Description

Komatsu PC35R-8, PC45R-8 2001 Service Manual

I’ve seen one too many guys wreck a valve cover gasket because they guessed the torque instead of looking it up. That’s why you need the Komatsu PC35R-8, PC45R-8 2001 Service Manual on your bench before you lay a wrench on these machines. This isn’t a reprint from some third-party shop that pulled specs off a forum. It’s the original OEM file – 271 pages of what Komatsu wrote for their dealers. Serial numbers F20518 and up for the PC35R-8, F20666 and up for the PC45R-8. Page 1 has that stamped in. If you’re working on one of these compact excavators and don’t have this, you’re gambling with time and parts money.

What the 2001 Komatsu PC35R-8 and PC45R-8 Service Manual Covers

This manual splits into three big sections: Structure and Function (they call it 10), Testing and Adjustments (20), and Removal and Installation (30). Under Testing and Adjustments you get the Norm or Standard Technical Data table – that’s where you find engine speeds, pressures, and clearances that apply to the whole machine. Then there’s a list of special tools required for the jobs in this book. Don’t start swapping an injection pump without reading the section on Control and Adjustment of the Injection Timing. You’ll be chasing your tail.

Removal and Installation covers every major component from the starter motor to the blade. Each one has its own REMOVAL and INSTALLATION sub-section. For example, Cylinder Head removal tells you the sequence and the torque pattern. No guesswork. Also includes how to R&R the engine-pump group, the swing machinery, and the track rollers. If you’re rebuilding an undercarriage, the Idler and Recoil Spring Assembly section walks you through disassembly and assembly of the recoil spring and thrust cylinder groups.

Valve Clearance Adjustment: Why You Need the Factory Spec

Under Testing and Adjustments, there’s a section called ADJUSTMENT OF VALVE CLEARANCE. This is where most aftermarket manuals screw you – they give a generic range that’s too loose or too tight. Komatsu gives you the exact clearance for intake and exhaust, measured cold. They also tell you the order to check them. If you skip that step and just set all valves to the same feeler gauge thickness, you’ll get a lazy cylinder and a customer who complains about power loss. The manual also includes measurement of compressor pressure and checking engine speed, all in one coherent procedure.

7 Systems Covered in the Structure and Function Section

Section 10 lays out the hydraulic and mechanical systems in detail. Here’s what’s in there:

• Power train and P.T.O.
• Swing circle and swing machinery
• Final drive and track frame with recoil spring
• Carrier rollers and track rollers
• Steel shoe and rubber track shoes
• Hydraulic circuit diagrams for both PC35R and PC45R
• Hydraulic pump, control valve, CLSS, swivel joint, swing motor, travel motor, cylinders, accumulator, PPC valves (work equipment and hammer), solenoid valve
• Electrical diagrams in three parts

That last point – electrical diagrams. If you’ve ever traced a short in the servo-control solenoid group without a factory schematic, you know how bad it gets. This manual gives you the full wiring for the machine.

Get the Right Torque Data from the Factory

In the Foreword section you’ll find STANDARD TIGHTENING TORQUE. That’s the baseline torque for all bolts that don’t have a specific value in the procedure. They also list coating materials and electric wire codes. Aftermarket manuals often skip the coating materials – they’ll tell you to tighten to a number but forget to mention whether threads need Loctite or anti-seize. Komatsu does not forget. Use that torque chart.

If you’re working on the swing motor or travel motor, the section under Testing and Adjustments called CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS gives you the exact psi you need to set the relief valves. Don’t trust generic specs. There’s also a procedure for bleeding air from the hydraulic circuits and eliminating residual pressures – safety-critical stuff. That’s where the manual earns its keep.

Does This Manual Cover the Hydraulic Circuit Diagrams?

Yes. Two separate diagrams – one for PC35R-8 and one for PC45R-8. They show the full hydraulic system including the CLSS (Closed Center Load Sensing System). You also get the swivel joint internal passage layout. If you suspect a drift in the boom or swing, the manual includes a whole sub-section: CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSES OF A DRIFT. That’s real troubleshooting, not just generic theories.

Who Should Use This Manual

Anyone who owns a PC35R-8 or PC45R-8 and doesn’t have a dealer-level diagnostic tool. Home garage mechanics who want to do their own track tension, valve adjustments, or final drive rebuilds. Shop owners who need a single source for torque specs and hydraulic pressure data so their techs stop guessing. Beginners should not buy this manual expecting it to teach them hydraulics from scratch – it’s a service manual, not a textbook. But if you already understand how an excavator works and need Komatsu’s exact procedures, this is what you need.

Source Validity: OEM vs Aftermarket

This is not a scanned copy of a photocopy. It’s the original OEM digital publication from 2001, copyright Komatsu America International Company. The OCR excerpt from page 1 shows the proprietary notice and serial number ranges. Aftermarket manuals often list inaccurate torque values for these machines because they cross-reference from generic data. I’ve seen a manual claim the cylinder head bolts take 65 ft-lb when the real spec from Komatsu is 54 ft-lb plus an angle. That difference costs you a head gasket job the next week. Stick with factory originals.

For related documentation, check the Komatsu PC35R-8 PC45R-8 Shop Manual for the same models in a different binding. There’s also the Komatsu PC35R-8 PC45R-8 Technical Manual – Factory OEM Shop Manual if you need more theory. And if you work on bigger Komatsu machines, the Demag Komatsu H 285 S Service Manual – 544 Pages of Factory Specs covers the heavy line. For general background on manual transmissions used in older equipment, see Manual Transmission on Wikipedia. For engine fundamentals, that same Manual Transmission article covers clutch and gear principles that apply to power take-offs.

Frequently Asked Questions

Does this manual cover the PC35R-8 with steel tracks?

Yes. Section 30 includes removal and installation procedures for both RUBBER TRACK SHOES and STEEL TRACK-SHOES, plus the sprocket wheel and final drive.

What torque values are listed?

Standard tightening torque table in the Foreword covers bolt grades and sizes. Specific torque values for cylinder head, injection pump, swing motor, and track roller bolts are in their respective removal sections.

Can I use this manual to diagnose hydraulic drifts?

Yes. Section 20 includes a dedicated sub-section for CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSES OF A DRIFT. It also has procedures for checking internal leakages in cylinders, swing motor, and swivel joint.

Is this the factory manual or a reprint?

OEM factory manual from Komatsu, 2001 edition. Not a third-party reprint. The file includes the full trademark and copyright notice on page 1.

Don’t waste a Saturday chasing a spec that’s wrong. Get the real data. Access the Factory Manual now and keep it at your toolbox.