Komatsu PC35R-8, PC45R-8 Deluxe Hydraulic Excavator Workshop Service Repair Manual F20932 and up,F21251 and up

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CONTENTS 00-1 PC35R-8 PC45R-8 10 STRUCTURE AND FUNCTION ............................................. 10-1 20 TESTING AND ADJUSTING ................................................ 20-1 30 REMOVAL AND INSTALLATION ........................................... 30-1 40 MAINTENANCE STANDARD ............................................... 40-1

00-2 PC35R-8 PC45R-8

Pages having no marks are those previously revised or made additions. 00-2-1 PC35R-8 PC45R-8 Mark Indication Action required C Page to be newly Add c Page to be replaced Replace ( ) Page to be delete Discard LIST OF REVISED PAGES The affected pages are indicated by the use of the following marks. It is requested that necessary ac- tions be taken to these pages according to table below. Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision 00-1 00-2 00-2-1 00-2-2 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-33 10-34 10-35 10-36 10-37 10-38 10-39 10-40 10-41 10-42 10-43 10-44 10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-52 10-53 10-54 10-55 10-56 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 20-1 20-2 20-3 20-4 20-5 20-6 20-7 20-8 20-9 20-10 20-11 20-12 20-13 20-14 20-15 20-16 20-17 20-18 20-19 20-20 20-21 20-22 20-23 20-24 20-25 20-26 20-27 20-28 20-29 20-30 20-31 20-32 20-33 20-34 20-35 20-36 20-37 20-38 20-39 20-40 20-41 20-42 20-43 20-44 20-45 20-46 20-47 20-48 20-49 20-50 20-51 20-52 20-53 20-54 20-55 20-56 20-57 20-58 30-1 30-2 30-3 30-4 30-5 30-6 30-7 30-8 30-9 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51

00-2-2 PC35R-8 PC45R-8 Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 40-1 40-2 40-3 40-4 40-5 40-6 40-7 40-8 40-9 40-10 40-11 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26 40-27 40-28 40-29 40-30 40-31 40-32 40-33 40-34 40-35

GENERAL PRECAUTIONS Mistakes in operation extremely dangerous. Read all the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions written on the decals which are suck on the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. . Always wear safety glasses when hitting parts with a hammer. . Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding or making any repairs, park the machine on hard, level ground, and block the tracks to prevent the machine from moving. 8. Before starting work, lower blade, bucket or any other work equipment to the ground. If this is not possible, use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the hydraulic circuit and engine cooling circuit, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are not hot when the engine in stopped, so be careful not to get burned. Wait for the oil water to cool before carrying out any work on the cooling water circuits. 00-3 PC35R-8 PC45R-8 IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and describe in this manual are both ef- fective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise, first consider safety, and take necessary steps to face. SAFETY

13. Before starting work, remove the leads from the battery. Always remove the lead from the negative ( ± ) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample ca- pacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damage wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can 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. 19. Be sure to assemble all parts again in their origi- nal places. Replace any damage parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly tightened. 21. When assembling or installing parts, always use specified tightening torques. When installing the parts which vibrate violently or rotate at high speed, be particulary careful to check that they are correctly installed. 22. When aligning two holes, never insert your fingers or hand. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurement. 24. Take sure when removing or installing tracks. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 00-4 PC35R-8 PC45R-8

00-5 PC35R-8 PC45R-8 FOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac- curate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This sections explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating «Problems» to «Causes» are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any notice. Contact your Komatsu distributor for the latest information.

VOLUMES Shop manual are issued as a guide to carry out repairs. These various volumes are designed to avoid duplicating the same information. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to Komatsu distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show you how to read the page number. Example 3. Additional pages: additional pages are indicated by a hyphen (-) and number after the page number. Fle as in the example. Example: 10-4 10-4-1 10-4-2 10-5 ] Added pages REVISED EDITION MARK (123 ....) When a manual is revised, an edition mark is re- corded on the bottom outside corner of the pages. REVISIONS Revised pages are shown on the LIST OF RE- VISED PAGES between the title page and SAFETY page. SYMBOLS In order to make the shop manual greatly chelpful, important points about safety and quality are marked with the following symbols. Symbol Item Remarks Safety Special safety precautions are necessary when performing the work. Extra special safety precautions are necessary when performing the work because it is under internal pressure. Caution Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Tightening torque Parts that require special attention for the tightening torque during assembly. Coat Parts to be coated with adhesives and lubricants etc. Oil, water Places where oil, water or fuel must be added, and their quantity. Drain Places where oil or water must be drained, and quantity to be drained. HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL 00-6 PC35R-8 PC45R-8 Item number (10. Structure and function) Consecutive page number for each item 10 - 3

Komatsu PC35R-8, PC45R-8 Deluxe Hydraulic Excavator Workshop Service Repair Manual F20932 and up,F21251 and up

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