Komatsu PC95-1 Excavator Factory Shop Manual (P/N WEBMPC9500)

• Coverage and document identity: Covers the Komatsu PC95-1 hydraulic excavator, serial number 5000007 and up, fitted with the Perkins 1004-4 engine. The 315-page PDF contains the English-language FKI FAI Komatsu Industries shop manual code WEBMPC9500, dated July 1996 (print code 6916GB-07/96).
• Hydraulic testing and adjustment: Details pressure checks and regulation for the main and secondary relief circuits, P1/P2 piston pumps, P3 gear pump, P4 swing circuit, servocontrol supply, summation horsepower control, and 3-circuit Mode System. Pump-delivery measurement, circuit bleeding, and residual-pressure release are included.
• Major component repair: Covers engine-pump and pump-group removal and installation; hydraulic-pump and gear-pump disassembly and assembly; and removal, overhaul, and installation work for the swing machinery, final drives, idler/recoil spring group, and work-equipment cylinders.
• Travel, swing, and undercarriage procedures: Includes swing-circle clearance measurement, track-tension adjustment, travel-deviation testing, travel-motor speed setting, internal-leakage checks, and service procedures for track shoes, sprockets, rollers, travel motors, the center swivel joint, and revolving frame.
• Standard and two-piece boom configurations: Provides separate procedures and inspection data for the one-piece boom and 2-piece boom, including their cylinders, PPC controls, boom-swing circuit, blade system, overload sensor, work-equipment removal, safety-valve adjustment, closing-speed control, and hydraulic-drift diagnosis.
• Schematics, troubleshooting, and service data: Supplies a complete hydraulic circuit diagram, engine-line, solenoid-valve-line, and light-line electrical diagrams, symptom-based hydraulic troubleshooting charts, special-tool references, standard torque and fluid tables, pressure-test data, component clearances, and wear limits.

This factory shop manual goes well beyond routine maintenance. Its system descriptions connect the power train, final drives, swing circuit, main and auxiliary pumps, control valve, servocontrol feed unit, PPC valves, accumulator, travel acceleration valve, and electrical controls to the tests used when a fault appears. The depth of the work, together with the required pressure gauges, lifting fixtures, and component-specific tools, makes it best suited to experienced heavy-equipment technicians and properly equipped repair shops.

Hydraulic Testing and Fault Isolation

The testing chapter starts with standard and permissible data for the machine and engine, then identifies the gauges, adapters, tachometers, flowmeter, and circuit-sectioning equipment used for diagnosis. Procedures cover engine speed, valve clearance, compression pressure, fan-belt tension, accelerator travel, PPC lever clearance, safety microswitches, and blade-control centering.

Hydraulic coverage includes pump delivery, travel deviation, swing- and travel-motor leakage, swivel-joint leakage, overload-sensor operation, and boom, arm, bucket, blade, boom-swing, and 2-piece-boom drift tests. The troubleshooting charts trace faults such as weak or intermittent work equipment, slow swing, poor swing braking, excessive travel deviation, unstable servocontrol pressure, ineffective control-lever movement, Mode System speed-change failure, abnormal pump noise, and engine stalling under load.

Component Repair, Tooling, and Inspection Limits

The disassembly chapter documents removal and installation across the machine, from the starter, alternator, radiator, oil cooler, tanks, cab, and counterweight to the control valve, swing circle, revolving frame, travel motors, and front equipment. Internal repair coverage is concentrated on the hydraulic pump, gear pump, swing machinery, final drives, idler/recoil spring, and hydraulic cylinders. Factory tool listings identify equipment such as swing-circle lifting fixture ATR200420, recoil-spring press ATR200430, cylinder service tool ATR200610, final-drive preload tool ATR500850, and swing-brake circuit-sectioning tool ATR200380.

Maintenance-standard tables provide repair limits and inspection criteria for the PTO, travel and swing machinery, undercarriage, pump drive, Mode System, auxiliary pump, control and relief valves, PPC valves, cylinders, and both boom arrangements. The illustrated references include the hydraulic circuit, the three named electrical circuits, and detailed final-drive/sprocket and swing-machinery section views.

During hydraulic-pump teardown, unprotected levering or hard vise jaws can damage machined surfaces and drive-gear teeth. Cylinder assembly likewise calls for dedicated seal-calibrating and insertion tools because an incorrect fit can damage seals, rod surfaces, or the cylinder bore.

1004-4 Engine Scope and Shop Safety

The manual includes 1004-4 engine checks and removal procedures for the starter, alternator, nozzle holder, air-filter group, muffler, and complete engine-pump group. Full internal engine overhaul is not included; the publication directs that work to the separate 1000 Series Engine Shop Manual.

Many procedures involve stored hydraulic pressure, raised work equipment, pressurized track-adjuster grease, heavy lifts, and spring-loaded parts. Use the manual's blocking, pressure-release, lifting, and component-specific safety instructions, and have qualified personnel perform work that exceeds the shop's equipment or experience.