid valve (B port)
b. c Port - From ST4 solenoid valve (A port)
10-12 PW95R-2
STRUCTURE AND FUNCTION REAR AXLE
1 2 3
Section A - A
7 6 5
9 10 11
8 5
a b
13 12
RKP05251
1. Pin 9. Nut
2 Nut 10. Screw
3. Dowel 11. Bushing
4. Brake bleeding screw 12. Spring
5. Brake lever 13. Brake disk
6. Push-rod a. From swivel joint (8a Port)
7. Pressure disk b. From swivel joint (11a Port)
8. Fulcrum lever
PW95R-2 10-13
STRUCTURE AND FUNCTION REAR AXLE
17 18 19 20
14 15 16
8
2 3
23 22 21
RKP05440
10-14 PW95R-2
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
RKP10413
1. Engine DESCRIPTION
2. Pump (P2) • 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-
– Y1: Rear steering cut out ders (9) and (10).
– Y2: Front/rear steering The solenoid valve group (8) can switch the oil flow to
provide three types of steering:
– Y13: Phase coincidence steering
1 - 2 wheels steering
– 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.
• 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
STRUCTURE AND FUNCTION STEERING SYSTEM
OPERATION
1 - Steering with front wheels, only
b 12 a 10 b 10 12 a
B A B A
e R T e R T
h h
5 3 5 3
g g
L P L P
4 4
f f
7 7
6 2 6 2
(P2) (P2)
Y1 Y2 Y1 Y2
RKP10421 RKP04391
10-16 PW95R-2
STRUCTURE AND FUNCTION STEERING SYSTEM
b 12 a 10 b 10 12 a
B A B A
h e R T
h e R T
g 5 3 g 5 3
L P L P
f 4 f 4
7 7
6 2 6 2
(P2) (P2)
Y1 Y2 Y1 Y2
C D C D
c 13 11 c
d 11 13 d
RKP04411 RKP04421
PW95R-2 10-17
STRUCTURE AND FUNCTION STEERING SYSTEM
b 12 a 10 b 10 12 a
B A B A
h e R T h e R T
g 5 3 g 5 3
L P L P
f 4 f 4
7 7
6 2 6 2
(P2) (P2)
Y1 Y2 Y1 Y2
C D C D
c c
11 13 d 13 11 d
RKP04431 RKP04451
10-18 PW95R-2
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a e b
LS
L R
T P
c d RKP03740
PW95R-2 10-19
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
4 5
1
Section C - C
2 Section A - A
3
6
Section B - B
D
7
A
D
C
6
Section D - D
C
B
B
8
Section E - E
A E
RKP12261
10-20 PW95R-2
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
6
8
5
9
4
10
3
11
2
12
RKP12270
PW95R-2 10-21
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC DIAGRAM STANDARD
B A d c
B f
ø 0.7 ø 0.7 A C
Parking brake
Y11 A1 e
ST4 Solenoid
T
valve group
P
M3
Y2 Y1
ø 0.6
Swing motor
ST1 Solenoid
valve group B A
T
350 bar
2-Piece boom
Boom swing
L.H. travel
Bucket
equipment
Y4
Additional
Y3
Boom
274 bar Y13
Travel
Arm
High
Y14
A2 speed
A3 Low
speed P1
Y10
Axle A
324 bar
A1 locking B
R.H. swing
31.4 bar
P T
196 bar
196 bar
Front axle
a b
PLS
4.9 bar
216 bar
Axle locking
ø 0.6
cylinder
TC TB TSW PB1 B1 A1 P2 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB7 B7 A7 PB8 B8 A8 PB9 B9 A9 PB10 B10 A10
B B
ø 0.7
ø 0.6
R.H. swing
L.H. swing
Forwards
Oil cooler Reverse
Lower
Close
Close
Close
Raise
Open
Open
Open
2-Piece boom cylinder
Boom swing cylinder
(Ø100xØ60-900)
Bucket cylinder
(Ø110xØ70-770)
Boom cylinder
R.H. side
L.H. side
(Ø90xØ60-800)
5 12 10 8 6 4 2
Swivel jonit
Arm cylinder
7 14 3 1
(Ø100xØ60-650)
13 11 9
(Ø90xØ60-650)
70 艎
Delivery
filter 25
Filter: 50
T
PEPC
ø 0.3min F R2 R1
PC motor
Q max
ø 0.9
T'1
B T1 P R
EPC
Q min
PR
PA
Ø1
P
ø 0.9
P1 T'2
170 bar
240 bar
B
32 bar
49 bar
1 bar T2
P CF
T L
PA3 PB PD PS PD2 T
EF LS
N
PGA
PGS
RKP12291
PW95R-2 10-23
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (WORK EQUIPMENT)
P1 P2 P1 P2
P2 P1 P2 P1
P1 P2 P2 P1 P1 P2 P2 P1
P1 P2 P1
P1 P2 P2 P1
P1 P2
A2 A7 A2 B2 A7 B7 PA2 PB2
B2 B7
PA2 PB2 PA7 PB7
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
RKP07193
PW95R-2 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
1 2 3
c 4 b
d e f
l 6
View Y h g 5
RKP03411
10-26 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
a b
A A
B B
View X
X Y
View Y
View Z RKP03401
PW95R-2 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 2 3 4 5 6 7 8 9
10 12 11
Section A - A Section C - C
D
C
C
D Section D - D
Section B - B RKP03151
10-28 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
• The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil
is discharged according to the load.
• It is possible to change the delivery amount by changing the swash plate angle.
1 2 3 4 5 A 6 7 8 9
B a 10
Section A - A RKP03121
STRUCTURE • The piston (6) carries out relative motion in the axial
• The cylinder block (7) is supported to the shaft (1) by direction inside each cylinder chamber of the cylinder
the spline a, and the shaft (1) is supported by the front block (7).
and rear bearings. • The cylinder block (7) seals the pressure oil to the
• Tip of the piston (6) is a concave ball, and shoe (5) is valve plate (8), and carries out relative rotation.
caulked to it to form one unit. The piston (6) and the This surface is so designed that the oil pressure bal-
shoe (5) form a spherical bearing. ance is maintained at a suitable level.
• The rocker cam (4) has a flat surface A, and the shoe And oil inside each cylinder of the cylinder block (7) is
(5) is always pressed against this surface while sliding sucked in and discharged through the valve plate (8).
in a circular movement.
The rocker cam (4) brings high pressure oil at the cy-
lindrical surface B with the cradle (2), which is se-
cured to the case, and forms a static pressure bearing
when it slides.
PW95R-2 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
1. Pump operation
1 4 5 A 7
1 - The cylinder block (7) rotates together with the shaft
(1), and the shoe (5) slides on the flat surface A.
At this time, the rocker cam (4) moves along the cy-
lindrical surface B, so the angle "α" between the
center line X of the rocker cam (4) and the inclination
of the cylinder block (7) in the axial direction chang-
es.This angle "α" is called the swash plate angle.
X
B RKP03560
7 E RKP03580
10-30 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PP
RKP03610
PW95R-2 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE
1 2 3 4 5 6 7 8
f
a
b c d e
RKP03420
VALVOLA PC
1 2 3 4 5 6 7 8 9 10 11
a b c d e
RKP03430
10-32 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 b c 2
RKP03380
PW95R-2 10-33
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE
FUNCTION
• The LS valve detects the load and controls the dis-
charge amount.
This valve controls main pump discharge amount Q
according to differential pressure ∆PLS (the differ-
Q ( / min)
ential between main pump pressure PP and control
Q.
• Relationship between the pump discharge pressure
PP and the pump discharge amount Q is as shown
in the chart.
Normally, it is set to the pump suction torque of the
standard mode, but when a signal from the PC-EPC
mode switching solenoid valve is inputted, the pump
suction horsepower lowers by approximately 20%
as shown by the light-load mode curve.
• Since the swing pump is mounted directly on the
main pump, when the swing pump is in operation,
suction torque of the main pump is reduced by the
amount sucked by the swing pump so that the sum
of the main pump suction torque and the swing
pump suction torque becomes the total suction
torque (100%).
10-34 PW95R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE
OPERATION
1. When the control valve is at "NEUTRAL" position
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
Gear pump
D
Main
pump C
Fixed throttle H 6 B 4
valve
A A
K J
Large
diameter end 11 Small diameter end
Direction of
RKP03461
min. discharge
10-36 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
(11).
• Though the pump pressure PP is always introduced
to the chamber J of the small diameter side of the
servo piston (11), because the force to the large di-
ameter side is larger due to the difference of the ar-
eas at two ends of the servo piston (11), the servo
piston (11) is moved to the minimum swash plate
angle side ( ).
PW95R-2 10-37
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. When the opening of the control valve is large (lever stroke large))
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
Gear pump E
Main
D
pump
C
B
Fixed throttle 6 4
valve
K J
Large
diameter end 11 Small diameter end
Direction of
RKP03491
min. discharge
10-38 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-39
STRUCTURE AND FUNCTION HYDRAULIC PUMP
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
Gear pump
D
Main
pump C
Fixed throttle 6 4
valve
K J
Large
diameter end 11 Small diameter end
Direction of
min. discharge RKP03501
10-40 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-41
STRUCTURE AND FUNCTION HYDRAULIC PUMP
4. When the pump flow is proper the demand of the control valve
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
E
Gear pump
D
Main
pump C
H 6 4
Fixed throttle
valve
PEN
A1 A2
Large
diameter end 11 Small diameter end
K J
RKP03481
10-42 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-43
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PLS
Control valve
PPLS
Servocontrol
feed unit
PP Swing
blade
PG
PT
Main pump
pressure Gear pump
C
Gear pump
pressure
4 6 Main pump
LS valve
Fixed
throttle
valve
2 3
Large
Small diameter end diameter end
Direction of Direction of
max discharge min. discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03471
10-44 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-45
STRUCTURE AND FUNCTION HYDRAULIC PUMP
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
PP Swing
blade
PG
B C
B
PT
Gear
C pump
A
D
Main pump
LS valve
8
G
9 Fixed
throttle
valve
2 3
J
Large
Small diameter end diameter end
Direction of
max discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03511
10-46 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-47
STRUCTURE AND FUNCTION HYDRAULIC PUMP
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
PP Swing
blade
PG
B PT
Gear
A C pump
D Main pump
2 3 4 6 7 E
LS valve
9 G
Fixed
throttle
valve
Large
Small diameter end diameter end
Direction of
min. discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03521
10-48 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-49
STRUCTURE AND FUNCTION HYDRAULIC PUMP
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
Swing
PP blade
PG
B C
B PT
Gear
A C pump
D Main pump
LS valve
9 Fixed
throttle
valve
2 3
J
Large
Small diameter end diameter end
Direction of
min. discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03541
10-50 PW95R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PW95R-2 10-51
STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
P
b
PP LS
EF CF
d c
RKP03680
10-52 PW95R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
A
C B
D A
aa
AA AA
Pt Ps
Pr O O
v N Pq
N x
Pp Po
t u
M M
Pn Pm
r s
L L
Pl Pk
p q
B K K
Pj n Pi
J J o
Ph Pg
l m
H H
Pf j Pe
G G
k
Pd h Pc
F F i
P Pb Pa
f g
E E xx
d e
BB BB
c
C D A
Pu
a b P B
View A
y
w
View B
RKP03162
10-54 PW95R-2
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
STRUCTURE AND FUNCTION CONTROL VALVE
17
15 16
13 14
11 12
9 10
7 8
5 6
3 4
1 2
18
Section A - A RKP03171
1. Travel suction valve (A3 port) 10 - R.H. outrigger suction valve (B7 Port)
2. Travel suction valve (B3 port) 11. Boom swing suction valve (Head side) (A8 port)
3. Boom suction valve (Bottom side) (A4 port) 12. Boom swing suction valve (Bottom side) (B8 port)
4. Boom suction valve (Head side) (B4 port) 13. 2-piece boom suction valve (A9 Port)
5. Arm suction valve (Head side) (A5 port) 14. 2-piece boom suction valve (B9 Port)
6. Arm suction valve (Bottom side) (B5 port) 15. Attachment safety valve (L.H. side) (A10 port)
7. Bucket suction valve (Head side) (A6 port) 16. Attachment safety valve (R.H. side) (B10 port)
8. Bucket suction valve (Bottom side) (B6 port) 17. Safety valve
9 - R.H. outrigger suction valve (A7 Port) 18. Lift check valve
10-56 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
11
10
Section B - B
RKP03181
PW95R-2 10-57
STRUCTURE AND FUNCTION CONTROL VALVE
18
8 16
7 15
6 14
5 13
4 12
3 11
2 10
1 9
17
19
Section C - C
RKP03191
10-58 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
Section D - D RKP03201
PW95R-2 10-59
STRUCTURE AND FUNCTION SWING VALVE
Section BB - BB RKP02822
5 3
4 Section E - E RKP02812
SWING VALVE
3. Spool (swing)
4. Spool (boom raise at joining pump discharge)
5. Check valve (swing)
10-60 PW95R-2
STRUCTURE AND FUNCTION BLADE VALVE
3
Section AA - AA
RKP02842
6
Section F - F RKP02832
BLADE VALVE
5. Spool (blade)
6. Main relief valve (P2 Port)
PW95R-2 10-61
STRUCTURE AND FUNCTION ARM VALVE - BUCKET VALVE
1 2
5 4
Section G - G RKP02852
6 7
10 9
Section H - H
RKP02862
10-62 PW95R-2
STRUCTURE AND FUNCTION ARM VALVE - BUCKET VALVE
1 2
RKP02870
5 4
Sezione J - J
6 7
RKP02880
10 9
Sezione K - K
PW95R-2 10-63
STRUCTURE AND FUNCTION OUTRIGGER VALVE - BOOM SWING VALVE
1 2
5 4
Section L-L RKP03211
6 7
10 9
RKP03221
Section M-M
10-64 PW95R-2
STRUCTURE AND FUNCTION 2-PIECE BOOM VALVE - ATTACHMENT VALVE
1 2
5 4
RKP03231
Section N-N
6 7
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 INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL VALVE
FUNCTION PRINCIPLE
1. Control of pump swash plate angle
•The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure ∆PLS, which
is the difference between the pump discharge pressure PP and the LS pressure PLS at the outlet Port of the control
valve (actuator load pressure), is maintained at a constant level.
(LS differential pressure ∆PLS=Pump discharge pressure PP -- LS pressure PLS).
• If the LS differential pressure ∆PLS becomes lower than the setting pressure of the LS valve, the pump swash plate
angle becomes larger, and if it becomes higher, the pump swash plate angle becomes smaller.
★ For the details of this action, refer to the descriptions of "HYDRAULIC PUMP".
Actuator
Max.
Min.
PLS
Pump passage
LS passage
0 LS differential
pressure ∆PLS Set differential
Main pump pressure of LS valve
PP
RKP02931
Min. Max.
Servo piston
∆PLS
LS valve
Differential
pressure high Differential
pressure
low
PC valve
PW95R-2 10-67
STRUCTURE AND FUNCTION CONTROL VALVE
Actuator Actuator
∆P ∆P
S1 S2
Pressure Pressure
compensation compensation
valve valve
LS valve RKP02941
10-68 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
LS
324 bar
1. Unload valve: LS pressure+31.4 bar
5 Ls ø0.5 2. Main relief valve (P1 Port) 294 bar
9
196 bar
3. Pressure compensation valve
A10
B10
4. Suction valve
196 bar Attachment 5. Safety valve: 324 bar
PA10 PB10
9 6. Main relief valve (P2 Port): 216 bar
3 4 7. Lift check valve
A9 8. Cooler bypass valve
B9 2-piece boom
PA9
4 PB9 9. Safety valve (attachment): 196 bar
3 4
A8
B8 Boom swing
PA8 PB8
4
3 4
A7
PA7
B7 R.H. outrigger
PB7
4
3 4
A6
B6
PA6 Bucket
PB6
4
3 4
A5
PA5
B5 Arm
PB5
4
3 4
A4
PA4
B4
Boom
PB4
4
3 4
A3
B3 Travel
PA3 PB3
4
3
A2
B2 Blade and/or
PB2
PA2
outrigger
P2
216 bar
6
A1
B1 Swing
PA1 PB1
PDB
TS
2 1 31 bar 8 TSW
274 bar 31.4 bar
7 TB
TC
P1
RKP10123
PW95R-2 10-69
STRUCTURE AND FUNCTION CONTROL VALVE
1. Unload valve
FUNCTION
1. When the control valve is at NEUTRAL, pump discharge amount Q for the minimum swash plate angle is released
to the tank circuit.
At this time, the pump discharge pressure PP is set at 31.4 bar by the spring (2) inside the valve.
(LS pressure PLS = 0 bar)
PP PLS
T
1 2 3
RKP02960
OPERATION
When the control valve is at NEUTRAL
• To two end surfaces of the spool (1), the pump discharge pressure PP is acting on the left and the LS pressure PLS
is acting on the right side.
• Since no LS pressure PLS is generated when the control valve is at NEUTRAL, only the pump discharge pressure
PP is acting, and PP is set only by the load of the spring (2)
• As the pump discharge pressure PP rises and reaches the spring load of the spring (2) (31.4 bar), the spool (1) is
shifted to the right ( ) side and the pump circuit PP becomes open to the tank circuit T through the drill holes in the
sleeve (3).
• In this way, the pump discharge pressure PP is set to 31.4 bar.
10-70 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
2. When the flow demand from the actuator is within the discharge amount for the pump minimum swash angle plate
during fine control of the control valve, the pump discharge pressure PP is set to the LS pressure PLS +31.4 bar.
Since the unload valve opens when the differential pressure between the pump discharge pressure PP and the LS
pressure PLS reaches the spring load of the spring (2) (31.4 bar), the LS differential pressure ∆PLS at this time be-
comes 31.4 bar.
PP PLS
T
1 2
RKP02970
OPERATION
Fine control of the control valve
• When the control valve is fine-controlled, the LS pressure PLS is generated and acts on the right end of the spool (1).
At this time, since the LS pressure PLS is small because the opening area of the spool of the control valve is small,
there is big difference from the pump discharge pressure PP.
• When the differential pressure between the pump discharge pressure PP and LS pressure PLS reaches the spring
load of the spring (2) (31.4 bar), the spool (1) moves to the right ( ) side and a path is formed between the pump
circuit PP and the tank circuit T.
• Thus, the pump discharge pressure PP is set to the combined pressure of the spring force (31.4 bar) and the LS
pressure PLS, and the LS differential pressure ∆PLS becomes 31.4 bar.
PW95R-2 10-71
STRUCTURE AND FUNCTION CONTROL VALVE
3. When the flow demand from the actuator becomes greater than the pump flow for the minimum swash plate angle
during operation of the control valve, the flow to the tank circuit T is cut off, and all the pump discharge Q flows into
the actuator circuit.
PP PLS
T
1 2
RKP02980
OPERATION
10-72 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
2. Introduction of LS pressure
Function
• The LS pressure denotes the actuator load pressure at the outlet Port of the control valve.
• Actually, in the control valves, the pump pressure PP is reduced to the same pressure of the actuator circuit pressure
A by the pressure reducing valve (3) in the pressure compensation valve before introducing into the LS circuit PLS.
Furthermore, the orifice C is provided in the middle of the circuit from the pump circuit PP to the pressure reducing
valve (3) for damper function.
• In the travel valves, the actuator circuit pressure A is directly introduced into the LS circuit PLS.
A
b
1
a d
PP SA PA 3 PLS1 SLS
2
C 4 PLS
RKP02990
OPERATION
Control valves (boom, arm, bucket, boom swing, attachment)
• When the spool (1) is operated, the pump pressure PP starts to flow to the actuator circuit A from the flow control
valve (2) and the spool notch a through the bridge path b.
• At the same time, the pressure reducing valve (3) moves to the right ( ) side, so the pump pressure PP introduced
from the orifice c is depressurized by the pressure loss at the notch d and introduced to the LS circuit PLS, and then,
further introduced to the spring chamber PLS1.
• At this time, the LS circuit PLS is open to the tank circuit T through the LS bypass plug (4) (refer to the description of
the LS bypass plug).
• Areas of the both ends of the pressure reducing valve (3) are same (SA=SLS), and on the SA side, the actuator cir-
cuit pressure PA (=A) is acting, and on the opposite SLS side, the reduced pump pressure PP is acting.
• Therefore the pressure reducing valve (3) balances at the point where the actuator circuit pressure PA and the
spring chamber pressure PLS1 are balanced, and the pump pressure PP reduced by the notch d is introduced to the
LS circuit PLS as the actuator circuit pressure A.
PW95R-2 10-73
STRUCTURE AND FUNCTION CONTROL VALVE
A
b
1
a d
PP 2 PA 3
e PLS
RKP03000
Travel valves
• When the spool (1) is operated, the pump pressure PP starts to flow to the actuator circuit A from the flow control
valve (2) and the spool notch a through the bridge path b.
• At the same time, the pressure reducing valve (3) is moved to the right ( ) side by the actuator circuit PA, and paths
are made between the notches c and d to the travel path circuit e and the LS circuit PLS respectively.
• By this, the actuator circuit pressure PA (=A) is introduced to the LS circuit PLS from the notch c through the notch d.
★ In the travel circuits, unlike the work equipment circuits, the actuator circuit pressure PA is directly introduced to the
LS circuit PLS.
10-74 PW95R-2
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
PLS
RKP03010
OPERATION
• 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
STRUCTURE AND FUNCTION CONTROL VALVE
FUNCTION
1. During complex operation, if the load pressure at one side becomes lower than that of the other actuator and the oil
flow is about to increase, pressure compensation is carried out.
(In this case, the other actuator (right side) of the complex operation has higher load pressure than that of this side
(left side).
W W
A A
PA
PPA
a a
T
PLS1
PPA PA
2 1
PP
PLS PP
RKP03020
OPERATION
• During complex operation, when the load pressure of the other actuator side (right side) becomes higher, the flow
in the actuator circuit A at this (left) side tends to increase.
• In this case, the LS pressure PLS at the other actuator acts on the spring chamber PLS1, and pushes the pressure
reducing valve (1) and the flow control valve (2) to the left ( ).
• The flow control valve (2) throttles the opening area between the pump circuit PP and the upstream side of the spool
PPA, and generates a pressure loss in between PP and PPA.
• The flow control valve and the pressure reducing valve (1) are balanced at the point where the differential pressure
between PA and PLS, which act on the both end surfaces of the pressure reducing valve (1), becomes equal to the
pressure loss in between PP and PPA before and after the flow control valve (2).
• By this operation, the differential pressures between the upstream pressure PPA and the down stream pressure PA
of both spools in the complex operation are made same, and the pump flow is distributed in proportion to the opening
areas of notches a of each spool.
10-76 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
S1 PPB PP 2 1 PA 3 S2
PLS
RKP03030
PW95R-2 10-77
STRUCTURE AND FUNCTION CONTROL VALVE
FUNCTION
• When the travel and another actuator are operated at the same time, by increasing the LS throttle amount in the LS
circuit PLS which is discarded, and relaxing the pressure compensation precision in the travel circuit, drop in the
travel speed is minimized.
• The bypass circuit is closed when the travel or another actuator is operated individually.
A1 1 A2 PA
PLS
PLS1
a
4
PB c
2
RKP03060
OPERATION
Normal operation
• When the boom spool (1) is operated, the pressure in the LS circuit PLS becomes same as the boom circuit pressure
A1.
• At the same time, the LS circuit pressure PLS is also introduced to the spring chamber PLS1 of the pressure re-
ducing valve (2) in the travel valve.
• Since the travel spool is not operated, the travel actuator circuit is closed, and the check valve (4) in the reducing
valve (2) is also closed.
• Thus, during individual operation of the boom, the travel LS bypass circuit is closed.
10-78 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
A1 1 A2 PA
PLS
PLS1
a
4
PB 2 c
RKP03070
PW95R-2 10-79
STRUCTURE AND FUNCTION CONTROL VALVE
1
B
A
4
2
T
3
a
PP PLS
RKP03080
OPERATION
• When there is hydraulic drift when lowering the boom, the pressure A at the bottom end of the boom cylinder (1) be-
comes higher than the pressure B at the head end.
• At this time, a part of the return flow at the bottom end passes the regeneration passage a of the boom spool (2),
pushes the check valve (3) open, and flows to the head end.
• As the result, the boom lowering speed is increased.
10-80 PW95R-2
STRUCTURE AND FUNCTION CONTROL VALVE
2. When lowering the boom, if the head pressure B of the cylinder (1) is greater than the bottom pressure A, and the op-
eration is in the load process, the check valve (3) closes to shut off the circuit between the head and the bottom sides.
B
A
4
2
T 3
a
PLS
PP
RKP03090
OPERATION
• During a load process such as lowering the boom, etc., the pressure B at the head side of the boom cylinder (1) be-
comes higher than the pressure A at the bottom side.
• At this time, the check valve (3) is closed by the pressure B at the head side and the spring (4), and the passage be-
tween the head circuit and the bottom circuit is shut off.
PW95R-2 10-81
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
a C A
B B
Z
e
C
View Z
RKP11921
10-82 PW95R-2
STRUCTURE AND FUNCTION SWING MOTOR
3 4 5 12 13 14 15 16 2
7 1
Section A - A Section B - B
10
11
RKP11931
Section C - C
PW95R-2 10-83
STRUCTURE AND FUNCTION SWING MOTOR
OPERATION
MA MB
Control valve
RKP11951
10-84 PW95R-2
STRUCTURE AND FUNCTION SWING MOTOR
P1
P0
t
T
RKP11970
OPERATION
When the circuit pressure is P0 1 2 a 3 4 5
• The relief valve does not operate.
P2
S RKP11960
PW95R-2 10-85
STRUCTURE AND FUNCTION SWING MOTOR
L.H. R.H.
4
3
P
1
2 RKP11980
L.H. R.H.
4
3
B
a
2 1 RKP11990
10-86 PW95R-2
STRUCTURE AND FUNCTION SWING MOTOR
2 5 RKP12000
PW95R-2 10-87
STRUCTURE AND FUNCTION SWIVEL JOINT
SWIVEL JOINT
Front of machine
Inlet axis
1 3A-7A-11A
2
10a 5a
3
9a 12a
4 14a
2a
14A Inlet axis Inlet axis
4A-8A-12A 1A-5A-9A-13A
13A
5
3a
6a
11A 11a
1a
12A 10A
13a
8a
6 9A 7a 4a
8A 7A Inlet axis
2A-6A-10A-14A
6A
5A View Z
4A 3A RKP11291
2A
1A
7
10
5 9
10-88 PW95R-2
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
5
c 1
2 4 a b 4
3
View X
RKP04461
1. Motor SPECIFICATIONS
2. Brake valve Min. displacement: 35.5 cc/rev
3. Displacement automatic control Max. displacement: 80 cc/rev
4. Relief/anti-cavitation valve Check valve rated pressure: 350 bar
5. Gear power change solenoid valve (Y25)
PW95R-2 10-89
DISPLACEMENT AUTOMATIC CONTROL
STRUCTURE AND FUNCTION HIGH PRESSURE RELATED
cc
1 1 6
Xc
5
4
4
a
7
5
Detail X
RKP04471
FUNCTION
• This device automatically varies the displacement in • The pressure moves the positioning piston (2) which,
function of the working pressure. because it is connected mechanically to the engine
A displacement increase leads to a reduction in the cylinder, causes this to move and increase the dis-
engine shaft rpm and an increase in the torque. placement.
The movement of the positioning piston (2) continues
OPERATION until equilibrium has been reached between the de-
• The pressurized oil coming from the control valve ar- livery pressure acting on the smaller surface of the
rives through the brake valve (1) on the smaller sur- piston and the pressure acting on the larger surface.
face of the positioning piston (2), thus pushing it Once equilibrium has been reached the spring (6) re-
towards the minimum displacement limit stop. turns the measuring piston (5) to its neutral posi-
The smaller surface is connected hydraulically to the tion.“Maximum displacement is determined by the
pilot system bushing (4), which contains a measuring mechanical limit stop (7).
piston with two different surfaces. The available pres- • When delivery line pressure diminishes there is no
sure therefore acts in a differential manner and, with longer equilibrium between the forces acting on the
the spring (6), causes the piston (5) to perform the positioning piston; the measuring piston moves, and
function of governing the pressure flows. opens passage c to release the existing pressure in
• When delivery line pressure increases the measure- chamber b.
ment piston (5) moves, compresses the spring (6), Under this new pressure the positioning piston (2)
and allows oil to pass through line a into chamber b of gradually returns to the minimum displacement posi-
the larger surface of the positioning piston (2). tion. The movement stops when a new equilibrium is
reached between the forces acting on the measure-
ment piston (5) and the positioning piston (2).
10-90 PW95R-2
STRUCTURE AND FUNCTION TRAVEL MOTOR BRAKE VALVES
8 9 10 11 f 11 10 9 2
5
5
3
6
4
7 c
b a RKP04550
PW95R-2 10-91
STRUCTURE AND FUNCTION CYLINDERS
CYLINDERS
BOOM
2 3 4 5 6 7 8 9 10
1 17 16 15 14 13 12 11
RKP04340
ARM
2 3 4 5 6 7 8 9 19 11
1
17 16 15 14 13 12 20
RKP04310
2 3 4 5 6 8 9 10 11
1
17 16 15 14 12 13
RKP05700
10-92 PW95R-2
STRUCTURE AND FUNCTION CYLINDERS
2-PIECE BOOM
2 3 4 5 6 8 9 18 11
1
17 16 15 14 13 12 RKP04330
Blade or
Cylinder Boom 2-piece boom Arm Bucket Boom swing
outriggers
PW95R-2 10-93
STRUCTURE AND FUNCTION AXLE LOCKING CYLINDER
B
2
3 4 5 6
Section A - A Section B - B
RKP03771
1. Cylinder
2. Piston
3. Cover
4. Plunger
5. Valve seat
6. Screw
7. Oil seal
8. Gasket
10-94 PW95R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION SERVOCONTROL FEED UNIT
a d
B
A A
c
RKP03961
10-96 PW95R-2
STRUCTURE AND FUNCTION SERVOCONTROL FEED UNIT
11 6 5 4
Detail Z
1
8 7 Z
Section A - A
10 9
Section B - B RKP03971
1. Hydraulic pump
2. Valve
3. Spring
4. Screw
5. Poppet
6. Spring (reducing valve pilot)
7. Spring (reducing valve)
8. Spool (reducing valve)
9. Spring (safety valve)
10. Ball
11. Filter
PW95R-2 10-97
STRUCTURE AND FUNCTION SERVOCONTROL FEED UNIT
OPERATION
T
PR
Hydraulic diagram
RKP03861
Control valve
P2
PC 2 3
P1
PR
8 7 5 6
LS valve
RKP03871
Fig. 1
10-98 PW95R-2
STRUCTURE AND FUNCTION SERVOCONTROL FEED UNIT
2. At neutral
Control valve
3. When load pressure P2 is low (when moving
P2
down under own weight boom LOWER or arm
IN) PC d 2 3
Note: When load pressure P2 is lower than output pres-
sure PR of the self-reducing pressure valve.
• Valve (2) receives force in the direction to close the
P1
passage from Port P1 P2 from spring (3) and
pressure PR (when the engine is stopped, the pres-
sure is 0 bar).
However, when hydraulic oil flows in from Port P1, T
the pressure is balanced so that pressure P1 ⱶ
force of spring (7) + (area Ød x pressure PR), and
the opening from Port P1 P2 is adjusted so that
pressure P1 is kept at a certain value above pres-
sure PR. PR
• When pressure PR goes above the set pressure,
8 a 7 5
poppet (5) opens, and the hydraulic oil flows in the
following circuit: Port PR hole a inside spool (8)
opening of poppet (5) tank Port T.
As a result, a pressure difference is created on both M
sides of hole a inside spool (8), so spool (8) moves in
the direction to close the opening from Port PC valve PPC valve
P1 PR.
LS valve
Pressure P1 is reduced to a certain pressure (set
RKP03881
pressure) by the amount of opening at this point, Fig. 2
and is supplied as pressure PR. (See Fig. 2)
LS valve
RKP03891
Fig. 3
PW95R-2 10-99
STRUCTURE AND FUNCTION SERVOCONTROL FEED UNIT
10 9
Fig. 4 RKP03901
10-100 PW95R-2
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
RKP03910
PW95R-2 10-101
STRUCTURE AND FUNCTION PPC VALVES
PPC VALVES
ATTACHMENT
a e
f
d b
A A
c
View A RKP12621
10-102 PW95R-2
STRUCTURE AND FUNCTION PPC VALVES
7
3
2 1
Section A - A RKP12631
1. Spool 5. Joint
2. Metering spring 6. Cover
3. Centering spring 7. Retainer
4. Plunger 8. Body
PW95R-2 10-103
STRUCTURE AND FUNCTION PPC VALVES
FUNCTION
1. At neutral
Ports A and B of the control valve and Ports P1 and
P2 of the PPC valve are connected to drain chamber
D through fine control hole f in spool (1). (Fig. 1)
f T
A Control valve
B
Fig. 2
RKP12851
10-104 PW95R-2
STRUCTURE AND FUNCTION PPC VALVES
7 D
2
T
1
f
PP
P1 P P2
A Control valve
B
RKP12871
Fig. 4
PW95R-2 10-105
STRUCTURE AND FUNCTION PPC VALVES
A
Z
c d
View Z RKP12241
10-106 PW95R-2
STRUCTURE AND FUNCTION PPC VALVES
6
3
2 7
1
8
Section A - A
RKP12641
1. Spool
2. Metering spring
3. Centering spring
4. Plunger
5. Lever
6. Cover
7. Retainer
8. Body
PW95R-2 10-107
STRUCTURE AND FUNCTION PPC VALVES
FUNCTION
1. At neutral
Ports A and B of the control valve and Ports P1 and
P2 of the PPC valve are connected to drain chamber
D through fine control hole f in spool (1). (Fig. 1).
D
T
P
f
1
P1 P2
A Control valve B
2. During fine control
(NEUTRAL fine control) RKP12911
Fig. 1
When piston (4) starts to be pushed by lever (5), re-
tainer (7) is pushed; spool (1) is also pushed by me-
tering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time,
it is connected to pump pressure chamber PP, so pi- 5
lot pressure oil from the control pump passes
through fine control hole f and goes from Port P1 to
Port A. 4
When the pressure at Port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP. 7
At almost the same time, it is connected to drain
chamber D to release the pressure at Port P1. When
this happens, spool (1) moves up or down so that
2 T
the force of metering spring (2) is balanced with the
pressure at Port P1. The relationship in the position D
of spool (1) and body (8) (fine control hole f is at a P
point midway between drain hole D and pump pres- f
sure chamber PP) does not change until retainer (7)
contacts spool (1). 1
Therefore, metering spring (2) is compressed pro-
P1 P2
portionally to the amount of movement of the control
PP
lever, so the pressure at Port P1 also rises in pro-
portion to the travel of the control lever. In this way,
the control valve spool moves to a position where
the pressure in chamber A (the same as pressure at A B
Control valve
Port P1) and the force of the control valve spool re-
turn spring are balanced. (Fig. 2). Fig. 2 RKP12901
10-108 PW95R-2
STRUCTURE AND FUNCTION PPC VALVES
A Control valve B
4. At full stroke Fig. 3
When lever (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut RKP12891
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. 5
The oil returning from chamber B passes from Port
P2 through fine control hole f' and flows to drain 4
chamber D. (Fig. 4)
2 T
D
P
f
f'
1
P1 P2
PP
A Control valve B
RKP12881
Fig. 4
PW95R-2 10-109
STRUCTURE AND FUNCTION BOOM SWING, 2-PIECE BOOM PPC VALVES
T
P
P1 P2
RKP03920
d c
RKP12250
10-110 PW95R-2
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
25
°
1
4
6 2 3
1
2
b
a 5
3
View Z RKP03691
1. Pedal
2. Pedal adjustment
3. Adjustable stop
4. Control unit
5. Support
6. Rubber jacket
PW95R-2 10-111
STRUCTURE AND FUNCTION BRAKE PUMP
BRAKE PUMP
1
2
c d
b
4
e g f a
i h
View A
RKP11561
10-112 PW95R-2
STRUCTURE AND FUNCTION BOOM AND ARM SAFETY VALVE
a b
c d
1 2
3
4
5
e
RKP04170
. Screw SPECIFICATIONS
2. Valve Pilot ratio: 22 : 1
3. Rod
4. Nut 20
Differential pressure ⌬p (bar)
5. Nut
16
a. T Port - To hydraulic tank
2
C
12 V2
V2
➔
From control valve (PB4 Port) C2
8
For arm
From control valve (PB5 Port) 4
c. V2 Port - For boom:
0
From control valve (A4 Port) 0 25 50 75 100 125 150
For arm: Amount Q ( / min)
PW95R-2 10-113
STRUCTURE AND FUNCTION BLADE OR OUTRIGGERS SAFETY VALVE
a b
A A
Section A - A
c d
RKP03761
14
12
10
8 C2
V2
6 V2
4 C2
2
0
0 6 12 18 24 30
Amount Q ( / min)
RKP04541
10-114 PW95R-2
STRUCTURE AND FUNCTION 2-PIECE BOOM SAFETY VALVE
a b
A A
1 1
2 3 3 2
Section A - A
c d
RKP04071
1. Screw SPECIFICATIONS
2. Plug Pilot ratio: 4,25 : 1
3. Valve
24
a. C1 - Port To the cylinder (Head side)
Differential pressure ⌬p (bar)
16
C2
0
0 12 24 36 48 60
Amount Q ( / min)
RKP04081
PW95R-2 10-115
STRUCTURE AND FUNCTION OVERLOAD SENSOR SWITCH
3 4 5
3
1
2
RKP11580
10-116 PW95R-2
STRUCTURE AND FUNCTION SOLENOID VALVES
SOLENOID VALVES
SOLENOID VALVE GROUP ST1 (Y3 - Y4 - Y10)
1
3
b c
d e
RKP12300
PW95R-2 10-117
STRUCTURE AND FUNCTION SOLENOID VALVES
1 2
c d RKP11550
1. Y7 - Servocontrol
2. Y11 - Parking brake
10-118 PW95R-2
STRUCTURE AND FUNCTION SOLENOID VALVES
1 a b 2
d c
RKP04570
1. Y17 Reverse
2. Y18 Forward Measured at V=41 mm2/s e t=50°C 1 2
10
a. Port P - From travel PPC valve (A Port)
Differential pressure ⌬p (bar)
8
b. Port B - To control valve (PB3 Port)
c. Port T - To hydraulic tank 6
0
0 20 40 60 80
Amount Q ( / min)
RKP04491
PW95R-2 10-119
STRUCTURE AND FUNCTION SOLENOID VALVES
2 3
a b
T A
P B
c 5 d
1 4
RKP03670
8 8
6 6
4 4
2 2
0 0
0 20 40 60 80 0 20 40 60 80
Amount Q ( / min) Amount Q ( / min)
RKP04501 RKP04511
10-120 PW95R-2
STRUCTURE AND FUNCTION SOLENOID VALVES
c d
b e
10
Differential pressure ⌬p (bar)
4
C
P
2
a f
0
10 30 50 70 90
Amount Q ( / min)
RKP05460 RKP04521
PW95R-2 10-121
STRUCTURE AND FUNCTION SOLENOID VALVES
a b
1 2
d c
RKP03940
10-122 PW95R-2
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low pressure steam
10
1a
3 1
8
5
4
7
9
INTERIOR OF CAB
RKP12650
PW95R-2 10-123
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
10-124 PW95R-2
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (1/8)
C-B1
X76 4
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
G-N1
X82
X82
X82
X82
X82
2.16
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
6 5 4 3 2
X76 1 X493 H-L1
R1 ACC BR R2 C 3.1
B1
OFF ACC M-B1
G-N1
H-L1
X75
G-M1
R1 8 4.1
H-G1
B-G1
R-V1
H-N1
A-R1
A-V1
Z-B1
V-B1
V-Z1
G0.5
S0.5
A1
ST
G1
V1
N1
R-G1
4.1
X76
X76
B
X75
X75
X75
X76
X75
X76
X75
X75
X76
X75
X75
X75
X75
S19 B1
3.8
H-N1
4.1
5 11
4 16 9 6 11 3 10 13 13 1 12 14 3 H-R1
HA5 4.1
M-N1
2.1
G4
R6
L6
H-G1
2.19
Z-N1 X75
4.18
15
R-N1
A-V1
2.1
G1
A-R1
1 1 5 16 7 19 20 9 5 11 4 8 2 12 4
Z-N1
Z-B1
V-B1
1
3.9
1 2 1 8 5 2 9 3 2 7 2
3.4
X34 X15 X41a X46 X46 X34 X46 X46 X46 X46
K8
V-B1
30
l K4 86 87a 87 4.13 86 87a 87
X45
R6 KT2 85 30 85 30
B-N1
V1
G4
R6
+15
53M
53S
K1 K2 K3
15
31
86 87a 87 86 87a 87 86 87a 87
+30
X45
X36
X36
X36
X36
- 85 30 85 30 85 30
M6 1 2 4 3 F4C F3B F6A
5A 7.5A 15A
G1
B1.5
N1
B-R1
K01 K03 K02
FUG2 FUG4 FUG1 86 87 86 87 86 87
50A 80A 30A
B-R1
Z-N1
Z-B1
85 30 85 30 85 30
B1 X5 X5 X5 X5 X6 X6 X6 X8 X9 X8 X9 X8 X7
10 5 11 3 3 6 4 9 3 3 13 13 14
B1.5
A-N1
H2.5
B-N1
A-N1
4.6
2 X23
B1.5
R10
R10
1
G4
B-R1.5
R-N1.5
3.1
X22
- l
H-R1
R70
H-G1.5
H-G1.5
A-G1
A-N1.5
B-R1.5
X41
X41
X55
1 2 1
H-N1
X39 X39 X38
+
1
S26 K12 86 87
V-B1
G1 30 50 D+ R1 1 R4
B1.5
R1.5
X43 HA4
1
S21
V1
M1 M G2 30 G W Y18 Y17
R3
X44 X56
p 85 30
12Vcc 3
HA2 1
U
X55
S17 S20
2
31
Y0 p p X23 1
B-G1
X39 S27
t X43 M2 2
3 X44
M S25 X22
N1.5
N1.5
N1.5
N1.5
-
N70
N1
N1
N1
N1
N1
N1
N1
N1
31
2.1
M1 Starter motor Y0 Fuel shut off solenoid valve X34 Power 3 way connector 3 X22
RKP11780
COMPONENTS M2 Transfer pump Y17 Reverse speed solenoid valve X36 Pull solenoid timer 4 way connector
G1 Battery Y18 Forward speed solenoid valve X38 Heating start 1 way connector X76 Dashboard extension 17 way connector
R1 Heating start
G2 Generator X39 Fuel shut off 3 way connector X81 Control panel 16 way connector
R3 Water temperature sender CONNECTORS
HA2 Reverse buzzer X41 Generator 2 way connector X82 Control panel 8 way connector
R4 Fuel level sender X3 Right lateral dashboard line 18 way connector
HA4 Frame horn S16 Heater switch X4 Right lateral dashboard line 12 way connector X41a Frequence alternator 1 way connector FUSES
HA5 Buzzer S17 Air filter switch X5 Engine line 11 way connector X43 Water temperature sender 2 way connector F1B Gear valve fuse 7.5A
K1 Forward speed valve relay S19 Starting switch X6 Lights switch-gear shift line 13 way connector X44 Back-up alarm 2 way connector F2B Joystick -instrument power fuse 3A
K2 Reverse speed solenoid valve relay S20 Engine oil low pressure switch X7 Steering interface line 21 way connector X45 Diode 2 way connector F3B Safety start- fuel shut off fuse 7.5A
K3 Speed connection relay S21 Brakes less pressure switch X8 Loom line 21 way connector X46 Dashboard wiring 9 way connector F4B Right traffic light and instrument light fuse 3A
K4 Key safety start relay S25 Fuel tank full sensor X9 Lights switch-gear shift line 21 way connector X47 1 way connector M6 (+30) F4C Generator and pull timers fuse 5A
K8 Horn relay S26 Transfer pump start button X11 Lateral dashboard line 13 way connector X49 Diode 2 way connector F6A Horn-current intake-transfer pump fuse 15A
K12 Transfer pump relay S27 Transfer pump switch X15 Parking brakes lamp 1 way connector X55 Optional horn connector FUG1 Fuel shut off fuse 30A
KT2 Pull fuel solenoid timer V1 Start antirepetition relay 1A diode X22 Fuel level sender 3 way connector X70 1 way connector M5 (+15) FUG2 General fuse 50A
X56 Current intake 12V X23 Transfer pump 2 way connector X75 Dashboard extension 21 way connector FUG4 Preheating fuse 80A
PW95R-2 10-125
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (2/8)
MANIPOLATORE DX
PULSANTIERA PRINCIPALE RIGHT JOYSTICK
MAIN SWITCHES PANEL
S10 S11
X79
X79
X79
X79
X79
X79
X79
X79
X79
X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X72 X72 X72 X72 X72 X72 X72 X72 X72 X72 X72 X72
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
G-N1.5
A-G1.5
R-G1.5
G-R1.5
A-R1.5
C-V1.5
B-N1.5
Z-G1.5
G-R1
M-B1
M-N1
R-G1
B-R1
R-N1
S-N1
Z-N1
V-N1
G0.5
R0.5
C0.5
V-B1
H0.5
C-L1
L-R1
S0.5
L0.5
Z1
M1
L1
M-N1
1.20
R-N1
1.20
L-R1
4.20
X49 6 S18
G0.5
1.10
R-N1 S0.5 2 9 12 10
3.1 1.7
X76
X76
X76
X76
G-N1 B0.5
1.20 3.1
H-G1 H-G1
1.20 3.1
V1
R-N1.5
3.16
10 12 5 7 8 6 1 2 18 3 9 10 15 16 14 12 13 9 11 17 1
X4 X11 X4 X3 X3 X3 X3 X3 X3 X3 X4 X3 X3 X3 X3 X3 X3 X3 X3 X3 X15
C1
11 14
4.12 4.1 +15 1 10
10 13 0 1
4.12 4.1
9 12
4.12 4.1
5 9
+15
8
4.13 +15 +15 F3A S2
7.5A
C0.5
F7A K9 F2C F2A
86 87a 87
15A 7.5A 5A C1
3.1
85 30
1 10
0 1
OP
5 9
S3
N1
N1
X6 X6 X5 X6 X6 X6 X8 X8 X8 X8 X8 X8 X9 X8
H0.5
2 8 1 13 12 11 15 7 20 8 19 6 21 18
G1.5
R1
S1
S-G1
L/G1
M1
R-N1
L-B1
M-V1
Z-N1
M-N1
A-V1
R1
S14
R1
X51
B R1 R1
1
3.13
G-N1
1
X50
S-G1 MANIPOLATORE SX
X19 LEFT JOYSTICK
OPTIONAL
OPTIONAL
X50 X50
C A
X19
2
V1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
31 31
1.18 3.1
RKP11710
COMPONENTS S13 Brake light pressure switch Y19 Hammer or close grab solenoid valve X11 Lateral dashboard line 13 way connector FUSES
K9 Stop light relay S14 PPC enable micro switch Y20 Open grab solenoid valve X15 Parking brakes lamp 1 way connector F2A Servocontrol valve fuse 5A
S2 Parking brake button S15 Anti overturning pressure switch CONNECTORS X19 Optional pliers solenoid valve 2 way connector F2C Steering buttons relais fuse 7.5A
S3 Axle lock button S18 Joystick horn button X3 Right lateral dashboard line 18 way connector X49 7 way connector lights switch and dashoboard line F3A Steering buttons relais fuse 7.5A
S8 Hammer pedal button S22 Parking brakes pressure switch X50 3 way connector stop light sensor F7A Stop light and heater 15A
X4 Right lateral dashboard line 12 way connector
S9 Pliers button S23 Work brakes proximity (NPN NC) X72 Switches panel 12 way connector
X5 Engine line 11 way connector
S10 Joystick hammer button or close grab bucket Y7 Servocontrol solenoid valve X73 Switches panel 18 way connector
X6 Lights switch-gear shift line 13 way connector
S11 Joystick open grab button Y10 Axle lock solenoid valve X76 Dashboard extension 17 way connector
X8 Loom line 21 way connector
Y11 Parking brake solenoid valve X79 10 way connector push-buttons dashoard
X9 Lights switch-gear shift line 21 way connector
PW95R-2 10-127
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (3/8)
1 10 G1
0 1 DEVIO LUCI
2 3 4
LIGHTS SWITCH 0 1 2
1 6 8 10
1 0
2 8 5 10
0 1 2 0 1
15/1 30/3 L/6
3
5 9
S1 1 2 3 4 5 6 7 8 9 10 11 12
3 2 9 4 6 3 1 7 49/4 30b/2 R/7
+ 1
X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 S4 S6 S16 S7
A-B1
H1
G-L1
R-N1
V1
X13a
L-N1
H-G1
A1
N1
R-G1.5
B-R1.5
H-G1
2.20 1
R-N1
2.3
B-R1.5
1.19
X15
2
X75
X75
X75
R-N1.5
X75
X75
X75
X75
C1
2.20 2.4
X75
X75
6 17 21 20 7 18 19
1 10 2 5
0 1
B1 X49 5
1.11
C-V1.5
A-G1.5
A-R1.5
S-G1
A-B1
A-N1
H-R1
G1.5
B1.5
V1.5
H1.5
L1.5
5 9
A1
R1
S5
B0.5 7 16 15 10 10 5 3 14 18 2 9 7 6 17 6 12 1 3 8 4 1
2.20 X9 X9 X9 X11 X11 X4 X9 X9 X9 X11 X11 X11 X9 X4 X9 X4 X11 X11 X11 X11
X76
H-L1
1.20
C-B1 2 +15 28
1.20 1.20 4.1
G-V1
H-L1
C-B1
F5A F5C
8 11 6 3A 10A
X9 X9 X9 +30
+15 +30 +15 K10
K5 86 87a 87 K6 86 87a 87
+15
F3C F5B F4A F7B F6C F6B +
15 1
4.1 1.20 3
1.20
16
4.1
G-R1
A-B1
R1
G1
R1
A1
S-N1
A-B1
G-R1
B1
G1
B1.5
R1
A1
M1.5
G-N1.5
B1.5
M1.5
C-V1.5
A-G1.5
A-R1.5
G1.5
H1.5
5 4 1 2 3 6 8 7
G1
A1
G-R1
1 3 2 4 1 6 4
A-B1
X64 X64 X64 X64 X63 X63 X63
1 2 1 2
X67
X25 X25 X26 X26 X57 X57 X60 X60 X65 X65 X65 X67 X67 X67 X65 H7
H2 H3 H4 H5
Y3 Y4
R
L
57
57
56a
56b
56a
56b
R
59c
59c
L
57
57
1 2 H1 H6 M H8
X16 X16
M3 M
31
31
31
31
AUTORADIO RIGHT LEFT LEFT B.
POWER SUPPLY X25 FRONT FRONT
X57 RIGHT B.
3 3
N1.5
N1.5
N1.5
N1.5
N1.5
R1
N1
N1
2.9
N1
N1
31 31
2.20 4.1
COMPONENTS K10 Flasher unit CONNECTORS X25 Right front light 3 way connector RKP11720
H1 Boom working light M3 Blower motor X4 Right lateral dashboard line 12 way connector X26 Right side and direction light terminals X76 Dashboard extension 17 way connector
H2 Front right light S1 Gear high-low speed button X5 Engine line 11 way connector X37 Rear line 8 way connector FUSES
H3 Front left light S4 Working light switch X6 Lights switch-gear shift line 13 way connector X49 7 way connector lights switch and dashoboard line F3C Radio and cabin power fuse 7.5A
H4 Rear left light S5 Shovel-stabilizer selection button X8 Loom line 21 way connector X57 Left front light 3 way connector F4A Main beam fuse 15A
H5 Rear right light S6 Hazard X9 Lights switch-gear shift line 21 way connector X60 Left side and direction light terminals F5A Left traffic light fuse 3A
H6 Number plate lamp S7 Rotating lamp switch X10 Colum switch line 5 way connector X61 Lights switch 12 way connector F5B Low beam fuse 15A
H7 Beacon lamp S16 Heater switch X11 Lateral dashboard line 13 way connector X63 Cabin 7 way connector F5C Lights switch power fuse 10A
H8 Cabin working light Y3 Slow speed valve X13a Air condition interface 1 way connector X64 Heater 4 way connector F6B Direction indicators power fuse 7.5A
K5 Main beam relay Y4 High speed solenoid valve X14 Colum switch-frame line 5 way connector X65 Left side and direction light terminals F6C Hazard power fuse 10A
K6 Low beam relay X15 Parking brakes lamp 1 way connector X67 Right side and direction light terminals F7B Working light fuse 10A
PW95R-2
X16 Radio 2 way connector X75 Dashboard extension 21 way connector F7C Cabin power(+15) and beacon fuse 10A 10-129
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (4/8)
X62 X62 X62 X62 X62 X62 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B-G1
S-N1
B-G1
H-R1
H-N1
H-N1
1.20
G-R1
R-G1
C-N1
G-V1
B-G1
B-N1
M-B1
C-L1
R-N1
S-N1
B-R1
A-V1
R-V1
Z-B1
Z-N1
L-R1
L-R1
V/B1
S1.5
B1.5
S1
C1
N1
V1
H1
R1
H-R1
1.20
R-G1
1.20
M-B1
1.20
Z-N1
7 7 4 5 2 1 3 4 5 11 12 20 19 17 18 9 21 6 10 8 3 13 2 15 4 1 1 1.4
X9 X7 X9 X9 X1 X1 X1 X1 X1 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X33
16
3.7
28 A-N1
3.20 1.20
X10 X10
2 3
R-N1
R-V1
V-B1
L-R1
R1
L-R1
H1
A1
S1
V1
9 8 13 10 12 11 6 2 3 5 7 1 4 14
1
X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30
X48
GIUNTO
JOINT
B-R1
C1
X30a X30a X28 X30a X30a X30a X30a X30a X30a X30a X30a X30a X30a X28 X28 X28
9 8 1 10 12 11 6 2 R1 3 5 7 1 4 3 4 2
B1
C-B1
Z1
G-R1
V-B1
H1
S1
A/V1
S1
V1
L1
3 2 5
X29
X29
X29
X29
S12 C B A C B A
R-N1.5
X63 X63 X63
R-N1
R-V1
X32a
X32a
X32a
X31a
X31a
X31a
1 2 3 4
H9
M4
M1
M1
N1
N1
L1
L1
Y12 Y15 Y1 Y2 Y14 Y13 L-R1
1
M
1
SENSORE DI
MOVIMENTO SENSORE PONTE SENSORE PONTE -
MOVEMENT ANTERIORE POSTERIORE XW
SENSOR FRONT AXLE REAR AXLE Y6
2
SENSOR SENSOR
+
XW
N2.5
N1.5
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
31 31
3.20 /./
RKP11730
COMPONENTS Y12 Stabilizer solenoid valve X10 Colum switch line 5 way connector X46 Dashboard wiring 9 way connector
H9 Cabin lamp Y13 Round steering solenoid valve X28 Inferior cart line 4 way connector X49 Diode 2 way connector
M4 Washer wiper motor Y14 Crab steering solenoid valve X29 Optional 4 way connector X62 Gear shift 6 way connector
S12 Speed connection microswitch Y15 Gear power change solenoid valve X30 Joint 17 way connector X63 Cabin 7 way connector
V2 Power Mode valve 1A diode X30a Inferior cart line 12 way connector X68 Steering and gear unit 35 way connector
CONNECTORS
Y1 Front steering solenoid valve X31a Rear axle sensor 3 way connector XW EV Power Mode 2 way conn.
X1 Gear-steering interface line 5 way connector
Y2 Double steering solenoid valve X32a Front axle sensor 3 way connector FUSES
X7 Steering interface line 21 way connector
Y6 Working Mode solenoid valve X33 Engine line 7 way connector F1A Steering valves fuse 7.5A
PW95R-2 X9 Lights switch-gear shift line 21 way connector
X35 Power Mode resistor 2 way connector F1C Axle proximity power fuse 3A
10-131
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (5/8)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO
COMUNE SPIE LENTA-VELOCE ILLUMINAZIONE NOTTURNA
L7-L8 X81/1 -- ISOLATA A-V1 +L X81/9 NIGHTLIGHT +LUCI G-M1
STRUMENTO IND. LIV. CARB. USCITA BUZZER
S3 X81/2 FUEL LEVEL GAUGE ohm G1 X81/10 BUZZER O/P NEGATIVO A-R1
S2 S3 STRUMENTO TEMPERATURA SPIA AVARIA FRENI (rosso)
H F S2 X81/3 COOLANT TEMP. GAUGE ohm H-N1 L5 X81/11 W/L BRAKE SYSTEM FAILURE (red) NEGATIVO V-Z1
SEGNALE DI START SPIA PRERISCALDO (giallo)
+50 X81/4 START SIGNAL +50 B-G1 L2 X81/12 W/L PREHEAT (yellow) POSITIVO R-V1
S1
SPIA BLOCCAGGIO PONTE (giallo)
X81/5 NC L12 X81/13 NEGATIVO S0.5
00000 00 h W/L AXLE BLOCKED (yellow)
MASSA SPIA FILTRO ARIA (rosso)
S1 GND X81/6 GROUND GND N1 L4 X81/14 W/L AIR FILTER (red) NEGATIVO V-B1
C E
L11 X81/7
SPIA PALA-STABILIZZATORI (giallo)
W/L SHOVEL-STABILIZER (yellow) NEGATIVO G0.5 L1 X81/15
SPIA GENERATORE (rosso)
NEGATIVO Z-B1
W/L CHARGE (red)
L1 L2 L3 L4 L5 L11 +15 X81/8
POSITIVO ALIMENTAZIONE (+12V)
+15 H-G1 L3 X81/16
SPIA PRESS. OLIO MOTORE (rosso)
NEGATIVO V1
POWER SUPPLY (+12V) W/L ENGINE OIL PRESS. (red)
F
POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO
SPIA INDIC. DI DIREZIONE (verde)
X82/1 NC L9 X82/5 W/L DIRECTION INDICATOR (green) POSITIVO A1
L6 L7 L8 L9 L10 L12 SPIA MARCIA LENTA (giallo) SPIA LUCI ABBAGLIANTI (blu)
L8 X82/2 W/L FLOAT (yellow) ISOLATA C-B1 L10 X82/6 W/L HIGH BEAM (bleu) POSITIVO B1
SPIA FRENO A MANO (rosso)
L6 X82/3 W/L PARKING (red) NEGATIVO G-N1 X82/7 NC
SPIA MARCIA VELOCE (giallo)
L7 X82/4 W/L FAST GEAR (yellow) ISOLATA H-L1 X82/8 NC
S2 S3
INTERNAL ELECTRICAL SCHEME
TABELLA VALORI DI TARATURA STRUMENTO TABELLA VALORI DI TARATURA STRUMENTO
X81/11
X81/15
X81/12
X81/16
X81/13
X81/10
X81/14
X81/7
UNITA' CALIBRAZIONI UNITA' CALIBRAZIONI
OUT BUZZER
ohm ohm
a >14,2K100 4,3K 100 2,9K 100 0 a >360 262 2 116 2 0
L1 L2 L3 L4 L5 L11 L12
n∞ barra 1 4 7 8 n∞ barra 0 1 4 8
TERMOMETRO LIVELLO
barra sempre barra barra lamp. tutte le barre barra riserva ACQUA CARBURANTE
Note accesa al +15 lampeggiante +suono buzzer Note spente lampeggiante
S2
S1
S1 CONTAORE
CONTAORE MECCANICO S3
CONNECTOR
CIFRE BIANCHE INDICANO LE ORE L6 L9 L10
X81/1
X82/3
X82/2
X82/5
X82/6
X82/4
4 8 8 16 X81/9
RKP11740
PW95R-2 10-133
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (6/8)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
12 N.C. N.C.
13 N.C. N.C.
14 OPTIONAL OPTIONAL
4 N.C. N.C.
5 N.C. N.C.
X72 6 PULSANTE PEDALE MARTELLO HAMMER PEDAL BUTTON
10 N.C. N.C.
2 N.C. N.C.
7 N.C. N.C.
RKP11750
PW95R-2 10-135
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (7/8)
X68
2 N.C. N.C.
13 N.C. N.C.
14 N.C. N.C.
15 N.C. N.C.
16 N.C. N.C.
17 N.C. N.C.
19 N.C. N.C.
21 N.C. N.C.
23 N.C. N.C.
27 N.C. N.C.
RKP11840
PW95R-2 10-137
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (8/8)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
X62 X62 X62 X62 X62 X62
X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61
15 SX DX MI MA I II
I 0
0 SX MI MA
DX II
+ +
56a 56b 30 57/58 L
X61 X62
POS DESCRIZIONE FUNZIONE FUNCTION DESCRIPTION POS DESCRIZIONE FUNZIONE FUNCTION DESCRIPTION
1 +15 DEVIO LUCI LIGHTS SWITCH POWER
1 + CAMBIO AVA./IND. GEAR FW/BW POWER S.
2 LUCI DI POSIZIONE SIDE LIGHT SIGNAL
2 + CAMBIO C. I e II GEAR I e II POWER S.
3 LUCI ABBAGLIANTI HIGH BEAM LIGHT SIGNAL
3 N.C. N.C.
4 N.C. N.C.
4 MARCIA AVANTI DEVIO FORWARD SPEED SIGNAL
5 LUCI ANABBAGLIANTI LOW BEAM LIGHT SIGNAL
5 OUT II VELOCITA' OUT II SPEED
6 AVVISATORE ACUSTICO HORN
6 MARCIA INDIETRO DEVIO REVERSE SPEED SIGNAL
7 MASSA CLAXON HORN GROUND
12 N.C. N.C.
RKP11760
PW95R-2 10-139
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL UNIT FUSES - RELAIS (1/2)
D1
+15V 4
X2 1 8 5 4 1 5 4 3 1 7 7
+30V
1A 1A
X1 X3 X4 3A X5 J3 X6
1 +BUZZER-
18 16 15 12 11 9 12 10 9 8 7 6 1 1 D2 D3
F1 F2 F3 F4 F6 F5 F7
A B C A B C A B C A B C A B C A B C A B C
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 15A
FUSE 15A
FUSE 10A
FUSE 15A
FUSE 15A
FUSE 10A
FUSE 15A
FUSE 10A
FUSE 10A
FUSE 3A
FUSE 3A
FUSE 5A
FUSE 3A
FUSE 3A
FUSE 5A
F1A
F1B
F1C
F2A
F2B
F2C
F3A
F3B
F3C
F4A
F4B
F4C
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
1 1 1 1 1 1 1
1A K1 1A K2 1A K3 1A K4 1A K5 1A K6 1A K8 1A K9
3A
Z1
L1
L2
L3
L4
1A D9 3A D17
R1
1A D9
J6
J4 J5 6A D18
L5
L6
L4
6A D5
12 12 12 4 8
X7 X8 X9 X10 X11
1 1 1 1 1
RKP11800
PW95R-2 10-141
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL UNIT FUSES - RELAIS (2/2)
K4A
D10
D11
19 2 L1 1
EV/4R/S 11 spia/m/veloce crusc.
18 2 L2 1 K3B 5
EV/tondo 9 com/spie crusc.
K3A
17 2 L31 2 1 2 1 3 4 F5C 15
+15
EV/granchio +/devio/luci
14 2 L4 1 5 6 16
sw/marcia/ins 2 1
58/devio pos.
5 2 1 18
ing. marcia Ava./Ind. 56B/devio anabb.
X7 ing/freno/parcheg.
15 10 56A/devio abb. X9
4 2
1
out/buzzer +L/devio/freccie
K5A
K6A
D13
D12
2 1
ing.2R/S direz/sx
13 12
2 2
2 2
2 2
2 2
ing/tondo direz/dx
3 17
ing/granchio spia/hazard
K1A
K2A
D8
D6
11 F1A 14
+EV/sterz spia/abbagl.
16
+15
1 2 F1B 20
1
+EV/cambio m/avanti/devio
6 3 4 F1C 19
+proximity/scheda m/indietro/devio
12 5 6 13
EV/freno/rotaz alim/presa +30
1 3
press/rotaz avv/acustico
21 21
EV/c/cilindrata puls/pedale mart.
L5 1
R1
2 2 1 F5A
1/2W
1 2 10 58/ant/sx (posizione)
+30 +30
F5B 5
prox/all/post 1 K6B 7 56/B (anabbaglianti)
3 3 4 K5B 3 4 5
prox/all/ant 56/A (abbaglianti)
1 2
X1 2 3 4 11
L6
L7
EV/stabilizz/lama F4A ev/freno/di lavoro
5 5 8
EV/veloce +press./luci stop
EV/lenta 4 2 press./luci stop
4 press./avaria freni X6
1
1 1a/veloce/Risc
D9
D7
9 2a/veloce/Risc
2
K1B 5 3
3 4
EV/M/avanti
K2B 6
3 EV/M/indietro
4 12 EV/martello
5 13 EV/benna
8 EV/freno/parcheggio
4 EV/veloce
10 EV/lenta
14 21
prox/all. anteriore EV/freno/rotaz
16 7
prox/all. posteriore EV/blocco/ass
8 F2A 20
+15
sw.2R/S +sw/servocom
7 1 2 18
sw/tondo puls/pinza
6 19
sw/granchio press/antiribalt.
buzzer 5 1 +autoradio
12 11
sw/freno parcheggio press/rotaz
EV/stabilizz/lama
15 K8B 5 3 avv/acustico X8
2 3 4 16
sw/martello 1
58/ant/dx
1
X3 sw/benna 2 17 56/B
5404
10 12
D19
sw/blocco/assale 56/A
3 15
(sw/freno/lavoro) EV/pinza
sw/pinza 11 2 Faro/lavoro su braccio
press/antirib. 13 14 direzione/dx
9 F6A
+30
puls/pedale mart 13 +pompa/travaso
17 F3A 1 2 9
+rele pulsantiera livello carb.
1 2 16
+15
+rele pulsantiera 18 F2C op
5 6 F4B J4
4 F2B 15
+scheda/pulsantiera 3 4 3 4 J5 op
12
+strum
7
58/strum 10
4 +alternatore
sw/avv/acustico 11
K9A
9 +elettrostop
D16
rele/pinza 5
8 cons/avviam
press/avaria freni K4B 5 6
11 58/dx
livello carb 3 4 9
X4 (-) rele/stop
10
K9B 1
58/sx
2 luci/arresto
lamp/sw/risc
3
2 1
3 4 3 avv/retrom
X5
lamp/sw/fari/lavoro 2 1 5 4
6 GND
direx/sx 7
5 2 1 direz/dx
freno/parcheg.
P600
D18
1 8 direz/sx
direz/dx 2
J3 op
4
K8A
D15
f/lavoro su cabina
4007
4007
P600
F3B 1 girofaro
+15
2
5404 D1
2 1 4 3 +15/CAB X10
1
2
5404
1
1
+30/CAB
D17
5
X2-2
X2-1
2 1 op
D5
D2
D3
FLASCHER UNITS
1
J6
2
2
3
2
+15 +30
Z1
+30/sw/hazard 7 F6C 6 5
5 6
6 F6B F4C
+15/sw/hazard 3 4
4 1
1 F7C
(+sw/girofaro) 5 6
+sw/riscald 12 F7A
1 2
5
+sw/f/lavoro1 9 F7B
3 4
out/f/lavoro su brac. 5
10
X11 out/f/lavoro su cab.
13
(out/1/velocita/R)
11
(out/2/velocita/R)
out/girofaro 4
L/intermitt. 8
spia/frecce 2 F3C
+30
+intermittenza 3 5 6
RKP1810
PW95R-2 10-143
PAGE INTENTIONALLY
LEFT BLANK
TESTING AND ADJUSTMENTS
Normal or standard technical data............................. 2 Checking and regulating the pressure of the
Special tools ............................................................ 16 steering system ........................................................41
Measuring the engine speed ................................... 17 Checking leakages in the steering cylinders ............42
Adjusting valve clearance........................................ 18 Checking the braking system ...................................43
Measuring compression pressure ........................... 19 Checking wear in the brake disks.............................48
Testing and adjusting fuel injection timing............... 20 Bleeding air from the brake lines..............................49
Testing and adjusting fan belt tension ..................... 22 Adjusting the parking brake......................................50
Checking and tightening the compressor fan-belt ... 23 Travel hydraulic equipment checking procedure......51
Adjusting the stroke of the accelerator lever ........... 24 Checking and adjusting the automatic
displacement control system of the travel motor ......52
Adjusting PPC valves clearance.............................. 25
Checking for leakages in the travel motor ................53
Adjusting the safety microswitch ............................ 26
Checking and adjusting the speed of
Measuring the swing circle axial clearance ............. 27
the travel propeller shaft...........................................54
Air bleeding from hydraulic circuits .......................... 28
Adjustment of the speed surveyor............................55
Releasing residual pressure from the circuits.......... 31
Adjusting boom and arm safety valves.....................56
Checking and regulating pressure in the
Adjusting 2nd boom safety valves............................57
hydraulic circuits ...................................................... 32
Measuring and setting of pressure switch
Testing and setting of main valves .......................... 33
signal overload operation .........................................58
Adjusting PC valve .................................................. 35
Measurement of internal oil leakages
Measuring ls differential pressure in the swing motor ....................................................59
and adjusting LS valve ............................................ 36
Checking for leakages inside the swivel joint ...........60
Checking and adjusting pressures in
Analysis of the causes of hydraulic drifts .................63
the servocontrol feed unit ........................................ 38
Testing the air-conditioning unit ...............................73
Measuring pumps delivery and flow control
starting point pump P1............................................. 39 Emptying the air-conditioning unit ............................75
Checking that the priority valve is
functioning correctly................................................. 40
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level ground.
Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine is un-
dergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed while the
liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
PW95R-2 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
20-2 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR ENGINE
PW95R-2 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
★ All tests, if not otherwise specified, should be performed with WORKING MODE in posizion P
Machine model PW95R-2
Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Engine speed with – 50 – 50
pump P1 2200 + 100 2200 + 100
at max. pressure
Engine speed with • Oil temperature: 45–55 °C – 50 – 50
pumps P1 and P2 • Engine oil pressure: in correct range 2150 + 100 2150 + 100
at max. pressure
Engine
Boom a b a b
Arm
Spool travel control valve
Bucket
a b
Swing
Boom swing mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3
Blade and outrigger
2nd boom
RKP08070
Travel
Attachment
Raise
Boom control lever Neutral 75±8 65--85
Lower
Extended
Arm control lever Neutral 75±8 65--85
Retracted
Open
Bucket control lever Neutral 75±8 65--85
Curled
Travel of levers and pedals
20-4 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ FOR MACHINE
275 +0 20 275 +0 20
Main valve
P1 pump (Safety)
pressure
PW95R-2 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
• Working Mode: P
• Engine speed: high idling
• Oil temperature: 45–55 °C
• Measure the time taken to make 5 full swings
• Check all the direction of swing
15°
20-6 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
2nd speed
– 50 – 50
1080 + 100 1080 + 100
4th speed
• Oil temperature: 45–55 °C
• Rest the front work equipment on the + 100 + 100
ground and push it down to raise the 3730 – 200 3730 – 200
machine
• Measure the speed of the propeller
shaft in 4th speed
Measuring posture
45°
2nd speed
9.9±1 9.9±1
RKP06030
• Working Mode: P
4th speed
Hydraulic drift
of travel motor
mm 0 --
15°
RKP06040
• Engine stopped
• Oil temperature.: 45–55 °C
• After 1 minute, mark the position; measure drift
for every 5 minutes and then check total drift in 15
minutes.
• Engine speed: 2000 rpm
• Oil temperature: 45–55°C
Leakage from
travel motor
• Working brakes: engaged /min – –
• 2nd fast gear engaged
• After 30 seconds start to measure for full minute
PW95R-2 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
20-8 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
A Boom
B A Max. 15 Max. 22
C L=1600
Outriggers RKP06081
mm Max. 10 Max. 15
• Engine: switched off
• Oil temperature: 45–55 °C
• Raise the outriggers and and measure the height
of the edge from the ground.
Measure the downward after 15 mins.
• Check one cylinder at a time
Blade
(measure the downward
movement of the edge of mm Max. 10 Max. 15
RKP06091
the blade) • Engine: switched off
• Oil temperature: 45–55 °C
• Raise the blade and measure the height of the
edge from the ground.
Measure the downward after 15 mins.
• Check one cylinder at a time
PW95R-2 20-9
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
(whitout braking)
Measuring posture
Raise
Boom 3.3±0.3 Max. 4.0
Bucket teeth on
the ground
RKP06100
Cylinders completely
Lower
extended 3.3±0.3 Max. 4.0
• Working Mode: P
• Engine speed: high idling
• Oil temperature: 45 –55 °C
Measuring posture
RKP06110
Cylinder completely
Inout
sec.
Measuring posture
Closed
Arm 0
3.2 + 0.8 Max. 4.5
Cylinder completely
retracted
RKP06120
Cylinders completely
Inout
• Whitout braking
extended 2.5±0.6 Max. 3.5
• Working Mode: P
• Engine speed: high idling
• Oil temperature: 45–55 °C
Measuring posture
Curled
Bucket – 0.2
3 + 0.4 Max. 4.0
Cylinder completely
retracted
RKP06130
Cylinders completely
Dump
20-10 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Measuring posture
L.H.
Boom swing 6.0±0.6 Max. 7.0
Cylinder completely
retracted
RKP06140
Cylinders completely
R.H.
• Work equipment at max. reach
extended 6.0±0.6 Max. 7.0
• Working Mode: P
• Engine speed: high idling
• Oil temperature: 45–55 °C
Measuring posture
Raise
– 0.1
Attrezzature di lavoro
Resting on ground
sec.
RKP06150
Fully raised
Lower
– 0.2
2.6 + 0.4 Max. 3.5
• Working Mode: P
• Engine speed: high idling
• Oil temperature: 45–55 °C
Measuring posture
Raise
– 0.1
Blade 2.5 + 0.5 Max. 3.5
height – 0.2
2.6 + 0.4 Max. 3.5
• Working Mode: P
• Engine speed: high idling
• Oil temperature: 45–55 °C
PW95R-2 20-11
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Measuring posture
RKP06170
• Engine speed: low idling
• Oil temperature: 45–55 °C
• Retract fully the cylinders of the arm and buc-
ket. Lower bucket to ground and measure time
taken for chassis to rise from ground.
Measuring posture
Work equipment
Time lags
Measuring posture
20-12 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Measuring posture
A
B Boom
C A Max. 2 Max. 3
L=1600
Boom
Arm RKP06201
B Max. 2 Max. 3
L=1850
• Engine speed: low idling
• Oil temperature: 45–55 °C
• Bring the boom into a horizontal po-
sition.
Retract the cylinder of the arm com- Boom
pletely and then extend it. C Max. 2 Max. 3
L=2300
Amount of time when arm stops for a
moment.
Measuring posture
Work equipment
Time lags
RKP06210 sec.
Bucket Max. 2 Max. 3
Measuring posture
PW95R-2 20-13
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Time lags
20-14 PW95R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Working Mode P
Pumps delivery
PW95R-2 20-15
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Commercially
Valve clearance A 1 Feeler gauge 1 –
available
Commercially
1 Multi-scale tachometer 1 20 - 4000 rpm
available
Engine speed C
Commercially
2 Stroboscopic tachometer 1 6 - 30000 rpm
available
Servocontrol kit
5 Digital differential 1 0–1000 bar
878000473 pressure gauge
Commercially
Thickness of brake disks G 1 Feeler gauge 1 4.5/4.3 mm
available
Commercially
1 Maintenance station 1 For coolant R134a
available
Commercially
3 Leak detector 1 For coolant R134a
available
20-16 PW95R-2
TESTING AND ADJUSTMENTS MEASURING THE ENGINE SPEED
PW95R-2 20-17
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE
• Adjusting procedure
RKPB4840
1 - Remove the cover valves (1).
RKP10501
2 - Install valves cover (1), fit O-Rings (6) and lock nuts (7).
5
RKP10511
20-18 PW95R-2
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE
RKPB4850
35
30
25
20
(bar)
200 250 300 350 400
Engine speed (rpm)
RKP10524
PW95R-2 20-19
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING
Flywheel
RKP11101
1
RKPB3840
Nº1
RKPB4860
RKP11111
20-20 PW95R-2
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING
1
RKPB3860
PW95R-2 20-21
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FAN BELT TENSION
RKPB4870
98 N
Water pump
pulley
10--15mm
Alternator
Crankshaft
pulley
RKP10533
20-22 PW95R-2
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT
1 2
RKP12610
PW95R-2 20-23
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR LEVER
RKPA5240
3 - Unscrew the nuts (5) and (6) and tighten the screws (3)
and (4) in the support.
9
4 - Move the accelerator lever (9) slowly towards low idling 9
5 3 6 4
position. Stop this movement when the lever (7) on the
cover of the injection pump comes into contact with the
low idling adjustment screw (8).
5 - Adjust the screw (3) until it is 0.1 mm from the lever (9)
and lock it in this position with the nut (5).
RKPA5250
6 - Move the lever (9) towards the high idling position. Stop
this movement when the lever (7) on the cover of the in-
8 10
jection pump rests against the lead-sealed high idling
adjustment screw (10).
7 - Adjust the screw (4) to 0.1 mm from the lever (9) and
lock it in this position with the nut (6).
★ After adjustment, replace the right-hand cover and
check that the aperture does not impede the move-
ment of the lever (9) towards its extreme positions.
7
RKPA5260
20-24 PW95R-2
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE
25
3 - Block the set position by tightening the nut (4) to the
°
specified torque.
Nut: 8±1 Nm
2
4
3
1
RKP11020
PW95R-2 20-25
TESTING AND ADJUSTMENTS ADJUSTING THE SAFETY MICROSWITCH
RKPA5270
2
1
16 0+1
RKP07480
20-26 PW95R-2
TESTING AND ADJUSTMENTS MEASURING THE SWING CIRCLE AXIAL CLEARANCE
2 - Extend the boom, the arm and the bucket, in such a way
that they cover the maximum radius of action when the
teeth of the bucket are at the same height as the lower
platform of the revolving frame.
RKP09250
2
RKPB0920
150 ÷ 200 mm
RKP09270
PW95R-2 20-27
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS
• Replace cylinder
❍ ❍ ❍
• Remove cylinder piping
• Replace swing
motor
❍ ❍
• Remove swing
motor piping
• Replace travel motor,
swivel
❍ ❍
• Remove travel motor,
swivel piping
• Replace steering unit or
priority valve
❍ ❍ ❍
• Remove steering unit or
priority valve piping
★1 Bleed the air from the swing motors or travel motors only when the oil inside the motor case has been drained.
2 - Fill the tank with oil up to the level of the hole in the 1
plug (1).
20-28 PW95R-2
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS
RKPB6130
PW95R-2 20-29
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS
of air.
20-30 PW95R-2
TESTING AND ADJUSTMENTS RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS
2 - Put the ignition key at position “I” and move the control 0 1
lever in all directions to relieve all pressure in the main
hydraulic circuits and the PPC valves.
PW95R-2 20-31
CHECKING AND REGULATING PRESSURE IN
TESTING AND ADJUSTMENTS THE HYDRAULIC CIRCUITS
SECTION 1
2 - Main relief valve (Section 2)
3 - Safety valve
SECTION 2
P2
DIESEL P1 P2 2
TANK
P1
1
RKP10581
Swing (Left-Right) A1 - B1
2
Blade (Down-Up) A2 - B2
9 9
Travel motor A3 - B3
10 10
Boom (Raise-Lower) A4 - B4
8 8
Arm (Open-Close)) A5 - B5
7 7
Bucket (Curl-Dump) A6 - B6
6 6
1 Blade and/or R.H. outrigger ✽ A7 - B7
5
5
(Lower - Raise)
4 4
Boom swing (Left-Right) A8 - B8
3 3
2-piece boom A9 - B9
2 2
★ Attachment (L.H. side - R.H. side) A10 - B10
1 1
✽ If expected
★ Optional
PORTS A B RKP10591
20-32 PW95R-2
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES
PW95R-2 20-33
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES
RKP10600
20-34 PW95R-2
TESTING AND ADJUSTMENTS ADJUSTING PC VALVE
ADJUSTING PC VALVE
★ In case the engine speed lowers as a load becomes
larger, or in case the work equipment speed is slow
even though the engine speed, pump discharge pres- 1
sure and LS differential pressure are normal, adjust the
PC (1) valve according to the following procedure.
1 - Loosen the lock nut (2). For the cases of slow speed,
turn the sleeve (3) clockwise, and for the cases of low-
ering of engine speed, turn the sleeve counterclock-
wise.
★ Clockwise rotation of the sleeve «increases» the
suction torque of the pump, and counterclockwise
rotation «decreases» the absurption torque.
RKPB1490
★ Rotation range of the sleeve (3) shall be within 180°
for both clockwise and counterclockwise.
2- After adjustment finished, tighten the lock nut (2).
2
3
RKP10830
PW95R-2 20-35
MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE
RKPA5370
E5
3
RKPB5850
Table 1
M1
Work Fuel Differential
Operation
mode lever pressure
P Full Lever at NEUTRAL
Travel speed: Hi
p Full 21.5±1
Travel idling (lever full) RKPB5430
20-36 PW95R-2
MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE
6 RKP10820
PW95R-2 20-37
CHECKING AND ADJUSTING PRESSURES IN
TESTING AND ADJUSTMENTS THE SERVOCONTROL FEED UNIT
2 - Start the engine and move the accelerator into its max- E1
imum position.
RKP10630
20-38 PW95R-2
MEASURING PUMPS DELIVERY AND FLOW CONTROL
TESTING AND ADJUSTMENTS STARTING POINT PUMP P1
PW95R-2 20-39
CHECKING THAT THE PRIORITY VALVE IS
TESTING AND ADJUSTMENTS FUNCTIONING CORRECTLY
4 - Start to turn the wheel very slightly and see whether the
pressure increases.
2 - Remove the cap (2) of the PP port and check (by push-
ing with a rod) that the spool (3) moves freely along the
entire length of the stroke. 4
3 - Check that the nozzle (4) inside the spool is free of ob-
structions. 1
4 - Re-assemble the priority valve (1). RKP09280
20-40 PW95R-2
CHECKING AND REGULATING THE PRESSURE
TESTING AND ADJUSTMENTS OF THE STEERING SYSTEM
Test E3
1 - Connect pressure gauge E3 (400 bar) to the adapter
M2.
2 - Start the engine and put it into high idling and turn the M2
steering wheel as far as it will go.
3 - Stop the engine and replace the cap (3), making sure
that the washer (5) is properly seated.
Cap: 50±10 Nm
PW95R-2 20-41
TESTING AND ADJUSTMENTS CHECKING LEAKAGES IN THE STEERING CYLINDERS
20-42 PW95R-2
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM
ue (140±10 bar).
4 - Using the push-button that engages the working
brakes, perform several braking actions to check
whether or not the accumulators start to recharge when
the normal minimum pressure is reached (110±10 bar).
Adjustment
If the pressures are not within normal values, proceed as fol-
lows:
3 - Loosen the nut (4) and adjust the initial recharging pres-
sure using the adjustment screw (5).
★ Initial recharging pressure: 110±10 bar.
• To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction. 5
• To DECREASE pressure, turn in a CLOCKWISE
direction.
4
4 - Secure the adjustment screw (5) with the nut (4).
RKPB5750
PW95R-2 20-43
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM
RKPB5460
9 8
RKPB5760
20-44 PW95R-2
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM
braking action.
6 - Watch the pressure shown by pressure gauge E2 for two
minutes. During this period the pressure value should
not vary with respect to the first reading.
★ If variations in the braking pressure are observed,
verify in the following sequence:
1 - Any visible leakages in the system.
PW95R-2 20-45
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM
RKPB2710
20-46 PW95R-2
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM
Adjustment
If the warning light comes on at values higher or lower than
80 +0 2 bar, adjust the intervention setting of the pressure
switch (16) that causes the warning lamp to light up.
The setting is obtained by turning the screw (17).
• Switching pressure: 80 +0 2 bar
• To INCREASE pressure turn in a CLOCKWISE direc-
tion. 16
• To DECREASE pressure, turn in a COUNTERCLOCK- 17
WISE direction.
RKPA7820
PW95R-2 20-47
TESTING AND ADJUSTMENTS CHECKING WEAR IN THE BRAKE DISKS
groups.
1- If the thickness «S» of one of the two brake groups
of an axle is equal to or less than the minimum per-
missible thickness, change the disks on both
brake groups.
2- After changing the brake disks, bleed air from the
brake line. G1
(See «BLEEDING AIR FROM THE BRAKE
LINES»).
S
RKPB2900
20-48 PW95R-2
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE BRAKE LINES
4 - Return the ignition key to position “I” and press the but- 1
ton that engages the working brakes.
PW95R-2 20-49
TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKE
Nut: 20–25 Nm
Nut: 50–60 Nm
10 - Stop the engine and check that when the parking brake
is on, the stem (9) juts out 4–5 mm from the head of cyl-
inder (1).
20-50 PW95R-2
TESTING AND ADJUSTMENTS TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE
PW95R-2 20-51
CHECKING AND ADJUSTING THE AUTOMATIC
TESTING AND ADJUSTMENTS DISPLACEMENTCONTROL SYSTEM OF THE TRAVEL MOTOR
E4
RKPA7900
Adjustment
1 - Take off the safety cap (2).
4 - ecure the position of the screw (4) with the nut (3). RKPA7910
Lock nut: 10 Nm
5 - Replace the cap of the control system (1).
Cap: 30 Nm
4
6 - Replace the safety cap (2) to protect against unauthor-
ised tampering. 3
RKP09320
20-52 PW95R-2
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR
★ Test conditions:
• Engine at working temperature 1 3
• Hydraulic oil: 45–55 °C
• Working brakes: engaged
• Selector in WORKING MODE: position P 2
1 - Disconnect the drainage tube (1) from the lower union
(2) of the motor (3) and plug it.
4 - Select the 2nd fast forward gear and press the travel
pedal slowly to the end of its stroke.
5 - Hold the travel pedal in this position for 30 seconds and
then measure the oil drainage from the motor for the
next minute.
PW95R-2 20-53
CHECKING AND ADJUSTING THE SPEED OF
TESTING AND ADJUSTMENTS THE TRAVEL PROPELLER SHAFT
Test
★ Make a distinct mark (1) on the propeller shaft to facil-
itate the reading of the speed indicator C2.
1 - Position the machine with the arm vertical and the back
of the bucket resting on the ground. 10 cm
RKPB0821
2 - Push down the boom and the rear outriggers until the
machine is completely raised.
If the blade is mounted on the machine, rest it on the
ground after the machine has been raised. 1
3 - Place safety blocks, height 10 cm, beneath the centre of
the axles to prevent the machine from dropping acci-
dentally.
After having lowered the axles gently onto the
blocks, check that the wheels are raised approxi- C2
mately 10 cm above the ground.
4 - Use blocks to stop the front axle from turning.
5 - Select the 2nd fast forward gear. RKPB2730
Adjustment
RKPB2130
1 - Take off the safety cap (2).
2 - Loosen the nut (3).
3 - Regulate the speed with the minimum displacement ad-
justment screw (4).
• To INCREASE the speed turn in a COUNTER-
CLOCKWISE direction.
• To DECREASE the speed, turn in a CLOCKWISE
direction.
4 - Secure this position with the nut (3).
Lock nut: 69 Nm
5 - Apply a new safety cap (2) to protect against unauthor-
ised tampering. 4 3
RKP10070
20-54 PW95R-2
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE SPEED SURVEYOR
RKPB2740
PW95R-2 20-55
TESTING AND ADJUSTMENTS ADJUSTING BOOM AND ARM SAFETY VALVES
RKP07440
20-56 PW95R-2
TESTING AND ADJUSTMENTS ADJUSTING 2nd BOOM SAFETY VALVES
11 9
RKP07430
PW95R-2 20-57
MEASURING AND SETTING OF PRESSURE SWITCH
TESTING AND ADJUSTMENTS SIGNAL OVERLOAD OPERATION
4 - Raise boom until the lift end of stroke and increase lowly
the pressure; check the pressure value when appear
the overload signal.
★ Standard operating pressure: 140 bar RKPB1470
Setting
If the operating pressure in not within the standard limits,
make the pressure switch (1) setting as follows:
1 - Remove cover (2).
2 - Raise the boom checking on gauge E3 that hydraulic
cylinder approach the operating pressure.
3 - Loose the dowel (3) and turn the adjusting screw (4) un-
til to obtain the overload alarm signal. 1
• To INCREASE the operating pressure, turn the
screw in CLOCKWISE direction.
2
• To DECREASE the operating pressure, turn the
screw in COUNTERCLOCKWISE direction. RKPB6580
RKPB5620
20-58 PW95R-2
MEASUREMENT OF INTERNAL OIL LEAKAGES
TESTING AND ADJUSTMENTS IN THE SWING MOTOR
PW95R-2 20-59
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
20-60 PW95R-2
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
PW95R-2 20-61
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
5. Test
1 - Start the engine and bring it up to the test speed de-
scribed for each group or component.
2 - Pressurise the branch to be tested.
3 - After 30 seconds, watch for another minute if there are
any leakages.
★ If oil leaks out of one of the two provisional hoses, it
means that there is a leakage in the intermediate
gasket between the branch connected to the pro-
visional hose and the pressurised branch.
20-62 PW95R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKP09370
1. Boom test
2. Arm test
RKP09380
PW95R-2 20-63
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
3 - Disconnect:
For the boom, the head side pipe.
For the arm, the bottom side pipe.
4 - Start the engine and extend the arm completely for 1
the «Boom test», or raise the boom for the «Arm
test». V2
5 - Stop the engine and check for leakages from the
valve for 5 minutes.
• If there is any leakage, the valve is defective.
RKPB1051
20-64 PW95R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKP09390
3 - Disconnect the two pipes (1) and (2) and cap them
to prevent entry of impurities. 2
★ If a safety valve has been installed, remove it.
4 - Cap the cylinder couplings on the bottom side and
attach provisional hoses on the head side to collect
any leaking oil.
RKPB1600
PW95R-2 20-65
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKP09400
6. Bucket test
RKP09430
RKPB1610
20-66 PW95R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKP09420
slope.
6 - Stop the engine and check the position of the boom
for 15 minutes.
• If the boom tends to swing, the drift is due to the
cylinder gasket.
• If the boom does not tend to swing, the drift is
due to the control valve.
1 2
RKPA5490
PW95R-2 20-67
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKP09460
20-68 PW95R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
9. Blade test
5 - Plug the tube (3) on the head side of just one cyl- 2 2
inder (4) and attach a provisional tube on the base
side of the same cylinder to collect any leakages.
★ The second cylinder should be left completely
free.
3
6 - Start the engine, push down with the boom to raise
the machine in order to remove the block on which 3 1
the blade is resting. 4
7 - Lower the machine and stop the engine. 4
8 - Check the position of the blade for 5 minutes. RKPA7970
RKP09480
PW95R-2 20-69
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKPB6132
A RKP12492
20-70 PW95R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
3 - Insert the cock “A” between the brake (1) and the
tube (2).
Attach the pressure gauge E1 (60 bar) to the adapt-
er of cock “A”. to keep a check on the parking brake
release pressure throughout the test. RKP09520
4 - With the cock “A” open, start the engine and en-
gage and release the parking brake several times. 2
A
5 - Raise the front work equipment and travel the ma- 1
chine over a surface with a 15° slope.
★ The articulated axle should be facing towards
the lower part of the slope.
6 - Using the working brakes to hold the machine in po-
sition, close the cock “A”. in order to maintain pres-
sure (35 --0 3.5 bar) and thus to keep the parking
brake released.
Stop the engine. E1
RKPA7981
15°
RKP09530
PW95R-2 20-71
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
RKP09410
PW95R-2 20-72
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
Ambient
20 25 30 35
temperature (°C)
Outgoing air
6 -- 8 8 -- 10 8 -- 12 9 -- 14
temperature (°C)
PW95R-2 20-73
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
PW95R-2 20-74
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
PW95R-2 20-75
REMOVAL AND INSTALLATION
PW95R-2 30-1
L.H. PPC VALVE (ARM-SWING) BUCKET CYLINDER
Removal .................................................................. 79 Removal and installation ........................................204
Installation ............................................................... 80 BOOM SWING CYLINDER
OUTRIGGER AND BLADE PPC VALVE Removal and installation ........................................205
Removal and installation ......................................... 81 CYLINDERS FOR OUTRIGGERS OR BLADE
BOOM SWING PPC VALVE 82 Removal and installation ........................................206
Removal and installation ......................................... 82 WORK EQUIPMENT CYLINDERS
TRAVEL AND 2nd BOOM PPC VALVE Disassembly ...........................................................207
Removal and installation ......................................... 83 Assembly................................................................208
BRAKE PUMP WORK EQUIPMENT (For 1-piece boom)
Removal and installation ......................................... 84 Removal and installation ........................................212
STEERING UNIT WORK EQUIPMENT (For 2-piece boom)
Removal and installation ......................................... 85 Removal .................................................................213
Disassembly ............................................................ 86 Installation ..............................................................214
Assembly ................................................................. 92 BUCKET
PRIORITY VALVE Removal and installation ........................................215
Removal and installation ....................................... 102 ARM
Disassembly .......................................................... 103 Removal .................................................................216
Assembly .............................................................. 103 Installation ..............................................................218
TRAVEL MOTOR 2nd BOOM
Removal ................................................................ 104 Removal .................................................................219
Installation ............................................................. 105 Installation ..............................................................220
Disassembly .......................................................... 106
BOOM (For 1-piece boom)
Assembly ............................................................... 109
Removal and installation ........................................221
TRANSMISSION
BOOM (For 2-piece boom)
Removal and installation ....................................... 114
Removal .................................................................222
Disassembly .......................................................... 115
Installation ..............................................................223
Assembly ............................................................... 122
SWING SUPPORT
AXLE LOCKING CYLINDERS
Removal and installation ........................................224
Removal and installation ....................................... 129
BLADE AND OUTRIGGERS
FRONT AXLE
Removal and installation ........................................225
Removal ................................................................ 130
Installation ............................................................. 132 BLADE AND OUTRIGGER ARMS
Removal and installation ........................................226
REAR AXLE
Removal ................................................................ 133
Installation ............................................................. 135
AXLES
Disassembly .......................................................... 136
Assembly ............................................................... 162
BOOM CYLINDER (For 1-piece boom)
Removal and installation ....................................... 198
BOOM CYLINDER (For 2-piece boom)
Removal ................................................................ 199
Installation ............................................................. 200
Installation
2nd BOOM CYLINDERS
Removal ................................................................ 201
Installation ............................................................. 202
ARM CYLINDER
Removal and installation ....................................... 203
30-2 PW95R-2
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
(2) Information needed for installation is marked with the symbol 1 . The same symbol is repeated at the end
of each removal procedure for the same item, to indicate to which installation item it refers.
(Example)
REMOVAL GROUP ● ● ● : .......................................................Title of operation
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific «PRE-
CAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks
and containers
(1) In the operating procedures, you will find the symbols , , , . In the following order, these rep-
resent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES OF
OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
PW95R-2 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHEN WORKING
30-4 PW95R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Removal/Installation of
counterweight Commercially Dynamometric wrench
A 1 1 Max. 700 kgm (700 dNm)
Disassembly/Assembly of available with multiplier
cylinder nut
Commercially
Air conditioning unit D 1 Maintenance station 1 –
available
1 – Wrench 1 –
Removal/installation of
2 – Tool 1 differential planetary
wheel pins
3 – Bushing 1
Installation of differential
4 – Tool 1 planetary wheel pins
– Wrench 1
5 Flange locking
– Wrench 1
8 – Block 1 –
9 – Spacer 1 –
Disassembly/Assembly axles M
– 1
Bearing inner ring
10 – 1 Installation pinion bearing
installation kit
– 1
Pinion dimension
11 – Tool 1 measuring
14 –0 Plunger 1
15 – Plunger 1
17 – Bush 1
PW95R-2 30-5
REMOVAL AND INSTALLATION SPECIAL TOOLS
18 – Extension 1
19 – Plunger 1
20 – Plunger 1
21 – Plunger 1
22 – Plunger 1
Disassembly/Assembly axles M
23 – Plunger 1
24 – Plunger 1
26 – Plunger 1
27 – Plunger 1
30-6 PW95R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS
50
C1
20
120± 0.1
=
200
=
90
= = 840
930
RKP12980
C2 125 C3 59
15 14
10
3.2
3.2
3.2
Ø78.5 ± 0.1
Ø84.5 ± 0.1
Ø74 ± 0.1
1 x45°
Ø35
Ø62
Ø76
Ø90
1x45°
R2 R2
R2
RKP13310
RKP13330
C4
14
6
Ø40
3.2
Ø124 ±0.01
3.2
Ø130 ±0.01
RKP133200
PW95R-2 30-7
REMOVAL AND INSTALLATION SPECIAL TOOLS
Ø125
10x15°
Ø41
M1 Ø35.5 ---- 0.1
0.2
M2 Ø25
0.8 Ø20 + 00.2
1x45°
Ø5.5
R1
0.8
Ø15H7-n6
100
5
Ø14
2 x15°
36
8
31
26
0.8
20
24
17
20
238
0 0.8
R1 Ø25
Ø10 M26X1.5
Ø35
123
125
Ø5.5
33
36
18
22.5
0.8
33
6 9
10.5
Ø37H7-n6
1 x45°
Ø47
6
0.8
Ø106 ± 0.1 Ø20 + 00.2
R30
25
Ø25
Ø41 RKP13100
RKP13090
8.5
0
Ø30
0.8
Ø6
15° 10 46.45 ± 0.1 ± 0.5
10 19.6
56.6 29.6
Ø20 ++ 0.08
0.12
0.5x45°
Ø27 ---- 0.1
0.2
Ø23
Ø30
0.8
Ø19.9 +-- 0.1
0
RKP13110
1x30°
175
RKP13120
135 ±0.5
Ø185 ± 0.2
M5
97
73
Ø105 ± 0.2
120
61.5
80
61.5
85
126 12
Ø32 Ø105 ± 0.2
25
10
150 125
10
15
15
125
25
100
Ø34.5--+ 00.2
Ø45 Ø50 RKP13160
30-8 PW95R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS
Ø85
M6 Ø66 M7 Ø75
0.8
0.8
5 x15
Tornito Ø
0.8
32,25
22
75
35
10
60
15
6
14
34
60
6 3/4"
Ø15H7-n6
20
40
20
15°
60
100
275 RKP13170
RKP13180
M8 99.5
M9 Ø30.2 ± 0.001
Ø17
5x45°
25
Ø88.8 ± 0.005
131
Ø42
20
RKP13200
RKP13190
M10
Ø19.55H7
A
21°
0.8
R5
R2
23
B 3x15°
Ø83
Ø40
Ø88
R2
0.8
0.8
Ø20 +-- 00.1
0.8
21°
0.8
R2
23 40
0.8
R2 73
10 56 C B A
66
Ø16.5---- 0.1
0.2
M18x1.5
M18x1.5
473.5
C 433.5
0.8 0.8 0.8
Ø35
Ø40
15°
5 5x15°
Ø19.5 ---- 0.12
0.08
11 30
45
RKP13210
PW95R-2 30-9
REMOVAL AND INSTALLATION SPECIAL TOOLS
25 25
20
50
0.02
61---- 0.01
4 x45°
R5
41
30
Ø20 Ø41.2 +-- 0.03
0
15
Ø9
195
95
14
Ø11
35
40 300
Ø80
10
50
RKP13250
Ø6.5
M12
ENERPAC Mod. RCH-123
23
3x15°
64
R2
0.8
0.8
R3 0.8
21°
Ø54
Ø55
Ø83
Ø40
0.8
R2
R2
10 56
66
312
M18X1.5
M18X1.5
267
50 5x15° 0.8
0.8
15°
Ø40H8
R3
-- 0.2
-- 0
17min.
Ø19
30 RKP13240
30-10 PW95R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS
M13 Ø75
M14
Ø55 ---- 0.08
0.12
Ø50
5x45°
5x15
Tornito Ø
0.8 32,25
35
Ø10
60
63
87
74
15
14
R5
2 -- 0.2
0
48
59
12
R5
30
0.8
12
3x15°
0.8
M6
5
Ø20
Ø37.75 ++ 0.12
0.08
0.8
Ø40H7-n6 1/4”
Ø55 ---- 0.3
0.2
Ø44
Ø89
Ø99
RKP13230
0.8
M8x1.25
RKP13150
R2 5°
.5
M15
1.5x45°
15
30
0.8
44
14
75
3
6
7
1
1
68
0.8
1x45
30°
38
Ø6.5
0.8
Ø20.4-- 00.05
Ø38.5 ---- 0.1
0.2
Ø65 RKP13140
M16
50
20
120± 0.1
=
120± 0.1
200
=
90
= = 840
930
RKP12980
PW95R-2 30-11
REMOVAL AND INSTALLATION SPECIAL TOOLS
M18
R110
100
50
R1
5 5x45°
27.5±0.2
55 500
555
±0.1
Ø23
17
125
RKP13080
125
M19 0
M20 Ø30
Ø54,5 -- 0.1
3x45°
30
Ø30
cementazione
R35
Proteggere da
0.8
46
130
70
155
14 10
0.8
1.5 x45°
0.8
2,5 -- 00.2
0
0.8 R1
3 x15°
7
0.8
0
Ø54 + 0.1
10
Ø79
R1 0.8
Ø90 -- 0.15
RKP13020
0.8
49.5
89
RKP13030
50
2 x45°
50
50
cementazione
Proteggere da
cementazione
Proteggere da
150
150
cementazione
Proteggere da
150
180
213
169
2 x45°
R1
3-- 00.2
0
1.5x45°
.5
13
R7
1.5
R5
.5
0.8
10
0.8
R1
52
20 10
50
+ 0.15
-- 0.4
0.8
19
0.8 9
R2
Ø67
0.8
5x15°
3x15°
30-12 PW95R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS
M24 M25
Ø75
Ø158.5
Ø25 Ø158.5
0.8
16
0.8
R3
113
Ø132 -- 0.3
0.5
129
cementazione
Proteggere da
117
R3
--
148
102
150
R5 20°
100
25
R3
8x15°
Ø40
233
Ø140
Ø50---- 0.08
0.12
0
Ø150
R1
3-- 00.2
Ø200 ±0.03
13
0.8
0.8 Ø95
75
70
Ø35
5x15°
0.8
Ø56
Ø64 RKP13050 RKP13130
175
1x45°
0.8
-- 0.2
-- 0.3
1
41
26
19
0.8 0.8
5.5
R3
5x15°
0.8
0
Ø139.5 -- 0.1
Ø153
10 15
0.8
25
Ø168
2x15°
Ø180 RKP13070
Ø39 0.8
Ø50 RKP13060
PW95R-2 30-13
PAGE INTENTIONALLY
LEFT BLANK
STARTER MOTOR
REMOVAL AND INSTALLATION
3
RKPB5070
INSTALLATION OF STARTER
MOTOR
• To install, reverse the removal procedure.
Screws: 78.4–98 Nm
PW95R-2 30-15
ALTERNATOR
REMOVAL AND INSTALLATION
REMOVAL OF ALTERNATOR
Disconnect the cable from accumulator negative termi-
nal (–).
RKPB6140
RKPB5090
4 - Loosen bolts (6), (7) and (8) sufficiently to allow the al- 7
ternator (9) to rotate.
4
5 - Free the pulley from the fan-belt (10) and remove al-
ternator (9). 2
5
6
RKPB4881
INSTALLATION OF ALTERNATOR
• To install, reverse the removal procedure. 10
9
1
★ Check the union gasket of exhaust pipe.
2
★ Adjusting of the fan-belt (For details, see «20. TESTING
8
AND ADJUSTMENTS»).
RKPB4871
30-16 PW95R-2
AIR-CONDITIONING UNIT COMPRESSOR
REMOVAL AND INSTALLATION
D1
RKPB6154
RKPB6160
3 - Loosen screw (5) and remove return (6) and delivery (7)
pipes. 1
6 7
5
8
12
RKPB6170
RKPB6180
PW95R-2 30-17
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
12
13
RKPB6190
INSTALLATION OF THE
AIR-CONDITIONING UNIT
COMPRESSOR
• To install, reverse the removal procedure.
1
Screw: 22.5–28.4 Nm
2
Screw: 22.5–28.4 Nm
3
★ Apply tension to the compressor belt.
(For detail, see «TESTING AND APPLYING TEN-
SION TO THE COMPRESSOR BELT».
30-18 PW95R-2
REMOVAL AND INSTALLATION INJECTION PUMP
RKPB1650
RKPB4861
9 7
8
RKPB5300
RKPB4960
PW95R-2 30-19
REMOVAL AND INSTALLATION INJECTION PUMP
13 14
RKPB4971
RKPB6200
17
RKPB1700
20
19
RKPA5611
30-20 PW95R-2
REMOVAL AND INSTALLATION INJECTION PUMP
X2
RKP07801
RKPB4970
PW95R-2 30-21
REMOVAL AND INSTALLATION INJECTION PUMP
1
Feed and return pipes: 24.5–34.3 Nm
2
High pressure pipes: 24.5–34.3 Nm
3
★ Replace safety cotter pin.
4
Cover gasket: ASL800070 Injection pump
drive gear
Timing gear system cover bolts: 18 Nm
5
Alignment reference
★ Align marks between gears before installing pump
and nut.
Gear lock nut: 83.3–93.1 Nm Idling gear
6 RKP07811
30-22 PW95R-2
REMOVAL AND INSTALLATION INJECTION NOZZLE
RKPB5030
INSTALLATION OF THE 5
INJECTION NOZZLES
• To install, reverse the removal procedure.
1 4
High pressure pipe fittings: 24.5–35.3 Nm
2
7
PW95R-2 30-23
REMOVAL AND INSTALLATION THERMOSTAT
Cooling liquid: 18 2
3
2
RKP12500
INSTALLATION OF
THE THERMOSTAT
• To install, reverse the removal procedure.
Coolant liquid: 18
2
Cover screws: 22–27.8 Nm
30-24 PW95R-2
REMOVAL AND INSTALLATION MUFFLER
RKPB6140
2 - Loose the nuts (3), nut (4) and remove the exhaust pipe
(5) and bracket (6). 9 4
3 - Loosen screws (7) and (8) and remove protection (9) 7 10
from L.H. side.
★ Pay attention not to drop the engine-hoisting lug
(10).
6 8
3
11 5 RKP11270
14
12
RKP11280
INSTALLATION OF
THE MUFFLER
• To install, reverse the removal procedure.
★ Replace the sealing gasket (11) and (17).
Nuts (14): 46±2 Nm
Screw (13): 27±2 Nm
Nuts (12): 27±2 Nm
Screws (11): 27±2 Nm
Screws (8): 46±2 Nm
PW95R-2 30-25
REMOVAL AND INSTALLATION CYLINDER HEADE
Cooling liquid: 18 2
1
1
1 - Remove the engine hood.
(For details see: «REMOVAL OF ENGINE HOOD»).
RKPB5921
RKPB5050
RKPB5220
30-26 PW95R-2
REMOVAL AND INSTALLATION CYLINDER HEAD.
RKPB1751
16
RKPB5060
RKPB5031
25
23
RKP11250
PW95R-2 30-27
REMOVAL AND INSTALLATION CYLINDER HEAD.
RKP07820
30-28 PW95R-2
REMOVAL AND INSTALLATION CYLINDER HEAD.
Coolant liquid: 18
★ Check carefully that there are no leaks.
2
High-pressure pipe fittings:24,5--34,3 Nm
3
Collar lock nuts: 9.8--11.8 Nm
4
★ Check the condition of the seals of the tappet cover
and the O-rings of the fastening nuts.
Thoroughly clean the contact surfaces on the cyl-
inder heads.
Cover fastening nuts: 25±3 Nm
5
★ Check that the tappets are firmly engaged in their
rods and that the valve collars are correctly assem-
bled.
Rods - tappets: Engine oil
★ Start tightening the rocker-arm shaft from the center to-
wards the outside.
Screws and nuts for the rocker-arm shaft:
22.5--28.4 Nm
BOLT LOOSENING ORDER
★ Adjust the valve clearances (For details, see «20.
TESTING AND ADJUSTMENTS»).
6 12 3 5 13
18 10 1 7 15
★ Install a new gasket.
16 8 2 9 17
Bolt and cylinder block threadings: Engine oil.
14 6 4 11
★ Tighten the screws, manually at first, and then in two
stages, following the sequence indicated.
Cylinder head bolts.
First tightening: 88.3--98.1 Nm RKP07830
PW95R-2 30-29
REMOVAL AND INSTALLATION SEAT
REMOVAL OF SEAT
Lower the work equipment until it is resting on the
ground, switch off the engine and remove the ignition
key.
1
1 - Raise the front window (1) completely.
RKPB1280
3 - Remove the four screws (3) that secure the seat (No. 4).
★ Slide the seat forwards and backwards in order to
reach the screws.
3
4 - Remove the seat.
Seat: 32 kg
RKPB0940
INSTALLATION OF SEAT
• To install, reverse the removal procedure.
30-30 PW95R-2
REMOVAL AND INSTALLATION CABIN
REMOVAL OF CABIN
Lower the work equipment until it is resting on the
ground, switch off the engine and remove the ignition
key.
1 - Disconnect the connector (1) and hose (2) from the
windshield-washer tank and remove all the clamps fix- 1
ing them.
3
2 - Remove screws (3), dashboard (4) and disconnect 4
heating pipe (5).
3
5
2
RKPB6210
RKPB6220
12
6
7 RKPB6230
8 - Remove knob (13) and (14), screws (15) and hood (16).
15 14
13
16
RKPB6240
PW95R-2 30-31
REMOVAL AND INSTALLATION CABIN
17
RKPB7630
19
RKPB6590
Cabin: 220 kg 23
23
24
RKPB1102
30-32 PW95R-2
REMOVAL AND INSTALLATION CABIN
INSTALLATION OF CABIN
• To install, reverse the removal procedure.
★ Make sure that the short screw (24) is placed on the
LH side.
PW95R-2 30-33
REMOVAL AND INSTALLATION ENGINE HOOD
1 - Detach the gas cylinder (1) from the engine hood (2).
Engine hood: 36 kg
1
2
RKPB6910
1
★ Position any shims.
★ Check the centering and adjustment of the closing
hook (5).
RKPB0950
30-34 PW95R-2
REMOVAL AND INSTALLATION CONDENSER UNIT
RKPB6154
RKPB6250
7
6
RKPB6260
9
6
8
RKPB6270
PW95R-2 30-35
REMOVAL AND INSTALLATION CONDENSER UNIT
10
5
10
RKPB6280
11
11
RKPB6290
INSTALLATION
OF CONDENSER UNIT
• To install, reverse the removal procedure.
1
Nut: 22.5–28.4 Nm
30-36 PW95R-2
REMOVAL AND INSTALLATION FRONT HOOD
RKPB1800
Engine hood: 27 kg
3
5
RKPB1810
1
★ Position any shims.
★ Check the centering and adjustment of the closing
hook (6).
RKPA5680
PW95R-2 30-37
REMOVAL AND INSTALLATION HEATING FAN UNIT
RKPB1754
5
RKPB6221
4 - Remove the knob (8) and (9), loosen the screw (10) and
remove the hood (11).
10 9
11
RKPB6241
RKPB6591
30-38 PW95R-2
REMOVAL AND INSTALLATION HEATING FAN UNIT
15 14 RKP12930
16
18 RKP12920
INSTALLATION OF
HEATING FAN UNIT
• To install, reverse the removal procedure.
PW95R-2 30-39
REMOVAL AND INSTALLATION AIR CONIDTIONING FAN UNIT
RKPB6300
RKPB6153
6
7
8 RKPB6231
7 - Remove the knobs (9) and (10), the screws (11) and the
hood (12).
11 10
12
RKPB6242
30-40 PW95R-2
REMOVAL AND INSTALLATION AIR CONIDTIONING FAN UNIT
13
14
13
RKPB6592
16
15
RKPB6310
17 18 19
RKPB6320
21
24
RKPB6330
PW95R-2 30-41
REMOVAL AND INSTALLATION AIR CONIDTIONING FAN UNIT
26 25
26
RKPB6340
29
27
28
RKP12940
INSTALLATION OF
AIR CONDITIONING FAN UNIT
• To install, reverse the removal procedure.
1
★ Film the valve and union with anticondensate mas-
tic.
30-42 PW95R-2
REMOVAL AND INSTALLATION RADIATOR
REMOVAL OF RADIATOR
Lower the work equipment until it is resting on the
ground and switch off the engine.
Completely eliminate all residual pressures in all cir-
cuits. (For details see: «20. TESTING AND ADJUST-
MENTS»). 2
1
Drain the engine coolant liquid.
Cooling liquid: 18
Hydraulic oil: 74 3
1 - Remove the cover (1) together with the exhaust pipe
(2). RKPB6141
4
8
RKPB5920
5 - Disconnect the hydraulic oil supply pipe (9) and the re-
turn pipe (10).
10
11 9
RKPB5230
Radiator: 37 kg
12
RKPB1840
PW95R-2 30-43
REMOVAL AND INSTALLATION RADIATOR
INSTALLATION OF RADIATOR
• To install, reverse the removal procedure.
Coolant liquid: 18
Hydraulic oil: 74
3 - Start the engine at low idling to circulate all the fluids and
to fill up the oil coolers.
4 - Stop the engine and top up all levels (coolant liquid and
hydraulic oil).
30-44 PW95R-2
REMOVAL AND INSTALLATION FUEL TANK
2 - Remove the cap (1) of the fuel tank (2), open the tank
drainage cock (3), and drain the fuel.
RKPB1651
4 - Disconnect the fuel return pipe (5) and the connector (6)
of the level gauge (7).
2
5
1
7
RKPB5890
2 8
RKPB6350
PW95R-2 30-45
REMOVAL AND INSTALLATION FUEL TANK
2
RKPB6930
Fuel tank: 43 kg
RKPB1870
30-46 PW95R-2
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
Oil tank: 62 kg
RKPB4902
INSTALLATION OF HYDRAULIC
OIL TANK RKPB5140
2 - Start the engine to circulate the oil and check that there
are no leakages.
PW95R-2 30-47
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
RKPB6142
RKPB6960
7
6
RKPB5181
30-48 PW95R-2
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
11
RKPB4962
13
12
RKPB5054
12
13
RKPB6301
RKPB5191
PW95R-2 30-49
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
RKPB5201
RKP10712
INSTALLATION OF
ENGINE-PUMP GROUP
• To install, reverse the removal procedure.
30-50 PW95R-2
REMOVAL AND INSTALLATION PUMP GROUP
1
★ Coat the coupling surfaces thinly.
PW95R-2 30-51
REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING JOINT
2 - Loosen dowel pin (1) fixing half joint (2) in more stages
and alternatively. 1
★ Heat dowel pins to 85 –100 °C
2
3 - Remove pump half joint (2).
★ If necessary, use a puller. RKPB1950
RKPB1960
INSTALLATION OF ENGINE-PUMP
COUPLING JOINT
• To install, reverse the removal procedure.
1
Pump flange joint mounting bolts: Loctite 262
Pump flange joint mounting bolts: 50 Nm
2
Drive flange bolts: Loctite 262
Drive flange bolts: 50 Nm
1 - Fill up tank unit maximum level.
During the filling operation, bleed air from the piston
pump (For details, see «20. TESTING AND AD-
JUSTMENTS»).
Hydraulic oil: 74
2 - Start the engine to allow oil circulation in all systems and
check the seals.
3 - Stop the engine and, if necessary, restore oil level in the
tank.
30-52 PW95R-2
REMOVAL AND INSTALLATION GEAR-PUMP
REMOVAL OF GEAR-PUMP
Lower the work equipment until it is resting on the
ground and switch off the engine. 1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
• Drain the hydraulic oil.
2 - Remove the bolts (3) and the pump (4), the joint (5) and
the gasket (6). 2
6
4
5
3 RKP10870
INSTALLATION OF GEAR-PUMP
• To install, reverse the removal procedure.
1
★ Before connecting the suction flange, check the condi-
tion of the seal and keep it in its seat by applying grease
ASL800050.
Flange screws: 35±3.5 Nm
2
Joint: ASL800050
Pump fastening screws: 98–123 Nm
1 - Fill the hydraulic oil tank to maximum level.
PW95R-2 30-53
REMOVAL AND INSTALLATION SWIVEL JOINT
1
★ Before connecting the top pipes, introduce hydraulic oil
into the draining branch (branch 6).
1 - Start the engine and bleed air from the circuits by fol-
lowing the procedure given below:
a - Move the outriggers and blade (if mounted) several
times to the end of their stroke.
b - Perform several steering actions on both axles and
in both directions.
c - Bleed air from the brake line. (For details, see «20.
TESTING AND ADJUSTMENTS»).
30-54 PW95R-2
REMOVAL AND INSTALLATION SWING MOTOR
RKPB6133
RKPB6380
INSTALLATION OF SWING
MOTOR
• To install, reverse the removal procedure.
1
★ Fill the motor with hydraulic oil through the top drain line
connection.
1 - Start the engine to allow oil circulation in all systems and
check the seals.
2 - Bleed the air from engine. (For details, see «20. TEST-
ING AND ADJUSTMENTS»).
PW95R-2 30-55
REMOVAL AND INSTALLATION SWING MACHINERY
INSTALLATION OF THE
SWING MACHINERY
• To install, reverse the removal procedure.
★ In order to centre the holes of the pins and of the fas-
tening screws, connect a hydraulic power unit “A” to the
hydraulic motor and slowly rotate the motor until the cor-
rect angle for the positioning of the reduction gear has
A
been obtained.
1
★ Fill with hydraulic oil through the breather (8).
RKPB6402
2
Screws: 294 Nm
1 - Start the engine to allow oil circulation in all systems and
check the seals.
2 - Bleed the air from engine. (For details, see «20. TEST-
ING AND ADJUSTMENTS»).
30-56 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
RKP12550
1 - Remove the oil drain plug (5) and remove the screw (6)
and hydraulic motor (1).
1
5
6
RKPB6381
RKPB6630
RKPB6640
PW95R-2 30-57
REMOVAL AND INSTALLATION SWING MACHINERY
RKPB6650
RKPB6660
10
RKPB6670
11
RKPB2161
30-58 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
RKPB6680
RKPB6690
RKPB2191
15
14
RKPB2201
PW95R-2 30-59
REMOVAL AND INSTALLATION SWING MACHINERY
C1
RKPB6701
16
RKPB2222
4 15
RKPB2231
17
RKPB2371
30-60 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
15
RKPB2361
17
4
RKPB2241
15 20
19
18 20
RKPB2273
4
21
RKPB2251
PW95R-2 30-61
REMOVAL AND INSTALLATION SWING MACHINERY
22
RKPB2261
30-62 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
2. INSTALLATION
20
1 - Mount the spacer (20) on the swing pinion shaft (15).
★ Check that the chamfered part rests on the pinion.
20
15
RKPB2281
19
RKPB2291
RKPB2301
PW95R-2 30-63
REMOVAL AND INSTALLATION SWING MACHINERY
Bearing: ASL800050
22
RKPB2311
C3
22
19
RKPB2323
C4
RKPB2331
C3
RKPB2342
30-64 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
21
RKPB2351
22
RKPB7640
15
RKPB2361
15
RKPB2372
PW95R-2 30-65
REMOVAL AND INSTALLATION SWING MACHINERY
C3
RKPB2342
13 - Mount the spacer (16) over the swing pinion shaft (15).
15
RKPB2223
15
RKPB2381
C1
RKPB2391
30-66 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
15
14
RKPB2401
RKPB2191
RKPB2181
RKPB2170
PW95R-2 30-67
REMOVAL AND INSTALLATION SWING MACHINERY
11
RKPB2161
RKPB2151
RKPB6660
Seat: ASL800050
RKPB6710
30-68 PW95R-2
REMOVAL AND INSTALLATION SWING MACHINERY
RKPB6720
RKPB6730
RKP12950
5
6
RKPB6381
PW95R-2 30-69
REMOVAL AND INSTALLATION SWING MACHINERY
17
RKP12961
30-70 PW95R-2
REMOVAL AND INSTALLATION CONTROL VALVE
RKPA5820
INSTALLATION OF CONTROL
VALVE 8
• To install, reverse the removal procedure.
1
Control valve check screws: 190 Nm
1 - Check the level of the tank; start the engine to allow oil to
circulate to all parts of the equipment. RKPB5700
Switch off the engine and top up the oil level.
PW95R-2 30-71
REMOVAL AND INSTALLATION REVOLVING FRAME
5 - Disconnect all the lower tubes (1) from the swivel joint
(2) and plug them. Also plug the fittings left on the joint.
1
6
6 - Remove the lower left-hand protective casing (3) of the
revolving frame (4) to gain access to the retaining nuts
of the LH area.
5 7
7 - Start the engine and swing the revolving frame (4) until a
screw (5) in the rear extraction compartment of the track
frame (6) has been centred.
8 - Remove the screw (5).
RKPB0330
9 - Repeat the same operations for the other screws (No.
39).
3
4
RKP11260
PW95R-2 30-72
REMOVAL AND INSTALLATION REVOLVING FRAME
1
★ After connecting up all the hydraulic tubes, start the
engine and move all parts of the equipment several
times to bleed air from the circuits, while checking
for leakages.
★ Switch off the engine and check level of the hy- 8
draulic oil.
2 7
★ Align the two positions corresponding to the center-
ing pins (8), then assemble.
Sealant and swing circle platform gaskets: RKPA5850
ASL800050
Internal swing circle grease: approx. 25 kg
10
3 12
Revolving frame attachment screws
(without nut): Loctite 262 11
9
Installation Procedure
motor (9).
★ Plug connections to avoid impurity entry.
2 - Connect a hydraulic power unit “A” and slowly rotate
the turret until correct centring is obtained.
3 - Insert the two screws left in the swing circle (7) and se-
cure them.
4 - Insert all the other screws (5).
5 - After having secured all the screws that joint the swing A
circle to the revolving frame, reconnect the delivery
tubes (10) of the swing motor (9), and the brake release
tube (12) and the drain line connection.
RKPB6402
6 - Detach the hoisting tackle.
PW95R-2 30-73
REMOVAL AND INSTALLATION COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
Lower the work equipment until it is resting on the
ground and switch off the engine.
1 - Remove the engine-hood.
(For details, see «REMOVAL OF ENGINE HOOD»).
1
2 - Remove the engine-hood hook support (1).
3 - Remove the protective caps and firmly tighten the hoist-
ing eyebolts (2).
4 - Attach the hoisting tackle and apply slight tension to the
cables.
5 - Using the tool A1, loosen the screws (3) and their safety
washers. 1 RKPB0860
2 2
4
RKPB0960
INSTALLATION OF
COUNTERWEIGHT
• To install, reverse the removal procedure. A
3
1
Counterweight screws: Loctite 262
PW95R-2 30-74
REMOVAL AND INSTALLATION SWING CIRCLE
3 - Remove the screws (1) that secure the swing circle (2).
1
2
RKPB0340
2 S
RKPB0351
INSTALLATION OF
SWING CIRCLE
★ Before installing the swing circle, check the condition of
the central gasket (3).
For reasons of safety, when installing the swing circle,
insert two screws into the front and back holes in the
frame.
• To install, reverse the removal procedure.
1
Before attaching the swing circle, check that the area
marked with an «S» is positioned on the right-hand side
of the chassis.
Attachment screws: Loctite 242
Lubricating grease: approx. 25 kg
PW95R-2 30-75
TRANSMISSION - REVERSER, DIRECTION INDICATOR AND
REMOVAL AND INSTALLATION HEADLIGHT DIPPER BEAM CONTROL GROUP
1 - Take out check screws (1) (No. 2) and remove the front
guard (2) of the steering column. 2
RKPB6740
RKPB6750
5 6
RKPB6760
INSTALLATION OF THE
TRANSMISSION - REVERSER,
DIRECTION INDICATOR AND
HEADLIGHT DIPPER BEAM
CONTROL GROUP
• To install, reverse the removal procedure.
PW95R-2 30-76
REMOVAL AND INSTALLATION R.H. PPC VALVE (BOOM-BUCKET)
RKPB6420
RKPB6430
PW95R-2 30-77
REMOVAL AND INSTALLATION R.H. PPC VALVE (BOOM-BUCKET)
1
★ Check the positions carefully when reconnecting
the tubes.
P - Pressure T
P1
T - Unload
P1 - L.H. swing P4
P2 - Arm opening
P3 - R.H. swing P
P2
P4 - Arm closing
P3
1 - Start the engine to circulate the oil and check the seals. RKPB6440
PW95R-2 30-78
REMOVAL AND INSTALLATION L.H. PPC VALVE (ARM-SWING)
5 3
RKPB6450
RKPB6460
5
RKPB6470
PW95R-2 30-79
REMOVAL AND INSTALLATION L.H. PPC VALVE (ARM-SWING)
6 - Disconnect the six tubes (11) from the PPC valve (12)
and plug them to prevent entry of impurities.
★ Mark the positions to avoid errors during assembly.
1
7 - Remove screws (13) and remove PPC valve (9). 13
12
If there is a slack on the control lever, adjust the
unit. (See «20. TESTING AND ADJUSTMENTS -
Adjustment of manual control slacks»).
11
RKPB6480
1 P1 T
★ Check the positions carefully when reconnecting
the tubes.
P - Pressure
T - Unload P2 P4
P1 - Arm closing P
P2 - L.H. swing P3
RKPB6490
P3 - Arm opening
P4 - R.H. swing
1 - Start the engine to circulate the oil and check the seals.
PW95R-2 30-80
REMOVAL AND INSTALLATION OUTRIGGER AND BLADE PPC VALVE
1. Blade version
1 - Disconnect the tubes (1), (2), (3) and (4) and plug them. 12
★ Make an identifying mark on the pipes to avoid mix- 13
ing them up during installation.
10
2 - Remove the screw (5) and the PPC valve (6).
INSTALLATION OF OUTRIGGER
AND BLADE PPC VALVE
• To install, reverse the removal procedure.
1 - Start the engine to circulate the oil.
2 - Bleed air from the blade cylinder. (For details, see «20.
TESTING AND ADJUSTMENTS»).
PW95R-2 30-81
REMOVAL AND INSTALLATION BOOM SWING PPC VALVE
RKP11052
2 - Disconnect the pipes (2) (No. 4 tubes) from the PPC val-
ve.
2
★ Place an identifying mark on the pipes to avoid mix-
2
ing them up during installation.
2 3
3 - Remove the side connections (3).
3
3
RKPB6540
4 - Pull out the screws (4) and remove the pedal control (5)
with the operation pedal (6).
RKPB6790
PW95R-2 30-82
REMOVAL AND INSTALLATION TRAVEL AND 2nd BOOM PPC VALVE
RKP11052
2nd BOOM
2 - Disconnect the pipes (2) (No. 4 tubes) from the pedal
control.
★ Place an identifying mark on the pipes to avoid mix-
ing them up during installation. 3
3 - Remove the connections (3) from the pedal control. 2
2
3
RKPB6560
2nd BOOM
4 - Pull out the screws (4) and remove the pedal control (5)
or (6) with the operation pedal. 6
5
RKPB6570
TRAVEL
INSTALLATION OF TRAVEL
AND 2nd BOOM PPC VALVE
• To install, reverse the removal procedure.
6
1 - Start the engine to circulate the oil.
RKPB6800
PW95R-2 30-83
REMOVAL AND INSTALLATION BRAKE PUMP
5
7
4 6
RKPB5820
INSTALLATION OF THE“BRAKE
PUMP
• To install, reverse the removal procedure.
1
★ Start the engine and bleed air from the brake lines.
(See «20. TESTING AND ADJUSTMENTS»).
2
★ After re-connection, make sure that the protective
sleeves are positioned correctly and firmly.
30-84 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
RKP07970
2
RKPA8290
6 RKP09570
INSTALLATION OF THE
STEERING UNIT
• To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing cir-
cuit (See «20. TESTING AND ADJUSTMENTS»).
RKPB0470
PW95R-2 30-85
REMOVAL AND INSTALLATION STEERING UNIT
RKPA7990
RKPA8000
5
34
RKPA8010
RKPA8020
30-86 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
RKPA8030
RKPA8040
RKPA8050
8 - Lift out the ball (10) of the check valve, and the pins (11)
and balls (12) of the anticavitation valves.
11
10
12
RKPA8060
PW95R-2 30-87
REMOVAL AND INSTALLATION STEERING UNIT
14
RKPA8070
10 - Remove the outside ring (15), the inside ring (16), and
the roller bearing (17) from the spool. Also remove the
ring (33).
★ The inside ring (16) sometimes gets left in the body
of the steering unit. Make sure that it has been re- 33
moved.
16
15 17
RKPA8080
11 - Lift out the cross pin (18), the bushing (19) and the spool
(20).
★ Use the special cover-fastening screw (3) for total 19
extraction.
3
18
20
RKPA8090
20
19
RKPA8100
30-88 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
20
RKPA8110
RKPA8120
24
RKPA8130
25
RKPA8140
PW95R-2 30-89
REMOVAL AND INSTALLATION STEERING UNIT
26
RKPA8150
27
RKPA8160
28 24
27 25
26
RKPA8170
29
30
RKPA8180
30-90 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
NOTE
Cleaning
• Clean all the components with an aliphatic solvent
(white spirits or similar).
Inspections and substitutions
• Change all the cup springs and seals.
RKPA8190
• Inspect all the pieces and change those in a doubtful
state of wear.
PW95R-2 30-91
REMOVAL AND INSTALLATION STEERING UNIT
RKPA8200
2 - Insert the two flat springs (21a) in the seating and centre
them with respect to the diameter of the spool (20). In-
sert the four curved springs (21b) between the two flat
springs (21a), arranged in pairs, and push them com-
pletely home.
21a
20
21b
RKPA8210
21
RKPA8220
21 19
RKPA8230
30-92 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
5 - Push the springs (21) and the spool (20) down together
until the springs are engaged in the seating of the bush-
ing (19).
21
20
19
RKPA8240
6 - Align the springs (21) with each other and centre them
with respect to the diameter of the bushing (19).
21
19
RKPA8250
19
33
RKPA8260
18
RKPA8270
PW95R-2 30-93
REMOVAL AND INSTALLATION STEERING UNIT
16
17
15
RKPA8280
20
19
RKP09580
11 - Place the body of the steering unit (14) with the hole hor-
izontal.
Insert the guide of tool Q2 into the hole of the spool/
bushing group. 14
Q2
RKPA8300
12 - Lubricate the seal ring (23a) and the O-ring (23b) and
mount them on the push-rod of tool Q2.
23a Q2
23b
RKPA8310
30-94 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
23
Q2
RKPA8320
14 - Push the gasket (23) into the seating of the body of the
steering unit (14), assisting the movement with slight ro-
tatory movements.
14
RKPA8330
15 - Extract the guide from the body of the steering unit (14)
using the tool Q2, and leaving in position the push-rod
carrying the gaskets.
14
RKPA8340
14
RKPA8350
PW95R-2 30-95
REMOVAL AND INSTALLATION STEERING UNIT
14
13
RKPA8360
18 - Rotate the body of the steering unit (14) until the central
hole is vertical.
Insert the ball (10) of the safety valve into the hole in-
dicated by the arrow.
10
14
RKPA8370
19 - Screw the valve threaded bush (8) into the hole in the
safety valve.
★ The upper part of the threaded bush should be low-
er than the surface of the body of the steering unit
(14). 8
14
RKPA8380
RKPA8390
30-96 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
11
RKPA8400
RKPA8410
14
RKPA8420
24 - Insert the drive shaft (6) in the hole and engage the
cross pin; check that the pin engagement is parallel to
the connection flange between the steering unit and the
6
steering column.
RKPA8430
PW95R-2 30-97
REMOVAL AND INSTALLATION STEERING UNIT
Q3
RKPA8440
RKPA8450
4a
RKPA8460
4b
RKPA8470
30-98 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
RKPA8480
RKPA8490
31 - Insert the six screws (1) complete with their cup springs.
Tighten the screws (1) crosswise with a torque of 30±6
Nm.
RKPA8500
22
14
RKPA8510
PW95R-2 30-99
REMOVAL AND INSTALLATION STEERING UNIT
33 - Press the dust-guard seal (22) into the body of the steer-
ing unit, using the tool Q4 and a plastic hammer.
Q4
22
RKPA8520
RKPA8530
32
RKPA8540
Cap: 50±1 Nm
29
30
RKPA8550
30-100 PW95R-2
REMOVAL AND INSTALLATION STEERING UNIT
RKPA8560
38 - Insert the springs (27) of the safety valves into the holes.
27
RKPA8570
RKPA8580
40 - Mount the sealing cup springs (25) on the caps (24) and
screw the entire group into the two holes of the safety
valves. 24
Use a 6 mm screw wrench.
Caps: 30 Nm 25
RKPA8590
PW95R-2 30-101
REMOVAL AND INSTALLATION PRIORITY VALVE
RKPB5450
2 RKP11070
INSTALLATION OF THE
PRIORITY VALVE
• To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing cir-
cuit. (See «20. TESTING AND ADJUSTMENTS»).
30-102 PW95R-2
REMOVAL AND INSTALLATION PRIORITY VALVE
3 - Lift off the cap (2) complete with the aluminium washer
2
and the spring (3).
ASSEMBLY OF THE
PRIORITY VALVE
★ Before assembly:
1 - Wash the pieces thoroughly in kerosene or similar
product.
PW95R-2 30-103
REMOVAL AND INSTALLATION TRAVEL MOTOR
RKPA8610
3 2
RKPB2780
5 - Loosen the four screws (8) that hold the motor (7).
RKPB2721
30-104 PW95R-2
REMOVAL AND INSTALLATION TRAVEL MOTOR
1
Screws: 34÷41 Nm
2
★ Before connecting the drainage tube (5), fill the mo-
tor casing with hydraulic oil.
3
★ Carefully check the O-ring seal between motor and
transmission. If there are any doubts as to its con-
dition, change it.
Sealant: ASL800050
PW95R-2 30-105
REMOVAL AND INSTALLATION TRAVEL MOTOR
RKP09640
RKP09880
RKP09600
9
8 3 3
7
5 6
RKP09610
30-106 PW95R-2
REMOVAL AND INSTALLATION TRAVEL MOTOR
34
RKP09750
RKP09760
11
RKP09620
14
17
RKP09780
PW95R-2 30-107
REMOVAL AND INSTALLATION TRAVEL MOTOR
9 - Stop with threaded pin (18) a washer (19) and a nut (20)
the cylinder barrel in zero position.
Remove maximum displacement adjusting screw (21). 20 19
★ Threaded pin: M5x71
18
21
RKP09890
22
RKP09900
23
RKP09910
24
25
RKP09920
30-108 PW95R-2
REMOVAL AND INSTALLATION TRAVEL MOTOR
24
27
26 25
RKP09930
RKP09790
23
RKP09940
RKP09800
PW95R-2 30-109
REMOVAL AND INSTALLATION TRAVEL MOTOR
11
RKP09810
RKP09950
29
23
RKP09960
Position
for item
B
452271
083010
452271
452269 452021
452014
RKP09971
30-110 PW95R-2
REMOVAL AND INSTALLATION TRAVEL MOTOR
11
RKP09981
RKP10030
RKP10081
12 - Remove equipment B.
PW95R-2 30-111
REMOVAL AND INSTALLATION TRAVEL MOTOR
17
RKP09820
RKP09990
RKP09620
9
8 3 3
7
5 6
RKP09610
30-112 PW95R-2
REMOVAL AND INSTALLATION TRAVEL MOTOR
RKP09600
18 - Using the plunger C, fit the gasket (3), spacer (2) and cir-
clip (1). C
1 2
3
RKP09832
PW95R-2 30-113
REMOVAL AND INSTALLATION TRANSMISSION
INSTALLATION OF THE
TRANSMISSION 1
• To install, reverse the removal procedure.
1
★ Adjust the position of the transmission sensor.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
★ Position the protective sleeve with the cable outlet
pointing towards the ground to prevent accumula- 7
tions of water or condensates.
8
RKPB2840
2
Nuts: Loctite 242
Nuts: 49÷51 Nm
3
★ Fill the transmission with lubricating oil.
30-114 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
3
2 1 View of gear
cylinder control
4
5 6 8 29
16 44 31
23
22 7
21 24
35 30
18
17 36 32
19
20
13
12 26
14
34
11
10
38
9 28
37
27
39 25
33
38 41
40
RKP09631
RKPA8670
PW95R-2 30-115
REMOVAL AND INSTALLATION TRANSMISSION
7
8
RKPA8680
RKPA8690
RKPA8700
RKPA8710
30-116 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
10
11
RKPA8720
7 - Remove the screw (12), spring (13) and ball (14) for
neutral position.
14 13
12
RKPA8730
8 - Remove the flange (1) with oil seal (4) and spacer (5).
★ Note the spacers thickness.
RKPA8740
16 17
RKPA8750
PW95R-2 30-117
REMOVAL AND INSTALLATION TRANSMISSION
16 18
17
RKPA8760
20
22
19
RKPA8770
23 24
RKPA8790
25
RKPA8800
30-118 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
40 25
38
RKPA8810
36
RKPA8820
41
RKPA8830
27
RKPA8840
PW95R-2 30-119
REMOVAL AND INSTALLATION TRANSMISSION
18 - Remove the cut flow housing (27) and, in one time, the
hub (28) and the fork (29) complete with pads (30) and
transmission shaft (31).
29
27
31 28
RKPA8850
30
32
28
RKPA8860
26
33
RKPA8870
37 21
34
38
RKPA8880
30-120 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
35
24
RKPA8890
24
44
RKPA8900
24 - Remove all the oil seal and clean and dry with accuracy
all the components before reassembling.
PW95R-2 30-121
REMOVAL AND INSTALLATION TRANSMISSION
Surfaces: ASL800050
1 - Install the bearing (44) into the casing (24) and fit seal
(4) and spacer (5) into the flange (1).
★ Lock the spacers into position using grease.
Spacers: ASL800050
4
44
24 1
RKPA8910
2 - Install the flange (1) onto the casing (24) and bolt it.
24
RKPA8920
Seal: ASL800050 35
RKPA8930
30-122 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
26
RKPA8940
X
19
RKPA8950
6 - Install coupling (28), the complete fork (29) and the flow
regulator casing (27) all at the same time.
29
27
28
RKPA8851
Screws: 25–26 Nm
RKPA8970
PW95R-2 30-123
REMOVAL AND INSTALLATION TRANSMISSION
8 - Install the needle bearings (38), the gear (39) and the
distance piece (34). 34
39 38
RKPA8960
41
RKPA8980
10 - Fit the flow regulator plate (41) into the reduction gear
housing (25) turning the oil inlet (Y) upwards.
Place it 5–5.5 mm from the surface of the body.
41
Y
25
5ⴜ5,5mm
RKPA8990
25
36
RKPA9000
30-124 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
12 - Fit the housing (25) onto the casing (24) making sure to
centre the pins.
24
★ Apply sealant to the surface of cover.
★ Use a plastic hammer to mate.
25
RKPA9010
Screws: 48–62 Nm
24
23
25
RKPA9020
14 - Lubricate the ball (14), spring (13) and the screw (12)
and install the neutral position assembly.
RKPA8730
10
11
RKPA8720
PW95R-2 30-125
REMOVAL AND INSTALLATION TRANSMISSION
Screws: 52–63 Nm
RKPA9030
19
RKPA9040
21
RKPA9050
RKPA9060
30-126 PW95R-2
REMOVAL AND INSTALLATION TRANSMISSION
19
RKPA9070
X 19
22
RKPA9080
Screws: 48–62 Nm
RKPA9090
23 - Fit the flange (17), the O-ring (18) and bolt them with the
nut (16).
Nut: 260–300 Nm
17
RKPA9100
PW95R-2 30-127
REMOVAL AND INSTALLATION TRANSMISSION
RKPA8690
25 - Fit the protection plate (8) onto the transmission (B) af-
ter coating the surface touching the transmission.
8
B
RKPA9110
Screws: 49–51 Nm
RKPA8681
Rod: 24–26 Nm
RKPA8670
30-128 PW95R-2
REMOVAL AND INSTALLATION AXLE LOCKING CYLINDERS
2 - Disconnect the pipe (2) from the cylinder (1) and plug it.
Cylinder: 32 kg
INSTALLATION OF
AXLE LOCKING CYLINDERS
• To install, reverse the removal procedure.
1 - Start the engine, then lock and release the axle several
times to restore the circuit and check it is leak tight.
PW95R-2 30-129
REMOVAL AND INSTALLATION FRONT AXLE
RKPA8610
RKPB2691
20 cm
RKP09850
5 - Lower the machine slowly onto the blocks (B) and that
the wheels remain raised above the ground.
30-130 PW95R-2
REMOVAL AND INSTALLATION FRONT AXLE
RKPA9141
RKPB2810
8
D
C
RKPA9171
12 - Lower the lifting platform (C) until the axle is free of the
chassis.
10
RKPB2692
PW95R-2 30-131
REMOVAL AND INSTALLATION FRONT AXLE
5 - Stop the engine and check the level of the oil in the tank
30-132 PW95R-2
REMOVAL AND INSTALLATION REAR AXLE
RKPA8610
3 2
RKPB2780
20 cm
RKP09840
PW95R-2 30-133
REMOVAL AND INSTALLATION REAR AXLE
6 - Mount the cage on the wheel group (4) and apply a slight
tension to the hoisting cables.
Using the dynamometric wrench A1, take off the nuts
and remove the entire wheel group.
RKPA9201
RKPB2820
RKPB2741
30-134 PW95R-2
REMOVAL AND INSTALLATION REAR AXLE
5 - Stop the engine and check the level of the oil in the tank.
PW95R-2 30-135
REMOVAL AND INSTALLATION AXLES
DISASSEMBLY OF AXLES
1. Planetary reduction
1
1 - Remove the securing screws (1) from the planetary car-
rier cover (2).
1
RKPB2910
RKPB2920
RKPB2930
4
RKPB2940
30-136 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB2950
RKPB2960
RKPB2970
RKPB2980
PW95R-2 30-137
REMOVAL AND INSTALLATION AXLES
RKPB2990
RKPB3000
RKPB3010
RKPB3020
30-138 PW95R-2
REMOVAL AND INSTALLATION AXLES
12
13
RKPB3030
RKPB3040
14
RKPB3050
15
RKPB3060
PW95R-2 30-139
REMOVAL AND INSTALLATION AXLES
RKPB3070
RKPB3080
2. Steering case
1
1 - Remove the guard (1) and disconnect the articulation
pin (2). (See «5. STEERING CYLINDER»).
RKPB3090
RKPB3100
30-140 PW95R-2
REMOVAL AND INSTALLATION AXLES
3 - Unloose and remove the fitting screws (3) from the bot-
tom articulation pin (4).
★ Screws cannot be re-used.
3
RKPB3110
4
RKPB3120
5 - Unloose and remove the fittin screws (3) from the top ar-
ticulation pin (6).
RKPB3130
6
5
RKPB3140
PW95R-2 30-141
REMOVAL AND INSTALLATION AXLES
RKPB3150
8 - Using a puller for inner parts, remove the top bush (8)
and the bottom ball-bush (9).
RKPB3160
9 - Remove the articulation pins (4) and (6) and the front
sealing rings (5).
★ Note down the side for assembly. 5
4 6
RKPB3170
11
RKPB3180
30-142 PW95R-2
REMOVAL AND INSTALLATION AXLES
3. Cardan shaft
1 - Remove the steering case.
(For details, see «2. Steering case»).
★ For front axle: introduce compressed air (approx. 7
3
bar) in the braking circuit.
2
2 - Unloose and remove the top and bottom check nuts (2)
from the dowels (3).
RKPB3190
RKPB3200
RKPB3210
5 - Remove the snap ring (5) from the bushing unit (6).
RKPB3220
PW95R-2 30-143
REMOVAL AND INSTALLATION AXLES
RKPB3230
7
8
8 9
10
RKPB3240
30-144 PW95R-2
REMOVAL AND INSTALLATION AXLES
4. Brakes
1 - Remove the swinging support (1) on the side opposite
the drive.
★ If the bushing (2) is worn and needs replacing, note 2 1
down the assembly side of the connection notch
“A”.
RKPB3250
RKPB3260
5 - Unloose and remove the screws (4) and the washers (5)
that fix the arm (3) to the central body (6). 4 5 6
3
RKPB3270
6 - Remove the arm (3) together with the pack of the brak-
ing disks (7). Place the arm on a bench.
3
RKPB3280
PW95R-2 30-145
REMOVAL AND INSTALLATION AXLES
7 - Remove the braking disks (7) and note down their order
of assembly.
★ If the disks do not need replacing, avoid switching
their position.
8 - Extract the u-joint (17).
(For details, see «3. CARDAN SHAFT»).
17
7
RKPB3290
8
RKPB3300
10
RKPB3310
9
RKPB3320
30-146 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB3330
6
3
RKPB3340
RKPB3350
4 5
7
RKPB3360
PW95R-2 30-147
REMOVAL AND INSTALLATION AXLES
RKPB3370
6 - Disconnect left and right steering bars (5) from the pis-
ton (2).
2
RKPB3380
RKPB3390
RKPB3400
30-148 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB3410
2 - With the help of a plastic hammer, push the head (2) in-
side the cylinder (3).
★ The head should line up with the edge of the cyl- 3
inder.
RKPB3420
3 - With the help of a drift, apply pressure to the stop ring (4)
that is placed inside the cylinder (3) and extract the ring
using a screwdriver. 3
RKPB3430
4 - Hammer the piston (5) on the rear of the head (2) using
a plastic hammer. Continue hammering until the head
(2) is ejected from the cylinder (3).
5
3
2
RKPB3440
PW95R-2 30-149
REMOVAL AND INSTALLATION AXLES
A RKPB3450
RKPB3460
30-150 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB3480
4 - Remove the snap ring (1) that checks the support (8)
and remove the distance piece (2).
8
1
RKPB3490
6 5
RKPB3500
6 - Place cylinder (4) into a vice with the spring seat side
(10) engaged in it and, using a bar “D”, loosen and re- D
move the cylinder unit (9) complete with piston (13) and
spring (12). 9
4 13
12
10
RKPB3510
PW95R-2 30-151
REMOVAL AND INSTALLATION AXLES
RKPB3520
8 - Remove seals (14) and guide ring (15) from the piston
(13). 15 14
★ Note down seals direction of assembly.
15 14
14
13
RKPB3530
9 - Only if necessary
Remove the guide ring (11) from the spring seat (10).
10
If the guide ring (11) is removed, it must be re-
placed.
11
RKPB3540
8. Differential
1 - Remove the complete arms. For detail, see
«CHECKING WEAR IN THE BRAKE DISKS».
RKPB3261
30-152 PW95R-2
REMOVAL AND INSTALLATION AXLES
2 - Mark the position of the ring nuts (1). Remove the fittin
screws (3) from the ring nuts (1).
3
1
RKPB3470
RKPB3550
RKPB3560
5 - Remove the fittin screws (4) from the middle cover (5).
4 5
4
RKPB3570
PW95R-2 30-153
REMOVAL AND INSTALLATION AXLES
RKPB3580
7
5 9
RKPB3590
RKPB3600
11
12
RKPB3610
30-154 PW95R-2
REMOVAL AND INSTALLATION AXLES
12
RKPB3620
14
RKPB3630
15
RKPB3640
13 - Remove the snap rings (16) from the two pins (17) of the
planet wheel gears (18).
16 17
RKPB3650
PW95R-2 30-155
REMOVAL AND INSTALLATION AXLES
18 18
RKPB3660
15
17
RKPB3670
17
15
RKPB3680
RKPB3690
30-156 PW95R-2
REMOVAL AND INSTALLATION AXLES
15
17
RKPB3670
RKPB3660
13
15
RKPB3700
9. Bevel pinion
1 - Remove the complete arms and the differential unit.
(For details, see «4. BRAKE» and «8. DIFFEREN-
TIAL»).
PW95R-2 30-157
REMOVAL AND INSTALLATION AXLES
RKPB3710
RKPB3720
RKPB3730
RKPB3740
30-158 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB3750
7
RKP11080
M6
RKPB3760
RKPB3770
PW95R-2 30-159
REMOVAL AND INSTALLATION AXLES
13
RKPB3780
10
11
RKPB3790
15
RKPB3800
16
11
RKPB3810
30-160 PW95R-2
REMOVAL AND INSTALLATION AXLES
17
RKP11090
PW95R-2 30-161
REMOVAL AND INSTALLATION AXLES
ASSEMBLY OF AXLE
1. Bevel pinion
17
RKP11090
M9
RKPB3880
RKPB3890
15
M10C
M10A
RKPB3900
30-162 PW95R-2
REMOVAL AND INSTALLATION AXLES
15
RKPB3910
RKPB3920
M11C M9 M11B
15
RKPB3930
RKPB3940
PW95R-2 30-163
REMOVAL AND INSTALLATION AXLES
10 - Lay bar M11A on gauged nut M11C and take the size
“A” at about 57 mm corresponding to the maximum di-
ameter of arms centring.
M11C
M11A A
RKPB3950
11 - Calculate size “B” which will be the first useful value for
calculating the size of the shims (16) that are to be in- M9
M11C
serted under the thrust block of the internal bearing (11).
R115
M11B
A
30.2 61
(61-A)+115+30.2=B B RKP11120
RKPB3960
(16) S
D Z
C=Z+D C RKP11130
30-164 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB3970
15 - Insert shim “S” (16) and the thrust block of the internal
bearing (11) in the central body.
★ To hold shim “S” (16) in position, apply grease.
16
11
RKPB3980
M10C M10A
RKPB3990
RKPB4000
PW95R-2 30-165
REMOVAL AND INSTALLATION AXLES
RKPB4010
20 - Re-install all and insert the distance piece (12) between M11C
11
bearings (11) and (15); manually tighten the whole 12 15
pack. M11B
RKPB4020
11 M11C
15
M11B
RKPB4030
RKPB3971
30-166 PW95R-2
REMOVAL AND INSTALLATION AXLES
23 - Position the internal bearing (11) and the pinion (10) un-
der a press; force the bearing onto the pinion.
10
11
RKPB4040
24 - Fit the pinion (10), shim “S1” (13) and distance piece
(12) in the main body (14). 14
★ The finer shims must be placed in- between the 12
thicker ones. 10
13
RKPB3780
RKPB4050
26 - Connect the pinion (10) to the tie rod M12A and M12B;
connect the tie rod M12C to the press and block.
10
RKPB4060
PW95R-2 30-167
REMOVAL AND INSTALLATION AXLES
27 - Apply Loctite 242 (for the front axle) or Loctite 270 (for
rear axle) to the thread of the ring nut (9) and screw the
nut onto the pinion (10).
10
9
RKPB4070
M6
RKPB4080
30 - Apply onto the pinion (10) the bar-hold “M13” and with
the help of a torque metre, check the torque of the pinion
(8).
M13
Torque: 120--170 Ncm
30-168 PW95R-2
REMOVAL AND INSTALLATION AXLES
M8
RKPB4130
RKPB3740
34 - Fit the flange (2) complete with the guard (4) and fasten
it. For keying the flange (2), use a plastic hammer if nec-
essary.
★ Make sure that the guard (4) is securely fastened
onto the flange and that it is not deformed.
2 4
RKPB4110
RKPB4120
PW95R-2 30-169
REMOVAL AND INSTALLATION AXLES
2. Differential
1 - Insert the shim washer (13) and the planetary gear (14)
in the differential carrier (15). 14
13
15
RKPB3700
2 - Position the shim washer (19) and the first planet wheel
gear (18). 18
Hold them in position using bar M4C.
19
M4C
RKPB4140
19 15
M4C
RKPB4150
M4C
RKPB4160
30-170 PW95R-2
REMOVAL AND INSTALLATION AXLES
18 18
RKPB3660
RKPB4170
RKPB4180
M3
M4B
17
RKPB4190
PW95R-2 30-171
REMOVAL AND INSTALLATION AXLES
M4B M3
M4B
17
15
RKPB4830
Make sure that the snap ring centres the seat and
that it rests on the surface of the differential carri- 16
er.Repeat the operations on the other planet wheel
pin or planet wheel axle.
17
RKPB4200
14
RKPB3630
12
RKPB4220
30-172 PW95R-2
REMOVAL AND INSTALLATION AXLES
15
RKPB4230
M15 8
M15 7
RKPB4240
RKPB4250
RKPB3580
PW95R-2 30-173
REMOVAL AND INSTALLATION AXLES
4
4
RKPB4260
RKPB4270
RKPB4090
RKPB4290
30-174 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4300
RKPB4270
23 - Apply Loctite 242 to the screws (3), fit them into one of
the two holes and tighten. 10
Torque wrench setting: 23.8--26.2 Nm
3
24 - Fit the top plug (10) after applying repositionable joint-
ing compound for seals to the rims.
RKPB4310
RKPB3261
PW95R-2 30-175
REMOVAL AND INSTALLATION AXLES
3. Brake
14
1 - Accurately clean the piston (9) and the seats of slide and
12
seal.
11
2 - Replace the O-rings (11) and (12) and the anti-extrusion
rings (13) and (14); make sure that the assembly side is 13
correct.
15
15 9
RKPB4330
4 - Lubricate the seals (11) and (12) and fit the piston (9)
into the arm (3).
Make sure that the piston seat fits into the stop pin A
(A) inside the arm.
RKPB4340
RKPB4350
30-176 PW95R-2
REMOVAL AND INSTALLATION AXLES
6 - Fit the pin screws (10) making sure that they are all of
the same colour.
9
White: 1 mm gap
Yellow: 0.75 mm gap
Blue: 0.5 mm gap
10
RKPB3310
8
RKPB3300
9 - Slightly lubricate the braking disks (7) and fit them in the
arm following the correct sequence; orient them so that
the oil circulation holes and the marks “B” are perfectly
lined up.
B
★ When installing the steel discs, the slot corre-
sponding to the oil level cap should always be kept
free.
7
RKPB4360
16
RKPB3281
PW95R-2 30-177
REMOVAL AND INSTALLATION AXLES
11 - Check the flatness of the arms using tool M16 and finally
lock the arms with the screws (4) and the washer (5) us- M16
ing the cross-tightening method.
RKPB4370
30-178 PW95R-2
REMOVAL AND INSTALLATION AXLES
13
RKPB3530
RKPB4380
11
RKPB3540
10
RKPB4390
PW95R-2 30-179
REMOVAL AND INSTALLATION AXLES
5 - Screw the cylinder (9) into the spring seat (10) and lock
it using a bar “D”. D
10
RKPB4400
6 - Apply Loctite 270 to the rod (5) and screw it in the piston
(13) as far as it will go.
RKPB4410
1
RKPB3490
8 - Install cylinder (4) complete with rod (5) and internal nut
(6) and external nut (7).
4
5
6
7
RKPB3461
30-180 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4420
PW95R-2 30-181
REMOVAL AND INSTALLATION AXLES
RKP11140
RKP11150
3 - Fit the seal (9) onto the outside of the head (2).
RKP11160
4 - Prepare the piston (5) by fitting it with the guide ring (10),
the magnetic ring (11), the O-ring (12) and the seal (13).
11
13 10
1 - In order to facilitate assembly, apply grease.
2 - If a centring sensor is not fitted, then the mag-
netic ring (11) should be replaced by another
guide ring (10). 12 5
RKP11170
30-182 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4430
6 - Push the piston (5) into the cylinder for 100 mm using a
plastic hammer.
5
3
RKPB4440
5
2
RKPB4450
8 - Apply grease to head (2) seals, fit the head onto the pis-
ton (5) and push it into the cylinder (3) using a plastic
3
hammer.
2
★ Insert the head as to line it up with the edge of the
M17
cylinder.
5
RKPB4460
PW95R-2 30-183
REMOVAL AND INSTALLATION AXLES
9 - Insert the stop ring (4) ensuring that it fits into the seat of
the cylinder (3). 4
3
RKPB4470
RKPB4480
RKPB3410
30-184 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4490
RKPB4500
RKPB4510
4 - Insert the pins (4) in the steering case (7) and lock into
position using a torque wrench setting of 260--290 Nm. 4
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (6) further. 7
RKPB4520
PW95R-2 30-185
REMOVAL AND INSTALLATION AXLES
5 - Insert the cotter pins (3) and bend the safety stems.
6 3
RKPB4530
10
RKPB3331
I max=0,80 A
NERO
BLACK
1
CONNETTORE
CONNECTOR
2 BLU
1 3
BLUE
--
4
BATTERIA
BATTERY
MARRONE
BROWN
+
2A
RKP11180
RKPB4550
30-186 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4560
9 - Inspect jut “C” on one side of the piston and note down
the size for checking later adjustments.
★ If cylinders come without a sensor, the centring of
C
the piston must be carried out on the basis of the
maximum stroke.
RKPB4570
M18
RKPB4580
RKPB4590
PW95R-2 30-187
REMOVAL AND INSTALLATION AXLES
7. Convergency adjustment
1 - Unloose the nuts (11) and screw them onto the ball-and-
socket joints (15). 15
11
RKPB4600
RKPB4610
8. Cardan shaft
1 - Using tools M19 and M20, insert the sealing ring (9) and
the bearing (8) in the bush (6).
★ Carefully check the assembly side of the seal (12).
M19 M20
9 8
6 6
RKPB4620
7
11
RKPB4630
30-188 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4640
4 - Fit the check ring (5) on the bushing unit (6); also put the
O-ring (10) into position.
10
6
RKPB3221
5 - Insert the u-joint and tighten the top and bottom dowels
(3).
RKPB4650
RKPB4660
PW95R-2 30-189
REMOVAL AND INSTALLATION AXLES
7 - Screw the check nuts (2) of the dowels (3) and lock them
using a dynamometric wrench.
RKPB4670
9. Steering case
1 - If the bottom articulation pin (4) has been extracted, po-
sition the pin under a press and fit the ball cover (11).
11
RKPB4680
2 - Fit the front sealing rings (5) onto the articulation pins (4)
and (6).
★ Carefully check that the rings are properly oriented 5
(5).
4 6
RKPB3170
3 - Lubricate the top bush (8) or the bottom ball bush (9)
and fit them into the fulcrum holes of the arm.
Use tools M21 and M22.
M21
8 M22
RKPB4690
30-190 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB3150
5 - Fit a new seal (5) onto the top articulation pin (6). Lu-
bricate and install the unit in the steering case. Position
the screws (3) and lightly tighten.
RKPB3140
7 - Fit a new seal (5) onto the bottom articulation pin (4). Lu-
bricate and fit the unit in the steering case. Position the 5
screws (3) and lightly tighten.
4
RKPB3120
9 - Tighten the new fittin screws (3) of top and bottom ar- 3
ticulation pins in sequence using the cross tightening
method.
3
RKPB4700
PW95R-2 30-191
REMOVAL AND INSTALLATION AXLES
RKPB3090
18
RKPB4710
16 17 M24
RKPB4720
4 - Position the lower part of tool M25A and the thrust block
of the external bearing (8) under the press.
M25A
RKPB4730
30-192 PW95R-2
REMOVAL AND INSTALLATION AXLES
M25A
RKPB4740
6 - Position the upper part of tool M25B and press the thrust
blocks into the hub (7) all the way down.
M25B
RKPB4750
15
RKPB4760
RKPB4770
PW95R-2 30-193
REMOVAL AND INSTALLATION AXLES
10 - Position tool M16 and press the sealing ring (14) into its
seat.
M26
14
RKPB4780
13
RKPB3041
12 - Insert the snap ring (12) in order to fix the flange (5) in
the crown (13).
★ Carefully check that ring (12) is properly inserted in
the slot of the crown (13).
12
13
RKPB4790
13 - With the help of tool M27, insert the planet wheel gears
(10) into the cover (2). M27
Accurately check the orientation.
10
RKPB4800
30-194 PW95R-2
REMOVAL AND INSTALLATION AXLES
14 - Lock the gears (10) into position by fitting the snap rings
(9).
RKPB3010
15 - Fit the steering case (3) onto the U-joint (19) and install
the articulation pins.
For pin assembly details, see Assembly «9. STEERING
CASE». 3
RKPB3000
RKPB3091
RKPB2990
PW95R-2 30-195
REMOVAL AND INSTALLATION AXLES
RKPB2980
RKPB4810
RKPB2950
22 - Apply Loctite 242 to the studs and fit in the nuts (4).
RKPB4820
30-196 PW95R-2
REMOVAL AND INSTALLATION AXLES
RKPB4210
24 - Fit the planetary carrier cover (2) onto the hub (3).
★ Check that the O-ring (20) is in good condition and 2
in position.
RKPB2930
RKPB4280
PW95R-2 30-197
REMOVAL AND INSTALLATION BOOM CYLINDER (For 1-piece boom)
INSTALLATION OF BOOM
CYLINDER (For 1-piece boom) 10
• To install, reverse the removal procedure.
1
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder rod) until a clearance of
1–2 mm is obtained.
2 11
When aligning the positions between hole and pin,
let the engine run at minimum idling. Do not insert RKPA7180
RKPB1582
30-198 PW95R-2
REMOVAL AND INSTALLATION BOOM CYLINDER (For 2-piece boom)
RKPA7200
4
4
2
5
5 3
RKPA7210
4 - Slide off the pin (5) that connects the RH 2nd boom cyl-
inder (1) to the 2-piece boom, until the piston rod is com-
pletely disconnected. 2 3 5
5 - Start the motor and retract the RH cylinder piston. 6
3
★ To secure the piston rod in this position, tie it with
wire and switch off the engine.
6 - Disconnect the tubes (6) from the RH cylinder (1) and 1
plug them.
7 - Slide out the pin (7) until the cylinder (1) is free and re-
move it. 2 4
7
RKPA7220
9 - Slide the pin (7) out until the boom cylinder piston rod (8)
is disconnected. 3 4
★ To hold the piston rod in its fully retracted position,
tie it with wire and switch off the engine.
8
10 - Start the engine and retract the piston.
7
11 - Lower the cylinder (8) and rest it on a stand (B).
B
RKPA7230
PW95R-2 30-199
REMOVAL AND INSTALLATION BOOM CYLINDER (For 2-piece boom)
12 - Disconnect the tubes (9) and (10) and plug them. Also
plug hole in the safety valve (11) to prevent impurities
from entering.
13 - Remove pipe (12) and plug the cylinder port and the 11 13
pipe to keep out impurities.
10
RKPB1583
8 14
15
RKPA7240
2
Inside bushings: ASL800050
3
When aligning the positions between hole and pin,
run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.
4
★ Insert the spacers to a given clearance (distributed
on both sides of the piston rod) until a clearance of
0.5--1 mm is obtained.
5
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder) until a clearance of
0.5--1 mm is obtained.
• Start the engine and bleed the air from the cylinders (For
details, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the level of the oil tank.
30-200 PW95R-2
REMOVAL AND INSTALLATION 2nd BOOM CYLINDERS
RKPB0100
4
4
2
5
5 3
RKPA7210
4 - Slide off the pin (5) that connects the RH cylinder (1) to
the 2-piece boom, until the piston rod is completely dis-
connected. 2 3 5
5 - Start the motor and retract the RH cylinder piston. 6
★ To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
6 - Disconnect the tubes (6) from the RH cylinder (1) and 1
plug them.
7 - Slide out the pin (7) to free the cylinder (1) and remove it.
2 4 7
RKPA7220
9 - Slide the pin (7) out to disconnect the boom cylinder pis-
ton rod (8). 2
10 - Start the engine and retract the piston.
★ To hold the rod in its fully retracted position, tie it 8
with wire and switch off the engine.
3 7
11 - Lower the cylinder (8) and rest it on a stand (B).
B
RKPA7230
PW95R-2 30-201
REMOVAL AND INSTALLATION 2nd BOOM CYLINDERS
7
9
RKPA7250
INSTALLATION OF
2nd BOOM CYLINDERS
• To install, reverse the removal procedure.
1
Self-locking nut: 118 Nm
2
Inside bushings: ASL800050
3
When aligning the positions between hole and pin,
run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.
4
★ Insert the spacers to a given clearance (distributed
on both sides) until a clearance of 0.5--1 mm is ob-
tained for each cylinder.
5
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder) until a clearance of
0.5--1 mm is obtained.
• Start the engine and bleed the air from the cylinders (For
details, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the level of the oil tank.
30-202 PW95R-2
REMOVAL AND INSTALLATION ARM CYLINDER
INSTALLATION OF
ARM CYLINDER
• To install, reverse the removal procedure.
1
★ Insert the spacers to a given clearance (distributed
on both sides of the piston rod) until a clearance of 7
1--2 mm is obtained.
2 6
When aligning the positions between hole and pin, RKPA5452
3
Inside bushings: ASL800050
9 8
4 1
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder) until a clearance of
0.5--1 mm is obtained.
• Start the engine and bleed air from the cylinder. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the oil level in the tank.
RKPA7010
PW95R-2 30-203
REMOVAL AND INSTALLATION BUCKET CYLINDER
2 - Remove the ring nut (2) and draw out the pin (3).
1 2 3
3 - Switch off the engine and retract the piston rod (4).
★ To hold the piston rod in its fully retracted position,
tie it with wire. 3
RKPA7690
7 - Remove the screw (6) and draw out the pin (7).
2 3 4
8 - Lift out the cylinder (1).
5
RKPA7270
INSTALLATION OF 5
BUCKET CYLINDER
• To install, reverse the removal procedure.
6
1 7
★ Insert the spacers to a given clearance (distributed
on both sides of the piston rod) until a clearance of
1--2 mm is obtained.
2
When aligning the positions between hole and pin,
do not insert fingers into the hole to check the align- RKPA7280
ment.
3
Inside bushings: ASL800050
4
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder) until a clearance of
0.5--1 mm is obtained.
• Start the engine and bleed air from the cylinder. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the oil level in the tank.
30-204 PW95R-2
REMOVAL AND INSTALLATION BOOM SWING CYLINDER
2 - Swing the revolving frame 45° and rest the work equip-
ment on the ground.
3 - Switch off the engine and move the PPC valve several
times to release all residual pressures.
2
9
When aligning the positions between hole and pin,
let the engine run at minimum idling. Do not insert RKPB0990
3
10
Inside bushings: ASL800050
12
4
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder) until a clearance of 11
0.5--1 mm is obtained. 6
• Start the engine and bleed air from the cylinder. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the oil level in the tank.
RKPA7290
PW95R-2 30-205
REMOVAL AND INSTALLATION CYLINDERS FOR OUTRIGGERS OR BLADE
4 - Take away the screw (1), remove the dowel (2), and dis-
engage the piston rod from the blade or from the out-
rigger. 1 2 3
5 - Start the engine and retract the piston rod (3).
★ Secure the totally retracted position by binding both RKP10050
INSTALLATION OF
CYLINDERSFOR OUTRIGGERS 5
OR BLADE
• To install, reverse the removal procedure. 8
1 4
★ Insert the spacers to a given clearance on both
sides of the piston.
6
2
When aligning the hole and pin, let the engine run at
minimum idling. Do not insert fingers into the hole to
RKPB2860
check the alignment.
3
Inside bushings: ASL800050
7
4
★ Insert the spacers to a given clearance on both
sides of the piston.
• Start the engine and bleed air from the cylinder. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the level of oil in the
tank.
RKPB0140
30-206 PW95R-2
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
piston (6).
2. Boom, bucket, boom swing and blade cylinders:
5 - Remove the screws (7) and remove the two half-flanges
1
(8). 4
2
4 6 7
RKPA7320
3 - Loosen and remove the nut (10). Use the tool and the
dynamometric tool A1.
★ Before continuing with the dismantling operations,
allow the piston rod to cool down.
RKPA7330
4. All cylinders
11
RKPA7340
PW95R-2 30-207
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
Sealant: ASL800050 6 5
7 1
4 2
2. Head assembly
4
3 2 4 RKP08010
1 2 B
7 2
RKPA7360
RKPA7371
30-208 PW95R-2
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
RKPA7381
3. Assembly of piston
RKPA7391
4 3 2 3 4
6 5 6
RKP08020
RKPA7401
PW95R-2 30-209
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
4 - Mount the O-ring (5) and the rings wear (6) in the end-
seating, for the sealing between the piston ring and pis- 5
ton.
★ For boom, arm and bucket piston ring, the seal is
housed in the piston itself. 7 8
6
5 - Mount in the correct sequence the brake bushing (7) (for
the boom and arm cylinders only) and the piston (8).
RKPA7420
6 - For the arm piston only: mount the brake pin (9) and
slide the thirteen retaining balls (11) (No. 12) into the
hole (10).
8 12
7 - Mount the half-flanges (12) that hold the piston (8) in 10
place, and secure them with the screws (13).
13
11 9
For the arm and 2nd boom piston only: RKPA7430
1 - Mount the nut (14) that holds the piston (8) in place,
and tighten with the socket wrench and the dy-
namometric tool with multiplier A1.
Piston retaining nut: Loctite 262 8
Piston retaining nut: 14
Arm: 294±19.5 daNm
2nd boom: 343±28.4 daNm 15
RKPA7331
30-210 PW95R-2
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
5. Cylinder assembly
1 - Place the cylinder (1) and the piston rod group (2) on the 1 3
4
equipment A and align their axes. 2
2 - Lubricate the external seals and insert the piston (3) in
the cylinder (1).
7
RKPA7470
PW95R-2 30-211
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 1-piece boom)
INSTALLATION OF WORK
EQUIPMENT
(For 1-piece boom)
• To install, reverse the removal procedure.
1
★ Insert the spacers to a given clearance (distributed 5 5
on both sides of the piston) until a clearance of 1--2
mm is obtained.
2
When aligning the positions between holes and RKPA7480
4
★ Insert the spacers to a given clearance (distributed
on both sides of the arm) until a clearance of 0.5--1
mm is obtained.
• Start the engine to circulate the oil, and bleed air from
the cylinder.
★ After bleeding the air, switch off the engine and
check oil level in the tank. 8
RKPB0150
30-212 PW95R-2
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 2-piece boom)
RKPA7500
B
RKPA7530
RKPA7520
3 - Put the boom (5) in a sling and apply slight tension to the
cables.
★ Pass the cables through the rigid tubes to avoid dis-
5
tortion.
7
4 - Remove the screws (6) and take out the pin (7).
2 3 4
5 - Raise the boom (5) until it is disengaged from the swivel
support (8) and take away the stand (A).
6
PW95R-2 30-213
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 2-piece boom)
6 - Swing the group to the side of the machine and rest the
boom on a stand (C).
5
RKP08030
INSTALLATION OF THE
WORKEQUIPMENT
(For 2-piece boom)
• To install, reverse the removal procedure.
1
★ Insert the spacers (distributed on both sides of the
top of the cylinder) until a clearance of 1--2 mm is
obtained.
2
When aligning the positions between holes and
pin, let the engine run at minimum idling. Do not in-
sert fingers into the hole to check the alignment.
3
Inside bushings: ASL800050
4
★ Insert the shims (distributed on both sides of the top
of the piston rod) until a clearance of 1--2 mm is ob-
tained.
• Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
★ After bleeding the air, switch off engine and check
oil level in the tank.
30-214 PW95R-2
REMOVAL AND INSTALLATION BUCKET
REMOVAL OF BUCKET
Lower the bucket to the ground, resting with its back on
a flat surface. 7
1 - Take out the safety pin (1) and the connecting pin (2) be-
4
tween bucket (3) and tie-rod (4). 6
1 2 3 2
2 - Take out the safety pin (5) and the pin (6) that connects 5
the bucket to the arm (7).
2 3 4 1 3
RKPA7540
INSTALLATION OF BUCKET
• To install, reverse the removal procedure.
1
★ Insert the spacers to a given clearance between
bucket (3) and tie-rod (4).
2
When lining up the hole and the pin, let the engine
turn at low idling speed. Do not insert fingers into
the holes to check alignment.
3
Inside bushings: ASL800050
4
★ Insert the spacers to a given clearance (on both
sides) between the bucket (3) and the arm (7), until
a play of 0.5--1 mm is obtained.
PW95R-2 30-215
REMOVAL AND INSTALLATION ARM
REMOVAL OF ARM
1 - Remove the bucket. (For details, see «REMOVAL OF
BUCKET»).
2
RKPA7550
4 - Loosen the ring nut (3) and pin (4) and remove the thrust
lever (5). 1 2
3
4
RKPA7560
5 - Raise the boom and bring the arm (6) into a vertical po-
sition and then lower it to the ground.
6
RKP09740
RKPA7570
30-216 PW95R-2
REMOVAL AND INSTALLATION ARM
A
RKPA7580
12
11
RKPA7590
13 - Take out the screw (13) and pull out the pin (14).
14
13
RKPA7600
RKPB0890
PW95R-2 30-217
REMOVAL AND INSTALLATION ARM
INSTALLATION OF ARM
• To install, reverse the removal procedure.
1
Inside bushings: ASL800050
★ Insert shim.
2
When aligning the positions between holes and
pin, do not insert fingers into the hole to check the
alignment.
3
★ Insert the spacers to a given clearance (distributed
on both sides of the piston) until a clearance of 1--2
mm is obtained.
4
Inside bushings: ASL800050
★ Insert the spacers to a given clearance (distributed
on both sides) until a clearance of 0.5--1 mm is ob-
tained.
30-218 PW95R-2
REMOVAL AND INSTALLATION 2nd BOOM
2 - Start the engine and bring the 2-piece boom (1) into a
vertical position. Lower it until it rests on the ground and
switch off the engine.
RKPB0891
6 4
RKPA7211
RKPA7221
7
RKPA7610
PW95R-2 30-219
REMOVAL AND INSTALLATION 2nd BOOM
1
Self-locking nut: 118 Nm
2
Inside bushings: ASL800050
3
When aligning the positions between holes and
pin, let the engine run at minimum idling. Do not in-
sert fingers into the hole to check the alignment.
4
• Insert the spacers (distributed on both sides of the
boom) until a clearance of 0.5--1 mm is obtained.
• Start the engine to circulate the oil, and bleed air
from the cylinder. (For details, see «20. TESTING
AND ADJUSTMENTS»).
★ After bleeding the air, switch off the engine and
check the oil level in the tank.
30-220 PW95R-2
REMOVAL AND INSTALLATION BOOM (For 1-piece boom)
Boom: 300 kg 3 4
5
INSTALLATION OF BOOM
(For 1-piece boom)
• To install, reverse the removal procedure.
1
★ Insert the spacers to a given clearance (distributed
on both sides of the piston rod) until a clearance of
1--2 mm is obtained.
2 RKPB1350
4
★ Insert the spacers to a given clearance (distributed
on both sides of the boom) until a clearance of
0.5--1 mm is obtained. 6 6
• Start the engine to circulate the oil and bleed air from the
cylinders.
★ After bleeding the air, switch off the engine and
check the oil level in the tank. RKPA7481
PW95R-2 30-221
REMOVAL AND INSTALLATION BOOM (For 2-piece boom)
2 - Replace the fulcrum pin (1) of the 2-piece boom and se-
cure it with the proper screws. 2 1
3 - Manoeuvre the boom (2) until the fulcrum pin is resting
on a stand (A), 1.60 m high.
A
4 - Switch off the engine and release any residual pres-
sures in the boom cylinder.
3
5 - Remove the 2-piece boom cylinders (3) and let the
boom cylinder (4) rest on a stand.
4
RKPB0180
RKPA7521
8 - Take out the four screws (7) (No. 4) and lift away the
complete rack of tubes. 7
RKPA7440
30-222 PW95R-2
REMOVAL AND INSTALLATION BOOM (For 2-piece boom)
9 - Screw four M10 UNI 2947 eyebolts (8) as far as they will
go into the holes of the rack of tubes.
11 - Take out the screws (9) and remove the pin (10).
Boom: 292 kg 2
9
RKPB0900
INSTALLATION OF BOOM
(For 2-piece boom)
• To install, reverse the removal procedure.
1
Inside bushings: ASL800050
2
Do not insert fingers in the holes in order to check
the alignment.
3
★ Insert spacers on both sides of the boom, until a
clearance of 0.5--1 mm is obtained.
• Start the engine to let the oil circulate and bleed air from
the cylinders.
★ After bleeding the air, switch off the engine and
check the level in the oil tank.
PW95R-2 30-223
REMOVAL AND INSTALLATION SWING SUPPORT
RKPA7651
INSTALLATION OF SWING
SUPPORT
• To install, reverse the removal procedure.
1
Lower pin: ASL800050
2
4
Upper pin: ASL800050
3
★ Insert the adjustments to a given clearance be-
tween the chassis and the support.
Unit: mm RKPA7660
30-224 PW95R-2
REMOVAL AND INSTALLATION BLADE AND OUTRIGGERS
A
RKPB0210
Blade: 210 kg
Outrigger: 29 kg
A
2
RKPB0220
1
Internal bushings: ASL800050
2
Do not insert fingers into the holes to check on
alignment.
3
★ Insert the shims on both sides of the arm, in order to
obtain a clearance of 0.5–1 mm
PW95R-2 30-225
REMOVAL AND INSTALLATION BLADE AND OUTRIGGER ARMS
2 - Take out the screw (1) and remove the dowel (2).
1 2 3
3 - Start the engine and retract the piston (3). Stop the en-
gine. 2
3
1
RKPB0230
RKPB0240
1
Internal bushings: ASL800050
2
★ Do not insert fingers into the holes to check on
alignment.
3
★ Insert the shims on both sides of the arm, in order to
obtain a clearance of 0.5–1 mm.
30-226 PW95R-2
STANDARD MAINTENANCE
PW95R-2 40-1
STANDARD MAINTENANCE P.T.O.
P.T.O.
44–54 Nm
85 Nm
70 Nm
44–54 Nm
RKP05341
40-2 PW95R-2
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
DIFFERENTIAL
24–26 Nm 128–142 Nm
with Loctite 242 A with Loctite 242
Loctite 242
24–26 Nm
A 1 2
500–570 Nm 1
with Loctite 242
Section B - B
280–310 Nm
with Loctite 270 B
35–50 Nm
35–50 Nm
3
Section A - A RKP05561
Unit: mm
No. Check item Criteria
Remedy
Standard clearance Clearance limit
Backlash of crown wheel
1
and pinion
0.18–0.23 – Adjust
PW95R-2 40-3
STANDARD MAINTENANCE FRONT AXLE
BRAKES
A
3
A
Section A - A
283–312 Nm
35–50 Nm
2
5–7 Nm
with Loctite 270
RKP05581
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installated Installated Free Installated
1 Returning spring
length length load length load
– – – – –
Standard thickness Min. thickness
2 Disk thickness Replace
– 4.5
Standard clearance Max. clearance
3 Disk clearance Adjust
0.75 –
40-4 PW95R-2
STANDARD MAINTENANCE FRONT AXLE
FINAL DRIVE
128–142 Nm
1
1st tightening: 120 Nm
60–70 Nm 2nd tightening: 255–285 Nm
with Loctite 242 with Loctite 242
40–50 Nm
128–142 Nm
RKP05590
Unit: mm
No. Check item Criteria Remedy
PW95R-2 40-5
STANDARD MAINTENANCE FRONT AXLE
STEERING CYLINDER
240–270 Nm
with Loctite 242
116–128 Nm
RKP05670
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Clearance
Standard size
Clearance between shaft clearance limit
1 and bushing Shaft Hole Replace
45 – – – –
40-6 PW95R-2
STANDARD MAINTENANCE FRONT AXLE
28° 28°
A A
47.2
260–290 Nm Detail B
Section A - A
1790±1
1000
1000
87.7
74 87.7
1790±1
RKP05662
PW95R-2 40-7
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
25 Nm
A
49–51 Nm
with Loctite 510
B
B
35–50 Nm
A 49–51 Nm
49–51 Nm
35–50 Nm
24–26 Nm
30 Nm
80–100 Nm
Section B - B RKP05611
40-8 PW95R-2
STANDARD MAINTENANCE TRANSMISSION
Loctite 510
Loctite 510
280–310 Nm 2
with Loctite 310
49–51 Nm
with Loctite 242
Loctite 510 Loctite 510
25–26 Nm RKP05620
Unit: mm
No. Check item Criteria Remedy
PW95R-2 40-9
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
DIFFERENTIAL
24–26 Nm
with Loctite 242 128–142 Nm
A with Loctite 242
Loctite 242
24–26 Nm
A 1 2
1
Section B - B
B
35–50 Nm
35–50 Nm
3 900–1000 Nm
with Loctite 270 RKP05571
Section A - A
Unit: mm
No. Check item Criteria
Remedy
Standard clearance Clearance limit
Backlash of crow wheel
1
and pinion
0.18–0.23 – Adjust
40-10 PW95R-2
STANDARD MAINTENANCE REAR AXLE
BRAKES
A
3
A
Section A - A
283–312 Nm
35–50 Nm Section B - B
2
5–7 Nm
with Loctite 270
B A B
1
35–50 Nm
with Loctite 270 RKP05601
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installated Installated Free Installated
1 Returning spring
length length load length load
– – – – –
Standard thickness Min. thickness
2 Disk thickness Replace
– 4.5
Standard clearance Max. clearance
3 Disk clearance Adjust
0.75 –
PW95R-2 40-11
STANDARD MAINTENANCE REAR AXLE
25–30 Nm
with Loctite 242
24–26 Nm
20–25 Nm
20–25 Nm
3 a
50–60 Nm
RKP05630
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installated Installated Free Installated Replace if
1 Returning spring damage or
length length load length load
deformed
– – – – –
2 Clearance with 10 kg force 0 – Set
Check
3 Piston jut 4–5 brake
–
thickness
and adjust
40-12 PW95R-2
STANDARD MAINTENANCE REAR AXLE
FINAL DRIVE
128–142 Nm
1
1st tightening: 120 Nm
60–70 Nm 2nd tightening: 255–285 Nm
with Loctite 242 with Loctite 242
40–50 Nm
128–142 Nm
RKP05590
Unit: mm
No. Check item Criteria Remedy
PW95R-2 40-13
STANDARD MAINTENANCE REAR AXLE
STEERING CYLINDER
240–270 Nm
with Loctite 242
116–128 Nm
RKP05640
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Clearance
Standard size clearance limit
Clearance between shaft
1 Shaft Hole Replace
and bushing
45 – – – –
40-14 PW95R-2
STANDARD MAINTENANCE REAR AXLE
28 28
A A
47,2
Detail B
260–290 Nm
Section A - A
1790±1
1000
1000
87,7 87,7
1790±1
RKP05653
PW95R-2 40-15
STANDARD MAINTENANCE SWING CIRCLE
SWING CIRCLE
290 Nm
Section C - C
Section A - A
1
290 Nm
Section B - B
D
290 Nm
A
D
314 Nm
C
C
Section D - D
B
B
Section E - E
A E
RKP12461
Unit: mm
No. Check item Criteria
Remedy
Standard clearance Clearance limit
1 Axial clearance
0.3–1.2 3 Replace
40-16 PW95R-2
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE SWING MACHINERY
SWING MACHINERY
3
49 Nm 85 Nm
1000±50 Nm
with Loctite 243
1
294 Nm
ASL800050
6
RKP12310
40-18 PW95R-2
STANDARD MAINTENANCE SWING MACHINERY
Unit: mm
No. Check item Criteria Remedy
Backlash between
3 No. 1 sun gear and
No. 1 planetary gear
Replace
Backlash between
4 No. 2 sun gear and
No. 2 planetary gear
PW95R-2 40-19
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
110.3 ± 12.3 Nm
View Y
13.25 ± 1.45 Nm 144.55 ± 12.25 Nm 100.45 ± 12.25 Nm
RKP03731
40-20 PW95R-2
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
A
C B
D A
AA AA
O O
N N
M M
L L
K K
J J
H H
G G
F F
P
E E xx
BB BB
C D A
Pu
P B
9.8–12.7 Nm 29.4–39.2 Nm
1 3
4 2
View B RKP03281
40-22 PW95R-2
STANDARD MAINTENANCE CONTROL VALVE
39–49 Nm 39–49 Nm
39–49 Nm 39–49 Nm
39–49 Nm 39–49 Nm
107.8–147 Nm
RKP03291
Section A - A
Unit: mm
No. Check item Criteria Remedy
– 33 231.4 N – –
PW95R-2 40-23
STANDARD MAINTENANCE CONTROL VALVE
1 1
1 1
1 1
1 1
1 1
1 2
1 3
2 2
1 1
3 3
RKP03371
Section B - B
Unit: mm
No. Check item Criteria Remedy
40-24 PW95R-2
STANDARD MAINTENANCE CONTROL VALVE
118–162 Nm
1
1
4
2
RKP03301
Section C - C
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
PW95R-2 40-25
STANDARD MAINTENANCE CONTROL VALVE
24.5–34.3 Nm
58.8–78.5 Nm
RKP03311
Section D - D
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Check valve spring Free length Installed Installed Free length Installed
x O.D. length load x O.D. load
Replace
– 22 3.92 N – –
Check valve spring
2 – 11.5 13.7 N – –
(Swing)
40-26 PW95R-2
STANDARD MAINTENANCE CONTROL VALVE
107.8–147 Nm
1
49–59 Nm
Section BB - BB RKP02823
19.6–27.4 Nm 65.7–85.3 Nm
with Loctite 638
Section E - E RKP02813
Unit: mm
No. Check item Criteria Remedy
– 46.4 138 N – –
PW95R-2 40-27
STANDARD MAINTENANCE CONTROL VALVE
34–44 Nm
88.3–107.9 Nm
34–44 Nm
19.6–27.5 Nm
34–44 Nm
RKP02843
Section AA - AA
39–49 Nm
49–59 Nm
Section F - F RKP02833
40-28 PW95R-2
STANDARD MAINTENANCE CONTROL VALVE
RKP02853
Section G - G
14.7–19.6 Nm 14.7–19.6 Nm
with Loctite 638 with Loctite 638
Section H - H RKP02863
14.7–19.6 Nm 14.7–19.6 Nm
with Loctite 638 with Loctite 638
RKP02873
Section J - J
PW95R-2 40-29
STANDARD MAINTENANCE CONTROL VALVE
14.7–19.6 Nm
with Loctite 638
RKP02883
Section K - K
14.7–19.6 Nm
with Loctite 638
RKP03321
Section L-L
14.7–19.6 Nm
with Loctite 638
40-30 PW95R-2
STANDARD MAINTENANCE CONTROL VALVE
14.7–19.6 Nm
with Loctite 638
RKP03341
Section N-N
14.7–19.6 Nm
with Loctite 638
20–25 Nm
RKP03351
Section O-O
147–186 Nm
RKP03361
Section P-P
PW95R-2 40-31
STANDARD MAINTENANCE SWING MOTOR
SWING MOTOR
A
108–142 Nm
58.8–78.4 Nm
34.3–44.1 Nm
2
Section A - A RKP120101
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Suction valve spring Free length Installed Installed Free length Installed
x O.D. length load x O.D. load Replace
– 11.5 0.9 N – –
2 Shuttle valve spring – 19.5 1.8 N – –
40-32 PW95R-2
STANDARD MAINTENANCE SWIVEL JOINT
SWIVEL JOINT
RKP03790
Unit: mm
No. Check item Criteria Remedy
Standard Standard Clearance
Tolerance
size clearance limit
Clearance between – 0.02
1 Shaft Replace
shaft and rotor – 0.05
85 0.12–0.20 0.25
+ 0.10
Hole
+ 0.15
PW95R-2 40-33
STANDARD MAINTENANCE TRAVEL MOTOR
TRAVEL MOTOR
__________ Nm
11
2 __________ Nm
1
3
__________ Nm _______ Nm
A __________ Nm
__________ Nm
__________ Nm
Sezione A - A
RKP11200
Unit: mm
No. Check item Criteria Remedy
– – – – –
40-34 PW95R-2
STANDARD MAINTENANCE TRAVEL MOTOR BRAKE VALVES
1 2 200 Nm
20 Nm
100 Nm
20 Nm
600 Nm
200 Nm
650 Nm
10 Nm 4
RKP04560
Unit: mm
No. Check item Criteria Remedy
Free Free
1 Pilot valve spring length Installed Installed Installed
length
length load load
xØe xØe
– – – – –
Replace
2 Main valve spring – – – – –
PW95R-2 40-35
STANDARD MAINTENANCE SERVOCONTROL FEED UNIT
3 22.0±4.9 Nm 29.4±4.9 Nm
9.8±2 Nm
1 2 9.8±2 Nm 4
66.2±7.3 Nm
Section A - A Section B - B
RKP04091
Unit: mm
No. Check item Criteria Remedy
40-36 PW95R-2
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
BOOM, ARM, BUCKET, SWING
1 2
3 3
RKP12670
Unit: mm
No. Check item Criteria Remedy
Replace
Metering spring
2
(For P1 and P3 port)
3 Checking spring
PW95R-2 40-37
STANDARD MAINTENANCE BLADE
BLADE
Section A - A RKP12681
Unit: mm
No. Check item Criteria Remedy
2 Metering spring
40-38 PW95R-2
STANDARD MAINTENANCE BLADE SAFETY VALVE
83 Nm
75 Nm
33 Nm
RKP04580
Unit: mm
No. Check item Criteria Remedy
Free Free
1 Check valve spring length Installed Installed Installed
length load length load
Replace
xØe xØe
PW95R-2 40-39
STANDARD MAINTENANCE CYLINDERS
CYLINDERS
BOOM - BUCKET, BOOM SWING, BLADE
1
49 Nm
49 Nm
RKP04370
ARM
49 Nm 2940±196 Nm
with Loctite 262
RKP04360
2-PIECE BOOM
3430±284 Nm
1 with Loctite 262
RKP04350
40-40 PW95R-2
STANDARD MAINTENANCE CYLINDERS
Unit: mm
No. Check item Criteria Remedy
– 0.03 0 0.030
Boom 70 0.326
– 0.06 + 0.166 0.226
– 0.05 0 0.025
2-piece boom 50
–0.025 + 0.166 0.216
0.316
Clearance
1 between
piston rod – 0.03 0 0.030
Arm 60
– 0.06 + 0.166 0.226
0.326
and cylinder head
– 0.03 0 0.030
Bucket 60 0.326
– 0.06 + 0.166 0.226
– 0.03 0 0.030
Boom swing 60
– 0.06
0.326
+ 0.166 0.226
Outriggers or 60
– 0.03 0 0.030
0.326
blade – 0.06 + 0.166 0.226
Outriggers or 50
– 0.050 + 0.08 + 0.13
1
blade – 0.089 + 0.119 + 0.208
Outriggers or 50
– 0.050 + 0.08 + 0.13
1
blade – 0.089 + 0.119 + 0.208
PW95R-2 40-41
STANDARD MAINTENANCE WORK EQUIPMENT
WORK EQUIPMENT
1-PIECE BOOM
D
G
A B
7 6 4 5 3
40-42 PW95R-2
STANDARD MAINTENANCE WORK EQUIPMENT
Section G - G
RKP05741
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Tolerance
Clearance between swing size clearance limit
1 bracket-to-revolving Shaft Hole
frame mounting and pin bushing
– 0.072 + 0.145 0.271–
100 0.8
– 0.126 + 0.044 0.116
PW95R-2 40-43
STANDARD MAINTENANCE WORK EQUIPMENT
WORK EQUIPMENT
2-PIECE BOOM
D
H
F
F
A B
7 6 4 5 3
8 2
40-44 PW95R-2
STANDARD MAINTENANCE WORK EQUIPMENT
9 10
Tolerance
Standard Standard Tolerance
Clearance between swing size clearance limit
1 bracket-to-revolving frame Shaft Hole
mounting and pin bush1ing
– 0.072 + 0.145 0.271–
100 0.8
– 0.126 + 0.044 0.116
PW95R-2 40-45