PC35 PC45R-8 Webm000300 PDF

CONTENTS
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
PC35R-8 PC45R-8
00-1
00-2
PC35R-8 PC45R-8
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00-2-2
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 Utility and describe in this manual are
both effective and safe methods of operation. Some of these operations require the use of tools specially
designed by Komatsu Utility 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
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous.

Read all the Operation and Maintenance Manual carefully BEFORE operating the machine.
7. Before adding or making any repairs, park the machine on hard, level ground, and block the tracks
to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read

all the precautions written on the decals which
are suck on the machine.
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.
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.
PC35R-8 PC45R-8
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
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 capacity. 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.
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.
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 original 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.
00-4
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 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
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 Utility distributor for the latest information.
PC35R-8 PC45R-8
00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES
SYMBOLS
Shop manual are issued as a guide to carry out repairs. These various volumes are designed to avoid
duplicating the same information.
In order to make the shop manual greatly chelpful,

important points about safety and quality are marked
with the following symbols.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will
be sent to Komatsu Utility distributors.
Get the most up-to-date information before you start
any work.
Symbol
Item
Special safety precautions are necessary when performing the

work.
Safety
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.
Item number (10. Structure

and function)
Consecutive page number for
each item
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
] Added pages
10-4-2
10-5
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.
Example
10 - 3
Remarks
Parts that require special attention

Tightening for the tightening torque during astorque
sembly.
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.
REVISED EDITION MARK

(1 2 3 ....)
When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED PAGES between the title page and SAFETY page.
00-6
PC35R-8 PC45R-8
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Heavy parts (25 kg or more) must be lifted

with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or
more is clearly indicated with the symbol
ing, and a serious accident can result.

Hooks have maximum strength at the middle
portion.
1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
. Check for removal of all bolts fastening the part
to the relative parts.
. Check for any part causing interference with
the part to be removed.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table below:
WIRE ROPES
(Standard S or Z twist ropes
without galvanizing)
Rope diameter (mm)
Allowable load (tons)
10
1.0
11.2
1.4
12.5
1.6
14
2.2
16
2.8
18
3.6
20
4.4
22.4
5.6
30
10.0
40
18.0
50
28.0
60
40.0
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound on to the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the rope, or slipping of the rope from its original
winding position on the load, which can cause dangerous accidents.
4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles.
The table below shows the variation of allowable load (kg) when hoisting is made with two
ropes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150.
The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of the
hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-
PC35R-8 PC45R-8
00-7
STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of Disassembly and Assembly.
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Thread diameter
of bolts
(mm)
Pitch of
bolts
(mm)
Width across flat

(mm)
kgm
Nm
kgm
Nm
10
0.96w0.1
9.5w1
1.3w0.15
13.5w1.5
1.25
13
2.3w0.2
23w2
3.2w0.3
32.2w3.5
10
1.5
17
4.6w0.5
45w4.9
6.5w0.6
63w6.5
12
1.75
19
10
7.8w0.8
77w8
14
22
12
12.5w1
16
24
14
18
2.5
27
20
2.5
22
11w1
108w11
122w13
17.5w2
172w18
19.5w2
191w21
27w3
268w29
14
27w3
262w28
37w4
366w36
30
17
38w4
372w40
53w6
524w57
2.5
32
17
52w6
511w57
73w8
719w80
24
36
19
66w7
644w70
92w10
905w98
27
41
19
96w10
945w100
135w15
1329w140
30
3.5
46
22
131w14
1287w140
184w20
1810w190
33
3.5
50
24
177w20
1740w200
250w27
2455w270
36
55
27
230w25
2250w250
320w35
3150w350
39
60
295w33
2900w330
410w45
4050w450
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):
00-8
1 Nm = 0.102 kgm
PC35R-8 PC45R-8
2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.
Thread diameter
of nut part
(mm)
Width across flats

of nut part
(mm)
TIGHTENING TORQUE
kgm
Nm
1/2" - 20
9/16" - 18
3/4" - 16
7/8" - 14
1.1/16" - 12
1.5/16" - 12
1.5/8" - 12
22
33
17
17
22
27
32
38
50
27
41
2.6w0.5
4w0.5
6.7w2
8w2
9.7w3
17w3
20w5
8w2
20w5
25.5w4.9
39.2w4.9
65.7w19.6
78.5w19.6
95.15w29.4
166.7w29.4
196.2w49
78.5w19.6
196.2w49
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Nomenclature
Adhesives
Code
Loctite 222
Applications
Used for low resistance locking of screws, check nuts and adjustment nuts.
Loctite 242
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262
Used for high resistant of threaded parts that can be removed with normal tools.
Loctite 270
Used for high resistant locking and for sealing threaded parts, bolts and stud
bolts.
Loctite 542
Used for sealing the union threads for hydraulic tubes.
Loctite 573
Used for sealing rather exact plane surfaces when the option of possible future
dismantling is required.
Loctite 601
Loctite 675
Used for high resistant locking of mechanical components that can be removed
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Loctite 518
Used by itself on mounting surface on the final drive and transmission cases.
(Clearance between flange surfaces within 0.2 mm).
Used by itself on mounting flat surface
(Clearance between surfaces within 0.5 mm)
Antifriction compound
(Lubricant including
Molybdenum disulfide)
ASL800040
Applied to bearings and taper shaft to facilitate press-fitting and to prevent sticking, burning or rusting.
Grease
(Lithium grease)
ASL800050
Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Gasket sealant
Vaseline
PC35R-8 PC45R-8
Loctite 510
Used for protecting battery electrode terminals from corrosion.
00-9
ELECTRIC WIRE CODE
CABLE
ELECTRIC WIRE CODE
In the wiring diagrams various colours 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
Number
strands
Copper wire
of strands
(mm)
Cross section
(mm2)
14
0.30
1.5
21
2.5
4
Nominal
number
Cable O.D.
(mm)
Current rating
(A)
0.99
2.80
11
Warning light, light etc.
0.30
1.48
3.35
14
Working beam, solenoid valve,

etc.
35
0.30
2.47
3.80
20
Control panel, etc.
56
0.30
3.95
4.60
28
Pre-heating
84
0.30
5.93
5.20
37
Control panel
35
266
0.40
9.20
12.20
125
Battery - Ground
Applicable circuit
CLASSIFICATION BY COLOUR AND CODE

Primary
Code
Colour
Light blue
Code
Colour
White
Code
Colour
Orange
Code
Colour
Yellow
Code
Colour
Gray
Code
Colour
Blue
Code
Colour
Brown
Code
Colour
Black
Code
Colour
Red
Code
Colour
Pink
Code
Colour
Green
Auxiliary
AR
A/R
Light blue - Red

BG
White Yellow
CN
C/N
Orange Black
GN
Yellow Black
HN
Gray Black
LR
Blue Red
MV
Brown Green
AV
Pink Black
VN
Green Black
BN
BR
White Black
CL
Orange Blue
G/R
LN
HR
Brown Black
RN
Red Black
Red Yellow
Brown White
RG
Gray Yellow
HG
Pink Yellow
MB
SG
Gray Red
Blue Black
MN
Gray Blue
Yellow Red
HL
White Red
Red Green
SN
AN
Light blue - Black
RV
Light blue - Green
COMPOSITION OF THE COLOURS

The coloration of two-colour wires is indicated by the composition of the symbols listed.
Example: G-V = Yellow-Green with longitudinal colouring.
G/V = Yellow-Green with transversal colouring.
00-10
PC35R-8 PC45R-8
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model
PC35R-8
PC45R-8
From serial no.
F20001-
F20001-
Engine assembly (dry)

. Engine
. Power train
. Pump
155
6
22.5
175
7
23
Radiator - exchanger
18
18
Revolving frame
1800
2300
Cabin
208
208
Canopy
73
73
Seat support
30
30
Seat
20
20
Platform
40
40
Engine hood
18
18
Fuel tank (without fuel)
Hydraulic tank (without hydraulic oil)
40
40
Control valve
33
33
Rear counterweight
322
450
Lateral counterweight
. L.H.
. R.H.
32
32
46.2
32
Swing motor
30.5
30.5
Swivel joint
20
20
1200
1700
4.5
6.6
Track frame assembly

Track roller
Idler assy.
52
55
Final drive
40
61
Sprocket
13
Swing circle
35
55
Shoe
. Steel shoe
. Rubber shoe
180
160
294
240
Swing bracket
70
93
Boom
132
180
Arm
. Standard
. Long arm
69
88
95
119
Bucket (standard)
68
105
Blade
154
235
Boom cylinder
30
40.5
Arm cylinder
28
37
Bucket cylinder
19.5
31
Boom swing cylinder
28
39.5
Blade cylinder
20
24
PC35R-8 PC45R-8
00-11
TABLE OF OIL AND COOLANT QUANTITIES

RESERVOIR
KIND OF
FLUID
CAPACITY ( < )
AMBIENT TEMPERATURE
20
10
10
20
Specified
30C
Refill
PC35R PC45R PC35R PC45R
FKI 907 10W

Crankcase sump
FKI 907 20W-20
OIL
. API CD
FKI 907 SAE 30
6.9
6.9
FKI 907 SAE 40

Hydraulic circuit
Final drive
(each)
Fuel
tank
OIL
FKI 907 10W
63
63
33
33
OIL
FKI 907 10W
1.3
1.3
51.5
51.5
WATER+
ANTI-FREEZE
6.8
7.5
WATER
6.8
7.5
6.8
7.5
. API CD
. API CD
FUEL
Engine coolant
system
]
ASTM D975 N. 2
PERMANENT
LIQUID
FKI 931
] ASTM D975 N. 1
ASTM: America Society of Testing and Materials

SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
NOTE:
(1) When fuel sulphur content is less than 0.5%,
change oil in the oil pan ebery periodic maintenance hours described in operation and maintenance
manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Fuel sulphur content
Oil change interval in engine oil

pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
00-12
(2) When starting the engine is weathers temperature

below 0C, be sure to use engine oil SAE 10W,
SAE 20W-20, even if weather temperature goes
up to 10C day time.
(3) Use classification CD as engine oil, if use classification CC, reduce the engine oil change interval to
half.
(4) Use original products, which have characteristics
specifically formulated and approved for the engine, the hydraulic circuit of equipment and for reductions.
PC35R-8 PC45R-8
GROUP
10
STRUCTURE AND FUNCTION
P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2
Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5
Final drive . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6
Track frame. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7
Recoil spring . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Carrier roller . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Track roller. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Steel shoe . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Hydraulic circuit diagram PC35R . .. . . . .. . . . . .. . . . .. . 11
Hydraulic circuit diagram PC45R . .. . . . .. . . . . .. . . . .. . 13
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
PC35R-8 PC45R-8
Control valve. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 22
CLSS . . . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 30
Swivel joint. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 52
Swing motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 54
Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 61
Accumulator . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 65
PPC Valves (Work equipment) . .. . . . . .. . . . . .. . . . .. . . . 66
PPC Valve (Hammer) .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 70
Solenoid valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 73
Electrical diagram (1/3) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 75
10-1
P.T.O.
3
4
RKP02590
1.
2.
3.
4.
5.
Joint
Spring pin
Dumper
Flywheel cover
Body
10-2
PC35R-8 PC45R-8
POWER TRAIN
1.
2.
3.
4.
5.
6.
7.
8.
9.
Swing motor
Swing circle
Idler
Control valve
Swivel joint
Travel motor
Engine
Hydraulic pump
Servocontrol - travel speed
increment solenoid valve
RKP02580
DESCRIPTION
The mechanical power from engine (7) is converted to hydraulic power by hydraulic pump (8). This hydraulic power
is divided by control valve (4) according to the purpose. it is converted back to mechanical power by hydraulic motor
(1), travel motor (6), or the hydraulic cylinders of each piece of work equipment, and is used to operate the travel,
swing and work equipment.
PC35R-8 PC45R-8
10-3
SWING CIRCLE
B
B
1
5
Sezione
SectionAA-AA
3
Section
SezioneBB-BB
RKP02640
1.
2.
3.
4.
5.
Outer race
Ball bearing
Inner race
Seal
Seal
10-4
PC35R-8 PC45R-8
SWING MACHINERY
M The figure represent PC35R
6
7
5
8
4
9
3
10
2
1
11
12
13
14
RKP02540
1.
2.
3.
4.
5.
6.
Seal ring
Oil drainage plug
No. 2 sun gear (Z=19)
Crown (Z=62)
Spacer
No. 1 sun gear
(PC35R Z=28 - PC45R Z=25)
7. No. 1 reduction gear
8. No. 1 planetary gear
9. No. 2 reduction gear
PC35R-8 PC45R-8
10.
11.
12.
13.
14.
No. 2 planetary gear

Hub
Bearing
Bearing
Pinion
(PC35R Z=11 - PC45R Z=10)
SPECIFICATIONS
Reduction ratio:
PC35R: 1 13.69
PC45R: 1 14.83
10-5
FINAL DRIVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Crankcase
No. 2 reduction gear
No. 1 reduction gear
Cover
No. 1 sun gear
(PC35R Z=15 - PC45R Z=10)
Oil drainage plug
No. 2 sun gear (Z=16)
Housing (Z=80)
10-6
RKP02560
SPECIFICATIONS
Reduction ratio:
PC35R: 1 37
PC45R: 1 53
PC35R-8 PC45R-8
TRACK FRAME
RKP02610
1.
2.
3.
4.
Idler
Track frame
Carrier roller
Travel motor
PC35R-8 PC45R-8
5.
6.
7.
8.
Sprocket
Track roller
Recoil spring
Track shoe
10-7
RECOIL SPRING
7
4
1.
2.
3.
4.
5.
6.
7.
SezioneA
A- A
A
Section
RKP02630
Idler
Support
Rod
Cylinder
Recoil spring
Nut
Nipple
10-8
PC35R-8 PC45R-8
CARRIER ROLLER
5
4
RKP02470
4. Seal ring
5. Cover
6. Roller
1. Bearing
2. Gasket
3. Shaft
TRACK ROLLER
1
RKP02520
1. Roller
2. Shaft
3. Bushing
PC35R-8 PC45R-8
4. Shoulder
5. Seal ring
6. Gasket
10-9
STEEL SHOE
8
7
2
3
RKP02460
1.
2.
3.
4.
5.
6.
7.
8.
Bushing
Pin
Master pin
Master bushing
Shoe
Screw
Nut
Link
10-10
SPECIFICATIONS
Width:
400 mm
Pitch:
135 mm
PC35R-8 PC45R-8
HYDRAULIC CIRCUIT DIAGRAM

PC35R
Swing motor
R.H. travel motor
PS
T1-T2
E
Arm
cylinder
Bucket
cylinder
Boom
cylinder
Hammer
Boom swing
cylinder
DB
R/G
P1
D
P
P1
P2
P2
L.H. travel motor
B
A
F
P1
R/G
Swivel joint
P2
A10
T1-T2
B10
PB10
B8
A8 PB8
B7
A7
B6
A6
B5
A5
PB5
B4
PB4
A4
B3
A3
B2
A2
B1
A1 PB1
LS
PS
250 kg/cm2
30 kg/cm2
Close
Reverse
Blade cylinder
Set 1.50.2
Open
Oil cooler
Arm
Forwards
L.H. travel motor
Reverse
Forwards
R.H. travel motor
Raise
Boom
Lower
Open
Curled
Bucket
Boom
swing Left
Right
Raise
Open
Left
Swing
Blade
Right
L.H. side
R.H. side
Additional equipment
280 kg/cm2
TS
Exhaust filter 10 m
Suction filter 104 m
PP
PA10
PA8
P2
A9
PA9
S2
PA5
PA4
PA1
PC
P1
S1
P2
R.H. PPC valve
L.H. PPC valve

Arm
Swing
Right
Open
Left
P1
Open
Close
E/G
Boom
Bucket
Raise
Curled
Lower
S1
Min
P
P4
P3
P2
P1
Max
Cylinder block
P
100 Mesh
P4
P3
P2
P1
100 Mesh
P1L
PLS
Valve LS
Valve PC
P
T
Y1
Y2
PC35R-8 PC45R-8
V=0,20
RKP03141
10-11
10-12
PC35R-8 PC45R-8
PC45R
Swing motor
R.H. travel motor
PS
T1-T2
E
Arm
cylinder
Bucket
cylinder
Boom
cylinder
Hammer
Boom swing
cylinder
DB
P2
R/G
P1
D
C
P
P1
P2
L.H. travel motor
B
A
F
P1
R/G
P2
Swivel joint
T1-T2
A9 PB9
B9
B8
A8 PB8
B7
A7
B6
A6
B5
PB5
A5
B4
PB4
A4
B3
A3
B2
A2
B1
A1 PB1
LS
PS
250 kg/cm2
30 kg/cm2
Close
Reverse
Blade cylinder
Set 1.50.2
Open
Oil cooler
Arm
Forwards
L.H. travel motor
Reverse
Forwards
R.H. travel motor
Raise
Boom
Lower
Open
Curled
Bucket
Right
Boom
swing Left
Right
Blade
Left
Swing
Raise
Right
L.H. side
R.H. side
Additional equipment
280 kg/cm2
TS
Exhaust filter 10 m
Suction filter 104 m
PP
PA10
PA8
P2
S2
PA5
PA4
PA1
PC
P1
S1
P2
R.H. PPC valve
L.H. PPC valve

Arm
Swing
Right
Open
Left
P1
Open
Close
E/G
Boom
Bucket
Raise
Curled
Lower
S1
Min
P
P4
P3
P2
P1
Max
Cylinder block
P
100 Mesh
P4
P3
P2
P1
100 Mesh
P1L
PLS
Valve LS
Valve PC
P
T
EV...
EV...
PC35R-8 PC45R-8
V=0,20
RKP03131
10-13
HYDRAULIC PUMP
a
Vista X
View
X
X
c
2
C
b
d
C
e
B
B
f
Vista
ViewZZ
a.
b.
c.
d.
e.
f.
PS Port
P2 Port
PDA Port
P1 Port
PLS Port
P1L Port
10-14
From hydraulic tank

To control valve (P2 Port)
Air bleeding
To control valve (P Port)
From control valve (LS Port)
From control valve (PP Port)
RKP02080
1. Main pump
2. Gear pump
PC35R-8 PC45R-8
1. MAIN PUMP
8
9
10
Section
A
Sezione A
A - A
Sezione C
C
-C
Section
C
Section BB -BB
Sezione
RKP02090
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Shaft
Oil seal
Case
Swash plate
Shoe
Piston
Cylinder lock
Valve plate
Spring
Servo piston
PC35R-8 PC45R-8
10-15
FUNCTION
. The rotation and torque transmitted to the pump
shaft is converted to hydraulic energy and pressurized oil is discharged according to the load.
. It is possible to change the discharge amount by
changing the swash plate angle.
a
RKP02110
STRUCTURE
. Cylinder block (7) is supported to shaft (1) by a
spline, and shaft (1) is supported by the front and
rear bearings.
. Piston (6) carries out motion relative to the axial direction inside each cylinder chamber of cylinder
block (7).
. The end of piston (6) has a concave ball shape and

shoe (5) is caulked to it to form one unit.
Piston (6) and shoe (5) form a spherical bearing.
. The cylinder block (7) carries out rotation relative to

valve plate (8) while sealing the pressurized oil, and
this surface ensures that the hydraulic balance is
maintained correctly.
The oil inside each cylinder chamber of cylinder
block (7) is sucked in and discharged through valve
plate (8).
. Rocker cam (4) has plane A, and shoe (5) is always

pressed against this surface as it slides in a circle.
Rocker cam (4) forms a static bearing sending high
pressure oil at cylindrical surface B with to the
case, and carries out a sliding movement.
10-16
PC35R-8 PC45R-8
OPERATION
1. Pump operation
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 cylindrical surface B, so the angle a between the center line X of the rocker cam (4)
and the inclination of the cylinder block (7) in
the axial direction changes.
This angle a is called the swash plate angle.
2 - When the center line X of the rocker cam (4)
maintains the swash plate angle a in relation
to the axial direction of the cylinder block (7),
the flat surface A acts as a cam for the shoe
(5).
By this, the piston (6) slides on the inside of
the cylinder block (7), creates a difference between capacities E and F, then suction and
discharge of oil for the amount of this difference (F E) will be carried out.
In other words, oil is discharge as the capacity
of the chamber F decreases when the cylinder
block (7) rotates.
In the mean time, the capacity of the chamber
E increases, and the oil is sucked at this process.
(The figure shows the state of the pump when
suction of the chamber F and discharge of the
chamber E have completed).
3 - When the center line X of the rocker cam (4)
becomes in line with the axial direction of the
cylinder block (7) (swash plate angle = 0),
the difference between capacities of E and F
inside the cylinder block (7) becomes 0. so
the pump does not carry out any suction or discharge action of oil.
(In actual fact, the swash plate angle never becomes 0).
4 - In other words, discharge amount of the pump
is directly proportional to the swash plate angle a.
PC35R-8 PC45R-8
6 7
X
B
E
RKP02120
E
RKP02130
10-17
2. Control of discharge amount

. As the swash plate angle a becomes larger, difference between the capacities E and F becomes larger, so the discharge amount Q increases.
The swash plate angle a is changed by the servo piston.
. The servo piston moves in a linear reciprocating

motion ( ) under the signal pressure of TCC
and LS valve.
This linear motion is transmitted to the rocker
cam (4), which is supported by the cylindrical
surface of the case (3), and the rocker cam
slides in the semi-circular reciprocating direction ( ).
. The upper and lower pressure receiving area of
the servo piston are different from each other,
and to the pressure chamber of the smaller piston side (upper), discharge pressure (self pressure) PP of the main pump is always introduced.
To the pressure chamber of the larger piston
side (lower), output pressure PEN of the LS valve
is introduced.
Movement of the servo piston is controlled by
the relationship between pressures PP and
PEN and the proportion of the pressure receiving
areas of the smaller and larger pistons.
10-18
RKP02140
PC35R-8 PC45R-8
PC35R-8 PC45R-8
10-19
2. TCC VALVE, LS VALVE, SERVO PISTON
2
5
6
b
7
8
9
c
RKP02150
SERVO PISTON
1. Spring
2. Spacer
3. Piston
4. Servo piston
a - P1 Port
b - GH Port
c - PLS Port
- Main pump pressure inlet port

- Gear pump pressure inlet port
- From control valve (LS port)
LS VALVE
5. Piston
6. Piston
7. Sleeve
8. Spring
9. Union
10-20
PC35R-8 PC45R-8
LS VALVE
Function
. The LS valve controls the pump discharge amount
according to the amount of movement of the control
lever (that is the oil flow demanded by the actuator).
. The LS valve detects the oil flow demanded by the
actuator from the differential pressure DPLS between main pump discharge pressure PP and control valve outlet pressure PLS, and controls main
pump discharge amount Q.
(PP is called the pump pressure, PLS is called the
LS pressure, and DPLS is called the LS differential
pressure).
. In other words, the pressure loss (=LS differential
pressure DPLS) generated by the flow of oil from the
pump passing through opening area of the control
valve spool is detected.
By controlling pump discharge amount Q so that
this pressure loss remains constant, a pump discharge amount is supplied in accordance with the
demands of the control valve by controlling pump
discharge amount Q.
. The engine speed is detected by pressures GH and

GL on both sides of the fixed throttle (metering
throttle) in the gear pump discharge passage.
This acts on LS valve No. 3 and No. 4 pressure receiving chambers a2 and b2, and changes the LS
setting. When the engine is running at low idling,
the gear pump discharge amount is reduced, so
pressures GH and GL on both sides of the metering
throttle become almost the same (the metering differential pressure between GH and GL becomes
lower).
On the other hand, when the engine is run at full
throttle, the gear pump discharge amount is increased and the metering differential pressure becomes higher.
. When the metering pressure is high (engine
speed is high) the LS setting is made higher.
. When the metering pressure is low (engine
speed is low) the LS setting is made lower.
. Pump pressure PP, LS pressure PLS, and the pressures on both sides of gear pump metering throttle
(GH and GL) are brought to the LS valve.
The relationship between pump discharge amount
Q and LS differential pressure DPLS changes as
shown in the diagram on the right.
PC35R-8 PC45R-8
Pump discharge amount Q ( / min)
. However, when carrying out fine control or in other

cases where the range does not exceed the maximum flow of the pump (the flow demanded by the
control valve is always supplied), the discharge
amount is the same as when the engine is at high
idling, even if the engine is at low idling.
To overcome this, a function has been added to
automatically lower the LS differential pressure
and reduce the discharge amount when the engine
is running at low idling.
Engine at
full throttle
Engine at
low idling
8
(8.4)
16
(16)
LS differential pressure PLS
p (bar)
(kg /cm2)
RKP02341
10-21
CONTROL VALVE
b
c
r
N
q
M
p
N
M
j
i
K
J
m
H
l
k
o
K
n
C
B
mm
cc
s
t
u
v
w
x
y
z
aa
bb
nn
ll
hh
gg
ff
ee
dd
A
B
C
View
Vista A
A
10-22
RKP02350
PC35R-8 PC45R-8
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
s.
t.
u.
v.
w.
x.
y.
z.
aa.
bb.
cc.
dd.
ee.
ff.
gg.
hh.
ll.
mm.
nn.
S2 Port
PA10 Port
PA8 Port
PA5 Port
PA4 Port
PA1 Port
LS Port
C Port
B1 Port
B2 Port
B3 Port
B4 Port
B5 Port
B6 Port
B7 Port
P2 Port
B10 Port
TS Port
A10 Port
A8 Port
A7 Port
A6 Port
A5 Port
A4 Port
A3 Port
A2 Port
A1 Port
P1 Port
T Port
PC Port
PB1 Port
PB4 Port
PB5 Port
PB8 Port
PB10 Port
PP Port
B8 Port
PC35R-8 PC45R-8
From swing motor (T Port)

From work equipment PPC valve (P2 Port)
From L.H. PPC valve (P3 Port)
From R.H. PPC valve (P4 Port)
From hydraulic pump (PLS Port)
To exchange oil cooler
To arm cylinder (Head side)
To swivel joint (B Port)
To swivel joint (D Port)
To boom cylinder (Bottom side)
To bucket cylinder (Bottom side)
To boom swing cylinder (Bottom side)
To swivel joint (G Port)
From hydraulic pump (P2 Port)
To attachment (R.H. side)
To hydraulic tank
To attachment (L.H. side)
To swing motor (A Port)
To swivel joint (F Port)
To boom swing cylinder (Head side)
To bucket cylinder (Head side)
To boom cylinder (Head side)
To swivel joint (C Port)
To swivel joint (A Port)
To arm cylinder (Bottom side)
From hydraulic pump (P1 Port)
To hydraulic tank
To ST1 solenoid valve (P Port)
From work equipment PPC valve (P1 Port)
To hydraulic pump (P1L Port)
To swing motor (B Port)
10-23
6
5
4
9
Section
SezioneAA- A
A
1.
2.
3.
4.
5.
6.
7.
8.
9.
Safety valve
Suction valve
Suction valve
Suction valve
Suction valve
Suction valve
Suction valve
Suction valve
Suction valve
10-24
RKP02360
(Close arm)
(Raise boom)
(Close bucket)
(L.H. Boom swing)
(Lower blade)
(Work equipment R.H. side)
(R.H. boom swing)
(Lower boom)
PC35R-8 PC45R-8
1
2
3
4
5
6
7
8
9
10
Section BB-BB
Sezione
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
RKP02370
Spool (Attachment)
Spool (Swing)
Spool (Blade)
Spool (Boom swing)
Spool (Bucket)
Spool (Boom)
Spool (R.H. travel)
Spool (L.H. travel)
Spool (Arm)
Main relief valve
PC35R-8 PC45R-8
10-25
21
4
5
20
19
18
17
16
10
15
14
11
13
Section
SezioneCC-C
C
1. Plug
2. Plug
FLOW COMPENSATION VALVE
3. Attachment
4. Blade - boom swing
6. Bucket
7. Boom
8. R.H. Travel
9. L.H. Travel
10. Arm
11. LS bypass plug
10-26
12
RKP02390
12. Cooler check valve

13. Unload valve
14. Reducing valve
REDUCING PRESSURE COMPENSATION VALVE
15. Arm
16. L.H. Travel
17. R.H. Travel
18. Boom
19. Bucket
21. Attachment
PC35R-8 PC45R-8
1
3
4
8
5
Section D
D -DD
Sezione
SectionEE- EE
Sezione
Section G
G -GG
Sezione
15
11
10
14
9
13
Sezione
SectionF F- F
F
12
16
RKP02380
1. Cooler check valve

2. Safety valve
3. Main relief valve
5 - LS bypass plug
5. Unload valve
6. Main relief valve (servocontrol)
7. Main relief valve spool
8. Reducing valve
11. Check valve

12. Reducing pressure compensation valve
13 - Flow compensation valve
TRAVEL VALVE
14. Spool
16 - Flow compensation valve
ARM VALVE
9. Spool
10. Suction valve
PC35R-8 PC45R-8
10-27
2
1
3
10
8
4
13
7
12
6
Section
H
Sezione H
H
-H
11
Section JJ-JJ
Sezione
22
15
14
21
16
23
20
17
19
Section
K
K
Sezione K
-K
18
Sezione L
L - L
Section
L
RKP02400
BOOM VALVE
1. Safety valve
2. Check valve
3. Check valve
4. Suction valve
6. Flow compensation valve
7. Spool
8. Suction valve
BUCKET VALVE
9. Suction valve
10. Check valve
13. Spool
10-28
BOOM SWING VALVE

14. Suction valve
15. Check valve
16. Suction valve
20. Spool
BLADE VALVE
21. Suction valve
22. Check valve
23. Spool
PC35R-8 PC45R-8
2
1
Section NN-NN
Sezione
Section
M -MM
Sezione M
3
7
Section
O
Sezione O
O
-O
5
RKP02530
SWING VALVE
1. Spool
2. Plug
ATTACHMENT VALVE
3. Suction valve
4. Check valve
7. Spool
PC35R-8 PC45R-8
10-29
CLSS
1. OUTLINE
FEATURES
The term "CLSS" stand for the "Closed Center Load Sensing System" which has the following features.
a) Fine-controllability not affected by loads.
b) Controllability enabling digging even in the fine control mode.
c) Complex operability ensured by flow distribution determined according to the opening areas of spools during
complex operation.
d) Energy-saving feature using variable pump control.
STRUCTURE
. The CLSS consists of a variable displacement single piston pump, control valve and actuators.
. The pump body consists of the main pump, TCC valve and LS valve.
Actuator
PLS
Control valve
TCC valve
LS valve
PP
Servo
piston
RKP00661
10-30
PC35R-8 PC45R-8
2. BASIC PRINCIPLE
1) Control of pump swash plate angle
. The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure DPLS,
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 DPLS=Pump discharge pressure PP pressure PLS).
. If the LS differential pressure DPLS 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.
H For the details of this action, refer to the descriptions of HYDRAULIC PUMP.
Actuator
Control valve
PLS
Pump passage
Main pump
LS passage
Min.
Max.
Servo piston
PLS
LS valve
Differential pressure
large (high)
TCC valve
Pump pressure high
PC35R-8 PC45R-8
Differential
pressure
small (low)
Pump
pressure low
RKP00651
10-31
2) Pressure compensation control

. Valves (pressure compensation valves) are installed at the inlet port side of the spools of the control valves to
balance the loads.
When the actuators are complex-operated, the pressure differences DP at the upstream (inlet) and downstream
(outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas S1 and S2 of each valve.
Load
Load
Actuator
Actuator
S2
S1
Pressure
compensation
valve
Pressure
compensation
valve
PIMP
RKP02311
10-32
PC35R-8 PC45R-8
3. Functions and operation of each valve
NAMES OF HYDRAULIC CIRCUITS AND VALVES

PP
TS
B9
Hammer
11
PA10
A9
PB9
Left
B8
Swing
motor
A8
PA8
PB8
Right
P2
13
8
B7
A7
Blade
S2
B6
A6
B5
11
8 13
PA5
A5
Bucket
PB5
B4
Boom
swing
11
1. Unload valve: LS+34.3 bar

(35 kg/cm2)
2. Safety valve:
279 bar (285 kg/cm2)
3. Main relief valve:
245 bar (250 kg/cm2)
4. Self-pressure reducing valve
5. Pilot relief valve:
29 bar (30 kg/cm2)
6. Self-pressure sequence valve:
30 bar (29 kg/cm2)
7. Pressure compensation valve
8. Suction valve
9. Lock valve
10. Cooler check valve:
0.4 bar (4 kg/cm2)
11. Check valve
12. Check valve
(Boom raise):
20 bar (20 kg/cm2)
13. Check valve
(Bucket raise):
25 bar (25 kg/cm2)
9
A4
PA4
Boom
PB4
11 8
Revers
B3
P2
R.H. travel
A3
P1
Forwards
Revers
B2
P1
L.H. travel
A2
P2
Forwards
B1
A1
PA1
PB1
Arm
7
PC
5
P1
LS
2
2
S1
C
RKP06681
PC35R-8 PC45R-8
10-33
1. Unload valve
FUNCTION
1) When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is
released to the tank circuit. When this happens, pump discharge pressure PP is set to 34.3 bar (35 kg/cm2) by
spring (2) inside the valve.
(LS pressure PLS=0 bar (0 kg/cm2)
S1
PP
PLS
S2
2
RKP02270
OPERATION
When control valve is at HOLD
. At the left end of spool (1), pump pressure PP is acting on area S1 and LS pressure PLS is acting on
area S3.
. When the control valve is at HOLD, LS pressure
PLS is not generated, so only pump discharge PP
has any effect, and PP is set by the load of spring
(2).
. In this way, pump discharge PP is set to 34.3 bar

(35 kg/cm2).
PP =Pump discharge
PLS=Load Sensing circuit
T =Tank circuit
A =To control valve spool
. As the pump discharge pressure PP rises and

reaches the load of spring (2), spool (1) is moved
to the right in the direction of the arrow. Pump circuit pressure PP then passes through the notch in
spool (1) and is connected to tank circuit T.
10-34
PC35R-8 PC45R-8
2) During fine control of the control valve, when the demand flow for the actuator is within the amount discharged by
the minimum swash plate angle of the pump, pump discharge pressure PP is set to PLS+34.3 bar (35 kg/cm2).
When the difference pressure between pump discharge pressure PP and LS pressure PLS reaches the load of
spring (2) (34.3 bar (35 kg/cm2)), The unload valve opens, so DPLS becomes 34.3 bar (35 kg/cm2).
1
PLS
PP
2
RKP02280
OPERATION
During fine control of control valve

. When fine control is carried out on the control
valve, LS pressure PLS is generated and acts on
area S3 at the right and of spool (1).
When this happens, the area of the opening of the
control valve spool is small, so there is a big difference between LS pressure PLS and pump discharge pressure PP.
. In other words, pump discharge pressure PP is set

to a pressure equal to the force of spring (2) (34.3
bar (35 kg/cm2))+LS pressure PLS, and LS differential pressure DPLS becomes 34.3 bar (35 kg/
cm2).
. When the difference in pressure between pump

discharge pressure PP and LS pressure PLS
reaches the load of spring (2), spool (1) moves to
the right, and pump circuit PP and tank circuit T
are connected.
PC35R-8 PC45R-8
10-35
3) When the control valve is being operated and the demand flow for the actuator becomes greater than the pump
discharge from the minimum swash plate angle, the flow of the oil out, to tank circuit T is shut off, and all of pump
discharge amount Q flows to the actuator circuit.
1
PLS
PP
2
RKP02220
OPERATION
Control valve operated
. When the control valve is operated to a larger
stroke, LS pressure PLS is generated and acts on
area S3 at the right end of spool (1).
When this happens, the area of the opening of the
control valve spool is large, so the difference between LS pressure PLS and pump discharge pressure PP is small.
. As a result, pump circuit PP and tank circuit T are

shut off, and all the pump discharge amount Q
flows to the actuator circuit.
. For this reason, the difference in pressure between

pump discharge pressure PP and LS pressure PLS
does not reach the load of spring (2) (34.3 bar (35
kg/cm2)), so spool (1) is pushed to the left by spring
(2).
10-36
PC35R-8 PC45R-8
2. Introduction of LS pressure
FUNCTION
. The LS pressure is the actuator load pressure at the outlet port end of the control valve.
. It actually reduces pump pressure PP at reducing valve (3) of the pressure compensation valve to the same pressure as actuation circuit pressure A, and sends it to the LS circuit PLS.
. With the boom swing and blade valves, pump pressure PP is reduced to the same pressure as actuator circuit
pressure A by one reducing valve (3) used for both systems, and the pressure is sent to the LS circuit PLS.
b
T
PLS1
2
PP
4
PLS
RKP02100
OPERATION
1) Boom, arm, bucket, swing valve
. When spool (1) is operated, pump pressure PP
flows from control valve (2) and notch a in spool
(1) through bridge passage b to actuator circuit A.
. Actuator circuit pressure PA (=A) acts on the left

end of reducing valve (3); the reduced pump pressure PP acts on the other end.
. At the same time, reducing valve (3) also moves to

the right, so pump pressure PP has its pressure reduced by the pressure loss at notch C. It is introduced to LS circuit PLS, and then goes to spring
chamber PLS1.
. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the
pressure of spring chamber PLS1 are the same.
Pump pressure PP reduced at notch C becomes actuator circuit pressure A and is taken to LS circuit
PLS.
. When this happens, LS circuit PLS is connected to

tank circuit T from LS by-pass plug (4) (see the section on the LS by-pass plug).
PC35R-8 PC45R-8
10-37
5
T
a
6
e
f
2
d
7
PP
PLS
4
RKP02170
2) Boom swing, blade valve

. When boom swing spool (1) is operated, pump
pressure PP is reduced by reducing valve (3) (in
the same way as in item 1), and is sent to the LS
circuit PLS.
. When the blade spool (5) is operated, pump pressure PP flows from flow control valve (2), passage
e, and notch a in blade spool (5) through bridge
passage b to actuator circuit A.
. As a result, pump pressure PP is reduced at notch

d, becomes the actuator circuit pressure, and is
sent to LS circuit PLS.
H The boom swing and blade valves are different
from the boom, arm, bucket, and travel valves: they
share one pressure compensation valve and bring
in the LS pressure.
. At the same time, the actuator circuit pressure

passes through notch f in hammer spool (6), then
goes through passage d, and acts on the left end
of piston (7). Piston (7) and reducing valve (3) then
move to the right.
10-38
PC35R-8 PC45R-8
3. LS by-pass plug
FUNCTION
. It releases the residual pressure of LS pressure PLS.
. It makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this discharge
throttled flow, it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effective LS differential pressure.
PLS
b
T
PP
T
RKP02260
OPERATION
. The pressurized oil for LS circuit PLS passes from
clearance filter a (formed by the clearance between
LS by-pass plug (1) and the valve body) through orifice b and flows to the tank circuit T.
PP =Pump circuit
PLS=LS circuit
T =Tank circuit
A =To valves
B =To pump LS valve
PC35R-8 PC45R-8
10-39
4. Pressure compensation valve

FUNCTION
. During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to
increase, compensation is received. (When this happens, the other actuator being used for compound operation
(right side) is at a higher load than the actuator on this side (left side)).
Side receiving
compensation
Side receiving
compensation
W
T
a
PPA
2
PA
PLS1
1
a
PPA
PA
PP
PLS
RKP02181
OPERATION
. If the load pressure of the other actuator (right side)
becomes higher during compound operations, the
oil flow in actuator circuit A on this side (left side)
tries to increase.
. If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing
valve (1) and flow control valve (2) are pushed to
the left (
).
. Flow control valve (2) throttles the area of opening
between pump circuit PP and spool upstream
PPA, and pressure loss is generated between PP
and PPA.
10-40
. Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure
between PLS and PA acting on both ends of reducing valve (1) and the pressure loss between PP
and PPA on both sides of flow control valve (2) are
the same.
. In this way, the pressure difference between upstream pressure PPA and downstream pressure
PA of both spools used during compound operations is the same, so the pump flow is divided in
proportion to the area of opening of notch a of each
spool.
PC35R-8 PC45R-8
5. Area ratio of pressure compensation valve

FUNCTION
. The pressure compensation valve determines the compensation characteristics by carrying out fine adjustment
of the area ratio (S2/S1) between area S2 of reducing valve (1) and area S1 of flow control valve (2) to match the
characteristics of each actuator.
S1=Area of flow control valve (2) Area of piston (3).
S2=Area of reducing valve (1) Area piston (3).
S1
S2
PPA
1
2
PP
PA
3
PLS
RKP02300
Area ratio (S1:S2) and compensation characteristics
. When ration is 1.00 :

[Pump pressure PP spool notch upstream pressure PPA]6[LS circuit pressure PLS actuator circuit pressure
PA (=A)] and oil flow is divided in proportion to area of opening of spool.
. When ratio is more than 1.00 : PP PPA>PLS PA (=A) and oil flow to side receiving compensation is divided in
a proportion less than area of opening of spool.
. When ratio is less than 1.00 : PP PPA<PLS PA (=A) and oil flow to side receiving compensation is divided in a
proportion more than area of opening of spool.
Ratio of area S1 and S2
Valve
Ratio
Valve
Ratio
Arm
0.98
Boom swing
0.98
Travel
1.00
Blade
0.98
Boom
0.95
Hammer
1.00
Bucket
1.00
PC35R-8 PC45R-8
10-41
6. Throttling LS introduction of pressure compensation valve

FUNCTION
. In the other actuator is relieved during compound operations, LS introduction throttle b of reducing valve (1) divides the flow and sends more oil to the side receiving compensation.
Side receiving
compensation
Side receiving
compensation
A
T
a
PPA
2
PA
PLS1
1
PPA
PA
PP
4
PLS
RKP02201
OPERATION
. If the other actuator (right side) is relieved during
compound operations, each circuit pressure (PPA,
PA) of the other actuator becomes the same as
the pump circuit pressure (PP=relief pressure).
. In this case, spring chamber PLS2 of the other actuator (right side) becomes the same as pump circuit pressure PP because of the balance of reducing valve (1).
10-42
. PLS2 passes through LS introduction throttle b of

reducing valve (1) and becomes PLS. PLS is connected to the tank circuit from LS by-pass plug
(4), so pressure loss is generated at LS introduction
throttle b (the condition becomes PLS<PLS2).
. As a result, even if the other actuator is relieved, a
pressure differential is created between PP and
PLS, so more oil flows to actuator circuit A on this
side (left side).
PC35R-8 PC45R-8
7. L.H., R.H. travel junction circuit

FUNCTION
. To compensate for any difference in the oil flow in the left and right travel circuits when travelling in a straight
line, the junction circuit opens when the left and right travel spools are operated.
In this way, the flow of oil to the left and right travel motors is almost the same when travelling in a straight line, so
there is no travel deviation.
. When steering the machine, the difference in the load pressure returns the reducing valve of the travel on the
inside of the turn and the opening of the notch in the travel junction valve spool becomes smaller, so the machine
can be steered.
LEFT TRAVEL
RIGHT TRAVEL
PAL
AL
AR
1L
PAR
1R
PLS
2
3
PP
b
c
RKP02071
OPERATION
When travelling in a straight lint
. When left and right travel spools (1) are operated,
the pump discharge flows from pump circuit PP
and circuits PAL and PAR to actuator circuits AL
and AR.
. When travelling in a straight line, to make actuator
circuits PAL and PAR equal, left and right reducing
valves (2) are pushed to the right by the same
amount, and notch a and the travel junction circuit
are opened.
. In this way, the left and right travel actuator circuits
are interconnected by the travel junction circuits, so
if any difference occurs in the flow of oil to the left
and right travel motors, the compensation is carried
out to prevent any deviation in travel.
PC35R-8 PC45R-8
10-43
LEFT TRAVEL
RIGHT TRAVEL
PAL
AL
AR
T
1L
PAR
T
1R
PLS
2
3
PP
b
c
RKP02211
Steering when travelling

. When travelling in a straight line, if left travel spool
(1L) is returned to the neutral position and the
steering is operated, a difference (AR>AL) is generated in the load pressure of left and right travel
actuator circuits PAL and PAR, and LS pressure
PLS becomes the same pressure as AR (the side
with the high load pressure).
. As a result, flow control valve (3) on the left travel
side is pushed on the left by LS circuit PLS.
Because of this, the opening of the left notch a is
made smaller, so it becomes possible to operate
the steering when travelling.
. Damper b is provided in the circuit to dampen any
excessive characteristics in the opening or closing
of the travel junction circuit if the spool is operated
suddenly.
10-44
PC35R-8 PC45R-8
8. Boom holding valve
3
2
TS
RKP02160
1.
2.
3.
4.
5.
6.
Poppet
Poppet spring
Pilot spool
Pilot spring
Check valve
Check valve spring
PC35R-8 PC45R-8
10-45
1. At boom RAISE
When the control lever is operated to boom
RAISE, the main pressure from the control valve
pushes up poppet (1) in the direction of the arrow.
Because of this, the main pressure oil from the
control valve passes through the valve and flows
to the bottom end of the boom cylinder.
RKP02290
2. Boom lever at HOLD

When the boom is raised and the control lever is
returned to HOLD, the circuit for the holding pressure at the bottom end of the boom cylinder is
closed by poppet (1). At the same time, the circuit
for the oil flowing into poppet (1) through orifices a
and b of poppet (1) is closed by pilot spool (3).
As a result, the boom id held in position.
b
3
1
a
RKP02320
10-46
PC35R-8 PC45R-8
3. Boom LOWER
When the control lever is operated to boom LOWER, the pilot pressure pushes pilot spool and the pressurized
oil in chamber c inside the poppet is drained.
When the pressure at cylinder bottom rises because of the pressurized oil from the bottom end of the boom
cylinder, the pressure of the pressurized oil in chamber c is lowered because of orifices a and b.
If the pressure in chamber c drops below the pressure at port (8), poppet (1) opens, the pressurized oil flows
from port (7) to port (8), and then flows to the control valve.
If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder, the safety valve is
actuated through check valve (5).
c
b
1
a
TS
7
8
5
RKP02250
PC35R-8 PC45R-8
10-47
9. Self-pressure reducing valve

FUNCTION
. This reduces pump discharge and supplies the pilot basic pressure (29 bar (30 kg/cm2)) to the PPC valve.
. When the actuator circuit pressure is low, the self-pressure sequence valve closes and raises the pump discharge pressure PP to ensure the pilot basic pressure
PP
LS
TS
PC
3
RKP02190
OPERATION
Control valve at HOLD
. Unload spool (1) moves and the pump discharge
pressure PP is set to 29 bar (30 kg/cm2). (For details, see the section 1. Unload valve)
. Pump discharge pressure PP is reduced to 29 bar
(30 kg/cm2) by self-pressure reducing spool (2)
and self-pressure reducing pilot relief valve 83).
The basic pressure is supplied from port PC to the
PPC valve.
10-48
PC35R-8 PC45R-8
When control valve is operated
b
3
1
a
RKP02320
OPERATION
. Unload spool (1) moves to the left (
) in the direction of the arrow, and pump discharge pressure PP
becomes higher than the pressure of actuator circuit (5) by the amount of the LS differential pressure. (For details, see the section 1. Unload
valve)
. If pump discharge pressure PP goes above 29 bar
(30 kg/cm2),pump discharge pressure PP is reduced to 29 bar (30 kg/cm2) by self-pressure reducing spool (2) and self-pressure reducing pilot relief
valve (3). The basic pressure is supplied from port
PC to the PPC valve.
. When this happens, self pressure reducing sequence valve (4) remains open.
PC35R-8 PC45R-8
10-49
5
4
PP
LS
TS
PC
3
RKP02240
. When pump discharge pressure PP is less than 29

bar (30 kg/cm2), self-pressure reducing sequence
valve (4) moves to the right (
) in the direction
of the arrow, so the size of the opening between
PP and actuator circuit (5) becomes smaller.
As a result, a difference in pressure is generated by
PP and actuator circuit (5), PP is raised to above 29
bar (30 kg/cm2) and pump discharge pressure PP is
reduced to 29 bar (30 kg/cm2) by self-pressure reducing spool (2) and self-pressure reducing relief valve
(3). The basic pressure is supplied from port PC to
the PPC valve.
10-50
PC35R-8 PC45R-8
10. Swing valve

FUNCTION
The swing section is the open center valve of the fixed
pump.
P2
To swing
motor
A8
B8
To swing
motor
PB8
PA8
From swing
PPC valve
From swing
PPC valve
Load check
valve
Load check
valve
RKP02331
OPERATION
. When the pressure at port PB8 is increased from
the PPC valve, the spool moves to the right (
)
and oil flows to port B8.
. When the pressure at port PA8 is increased from
the PPC valve, the spool moves to the left (
)
and oil flows to port A8.
PC35R-8 PC45R-8
10-51
SWIVEL JOINT
a
3
f
c
g
2
A
n
Section A
A-AA
Sezione
1
RKP02510
r
1.
2.
3.
4.
a.
b.
c.
d.
e.
f.
g.
h.
Cover
Body
Shaft
Gasket
H Port
A Port
B Port
F Port
G Port
D Port
E Port
C Port
10-52
From travel motors (T1 - T2 Ports)

To R.H. travel motor (P2 Port)
To L.H. travel motor (P1 Port)
To blade cylinder (Head side)
To blade cylinder (Bottom side)
To travel motors (PS Port)
i. a Port
l. f Port
m. b Port
n. g Port
o. c Port
p. e Port
q. d Port
r. h Port
From control valve (A2 Port)

From control valve (B2 Port)
From ST1 solenoid valve (B Port)
To hydraulic tank
PC35R-8 PC45R-8
PC35R-8 PC45R-8
10-53
SWING MOTOR
1
A
3
4
RKP02550
10-54
PC35R-8 PC45R-8
d
13
10
12
11
Section AA-AA
Sezione
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Plate
Cylinder
Piston
Disc
Shoe
Center spring
Safety valve spring
Plug
Check valve spring
Check valve
Plug
Recoil cylinder
Safety valve
PC35R-8 PC45R-8
a.
b.
c.
d.
RKP01510
DB Port
A Port
M Port
B Port
To hydraulic tank
To control valve (S2 Port)
SPECIFICATIONS
Max. pressure:
Displacement:
PC35R:
PC45R:
PC35R:
PC45R:
165 5 bar
200 5 bar
20.7 rev.
26.1 rev.
10-55
TRAVEL MOTOR
PC35R
B
A
8
10
9
11
16
12
15
14
10-56
Section
SezioneAA-AA
13
RKP02600
PC35R-8 PC45R-8
e
17
19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
18
Sezione B
Section
B -BB
Valve plate
Piston
Shoe
Swash plate
Piston spring
Piston
Cylinder
Center spring
Plug
Orifice
Check valve
Check valve spring
Orifice
Orifice
Counterbalance valve spring
Spool return spring
Plug
Spool return spring (travel increment)
Counterbalance valve spring (travel increment)
RKP02620
R.H. motor
a.
T1 Port -
Not used
b.
P1 Port -
From swivel joint (C Port)
c.
P2 Port -
From swivel joint (D Port)
d.
T2 Port -
From swivel joint (H Port)
e.
PS Port -
From swivel joint (E Port)
L.H. motor
a.
T1 Port -
b.
P1 Port -
From swivel joint (B Port)
c.
P2 Port -
From swivel joint (A Port)
d.
T2 Port -
Not used
e.
PS Port -
SPECIFICATIONS
Nominal pressure: 245 bar (250 kg/cm2)
Displacement:
. High speed:
16.00 cm3/rev.
. Low speed:
26.30 cm3/rev.
Swing speed:
. High speed:
. Low speed:
PC35R-8 PC45R-8
2250 rpm
1369 rpm
10-57
PC45R
1
A
B
A
10
d
13
12
14
19
15
18
17
Sezione A
A - A
Section
A
10-58
16
RKP06690
PC35R-8 PC45R-8
e
20
22
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Valve plate
Brake piston
Piston
Brake disc
Shoe
Swash plate
Piston spring
Piston
Cylinder
Center spring
Brake spring
Plug
Orifice
Check valve
Check valve spring
Orifice
Orifice
Counterbalance valve spring
Spool return spring
Plug
Spool return spring (travel increment)
Counterbalance valve spring (travel increment)
PC35R-8 PC45R-8
21
Sezione B
Section
B -BB
RKP02621
R.H. motor
a.
T1 Port -
Not used
b.
P1 Port -
From swivel joint (C Port)
c.
P2 Port -
From swivel joint (D Port)
d.
T2 Port -
e.
PS Port -
L.H. motor
a.
T1 Port -
b.
P1 Port -
From swivel joint (B Port)
c.
P2 Port -
From swivel joint (A Port)
d.
T2 Port -
Not used
e.
PS Port -
SPECIFICATIONS
Nominal pressure: 245 bar (250 kg/cm2)
Displacement:
. High speed:
16.00 cm3/rev.
. Low speed:
26.30 cm3/rev.
Swing speed:
. High speed:
. Low speed:
2910 rpm
1770 rpm
10-59
10-60
PC35R-8 PC45R-8
CYLINDERS
BOOM
2
3
10
11
RKP02420
1.
2.
3.
4.
Bushing (Head side)

Bushing (Bottom side)
Rod
Head
5.
6.
7.
8.
9. Ring
10. Piston
11. Nut
Gasket
Cylinder
Ring
Piston gasket
ARM
1
3 4
10
RKP02410
1.
2.
3.
4.
Bushing (Head side)

Rod
Head
PC35R-8 PC45R-8
5.
6.
7.
8.
Gasket
Cylinder
Piston gasket
Ring
9. Piston
10. Nut
10-61
BUCKET
1
3
10
RKP02430
1.
2.
3.
4.
5.
6.
7.
8.
Bushing (Head side)

Rod
Head
Gasket
Cylinder
Piston gasket
Ring
9. Piston
10. Nut
BOOM SWING
2
3
10
RKP02440
1.
2.
3.
4.
Bushing (Head side)

Rod
Head
10-62
5.
6.
7.
8.
Gasket
Cylinder
Piston gasket
Ring
9. Piston
10. Nut
PC35R-8 PC45R-8
BLADE
2
3 4
9 10
RKP02450
1.
2.
3.
4.
5.
6.
7.
8.
Bushing (Head side)

Rod
Head
9. Piston
10. Nut
Gasket
Cylinder
Piston gasket
Ring
PC35R
Cylinder
Boom
Arm
Bucket
Boom swing
Blade
45
45
40
45
45
80
80
75
65
85
90
Piston stroke
540
540
595
490
635
120
Max. cylinder length
1450
1450
1510
1270
1575
590
Min. cylinder length
910
910
915
780
940
470
Piston nut width

across flat
46
46
46
41
46
46
Arm
Bucket
Boom swing
Blade
Canopy
Cabin
Piston rod diameter
45
Cylinder inside diameter
PC45R
Cylinder
Boom
Canopy
Cabin
Piston rod diameter
50
50
50
50
50
50
Cylinder inside diameter
90
90
85
75
95
100
Piston stroke
665
665
695
580
635
140
Max. cylinder length
1700
1700
1725.5
1480
1610
632
Min. cylinder length
1035
1035
1030.5
900
975
492
55
55
55
50
55
55
Piston nut width

across flat
PC35R-8 PC45R-8
10-63
10-64
PC35R-8 PC45R-8
ACCUMULATOR
RKP00700
TECHNICAL DATA
FUNCTION
Servocontrol feed unit

Nominal volume:
0.35 ,
Pre-loading:
12 bar
Working pressure:
35 45 bar
. An elastic rubber bag (1) containing nitrogen is

fitted inside the accumulator to maintain oil pressure in the circuit to which the accumulator is connected.
OPERATION
. When the engine is running the chamber A of the
rubber bag (1) (containing nitrogen) is compressed
by oil under pressure coming from line B.
. If the oil under in line B falls below the maximum
calibration pressure (even after intensive use), the
rubber bag (1) will expand due to pressure from
the nitrogen it.
PC35R-8 PC45R-8
10-65
PPC VALVES
WORK EQUIPMENT
E
D
B
L.H. PPC VALVE

a. P2 Port
- To control valve (PB1 port)
b. P4 Port
c. P1 Port
- To control valve (PA1 port)
d. P3 Port
e. T Port
- To ST1 solenoid valve (T port)
f. P Port
- From ST1 solenoid valve (A port)
10-66
RKP01070
R.H. PPC VALVE

a. P2 Port
b. P4 Port
c. P1 Port
d. P3 Port
e. T Port
- To control valve (TS port)
f. P Port
- From ST1 solenoid valve (A port)
PC35R-8 PC45R-8
6
5
3
9
10
2
1
Section
A
Sezione A
A - A
Section
Sezione B
B- B
B
Section
SezioneDD- D
D
Sezione C
C - C
Section
C
Section
E
Sezione E
- EE
RKP01080
1.
2.
3.
4.
5.
6.
Spool
Adjusting spring (internal)
Return spring (external)
Plunger
Disc
Nut
PC35R-8 PC45R-8
7.
8.
9.
10.
Joint
Cover
Pin
Body
10-67
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
f
T
P
1
P3 (P1)
P4 (P2)
Control valve
FIG. 1
2. During fine control (NEUTRAL

fine control)
When piston (4) starts to be pushed by disc (5), retainer (7) is pushed; spool (1) is also pushed by metering 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 pilot pressure oil from the control pump
passes through fine control hole f and goes from
port P1 to port A.
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.
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 the force of metering spring (2) is balanced with
the pressure at port P1. The relationship in the position of spool (1) and body (8) (fine control hole f is
at a point midway between drain hole D and pump
pressure chamber PP) does not change until retainer (7) contacts spool (1).
Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in
proportion 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 port P1) and the force of the control
valve spool return spring are balanced. (Fig. 2)
10-68
RKP01091
5
4
3
2
T
P
PP
P1
10
P2
Control valve
FIG. 2
RKP01101
PC35R-8 PC45R-8
3. During fine control (when the lever is returned)

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at port P1.
When this happens, fine control hole f is connected
to drain chamber D and the pressure oil at port P1
is released.
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a
pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters chamber
B to fill the chamber with oil. (Fig. 3)
5
4
3
2
T
P
f
PP
P1
P2
Control valve
FIG. 3
4. At full stroke
When disc (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut
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.
The oil returning from chamber B passes from port
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4)
RKP01111
5
4
9
D
f
T
P
f
PP
P1
P2
Control valve
FIG. 4
PC35R-8 PC45R-8
RKP01121
10-69
PPC VALVE
HAMMER
b
A
5
4
c
2
8
1
9
Sezione
SectionAA-AA
RKP00960
a.
b.
c.
d.
T Port
P Port
P1 Port
P2 Port
10-70
To ST1 solenoid valve (T port)

From ST1 solenoid valve (A port)
To control valve (PB10 port)
To control valve (PA10 port)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spring
Adjusting spring (internal)
Return spring (external)
Plunger
Lever
Cover
Stopper
Body
Filter (100 mesh)
PC35R-8 PC45R-8
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)
T
P
f
1
P1
P2
Control valve
RKP00971
FIG. 1
2. During fine control (NEUTRAL

fine control)
When piston (4) starts to be pushed by lever (5), retainer (7) is pushed; spool (1) is also pushed by metering 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 pilot pressure oil from the control pump
passes through fine control hole f and goes from
port P1 to port A.
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.
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 the force of metering spring (2) is balanced with
the pressure at port P1. The relationship in the position of spool (1) and body (8) (fine control hole f is
at a point midway between drain hole D and pump
pressure chamber PP) does not change until retainer (7) contacts spool (1).
Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in
proportion 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 port P1) and the force of the control
valve spool return spring are balanced. (Fig. 2)
PC35R-8 PC45R-8
5
4
7
T
P1
P2
PP
Control valve
FIG. 2
B
RKP00981
10-71
3. During fine control (when the lever is returned)

When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at port P1.
When this happens, fine control hole f is connected
to drain chamber D and the pressure oil at port P1
is released.
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a
pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters chamber
B to fill the chamber with oil. (Fig. 3)
5
4
D
T
2
P
f'
P2
P1
Control valve
PP
FIG. 3
4. At full stroke
When lever (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut
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.
The oil returning from chamber B passes from port
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4)
RKP00991
5
4
D
T
8
P
f'
P1
P2
Control valve
FIG. 4
10-72
PP
B
RKP01001
PC35R-8 PC45R-8
SOLENOID VALVE
ST1 SERVOCONTROL (TRAVEL INCREMENT)
RKP00810
a.
b.
c.
d.
e.
S Port
A Port
B Port
P Port
T Port
To accumulator
To PPC valve (P port)
To swivel joint (e port)
From control valve (PC port)
To hydraulic tank
PC35R-8 PC45R-8
1. Y2 Servocontrol
2. Y1 Travel increment
10-73
10-74
PC35R-8 PC45R-8
ELECTRICAL DIAGRAM (1/3)

1
10
11
12
13
14
15
16
17
18
19
20
A2.5
2.1
A2.5
A2.5
X10
B - N1
G1
2.12
M - V1
R1
R1
ACC
BR
R2
FU2
FU9
3A
7.5A
OFF ACC
ST
HA1
S1
R - N2.5
X11
2
X11
A - V1
N1
G1
3
4
KT1
X5
A - R1
M4
M - N1
R - N2.5
R1
13
X10
C - N1
H3
H4
H5
H6
H7
H8
1
2
3
4
5
H9
6
7
9
10
11
12
13
14
P1
P2
t
P3
q
15
16
C - N1
C/N1
B - G1
N1
M4
S1
X11
C/N1
H2
R6
60A
R - V1
X11
X7
X5
X5
X5
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
H1
A - R1
R - V1
X5
B - N1
1
4
X-K1
M1
2.15
X-K1
X5
R1.5
X-K1
FUG
R1
B - G1
12
M1
R6
R6
K1
X5
X10
X10
X-K1
10
11
X2
X6
S1
B
R1
2.1
3.9
X4
X3 X3
X28
M1
G2
30
X8
50
30
V1
Y1
S3
S4
p
31
R1
X8
N35
R2
U
31
X4
00000 00 h
M4
12 Vcc
X4
S2
L - R1
S1
S - N1
R6
R35
G1
R - N2.5
X1
X4
C - N1
C/N1
X1 X4 X4
A - R1
X1
P4
N1
N1
31
2.1
RKP06570
COMPONENTS:
G1
G2
H1
H2
H3
H4
H5
H6
H7
BATTERY
ALTERNATOR
AIR FILTER CLOGGING WARNING LIGHT
(NOT USED)
PRESSURE OIL WARNING LIGHT
BATTERY WARNING LIGHT
PRE-HEATER WARNING LIGHT
BRAKE PRESSURE WARNING LIGHT
(NOT USED)
OIL LEVEL WARNING LIGHT
(NOT USED)
POSITION LIGHT WARNING LIGHT
(NOT USED)
PC35R-8 PC45R-8
H8
DIRECTION INDICATOR WARNING LIGHT

(NOT USED)
H9 DASHBOARD LIGHT
HA1 BUZZER
K1
STARTER RELAY
KT1 PRE-HEATER TIMER
M1 STARTER MOTOR
P1
TERMOMETER
P2
LEVEL INDICATOR
P3
COUNTER-HOUR
P4
INSTRUMENT PANEL
R1 PRE-HEATER
R2 WATER TEMPERATURE WATER
S1
S2
S3
S4
V1
Y2
DASHBOARD
PUSH-BUTTON
LOW PRESSURE ENGINE OIL PRESSURE SWITCH
HIGH WATER TEMPERATURE TERMOSTAT
TRAVEL INCREMENT SOLENOID VALVE DIODE
TRAVEL INCREMENT SOLENOID VALVE DIODE
CONNECTORS:
X1
X2
X3
X4
X5
X6
X7
X8
X10
X11
X28
X-K1
4-WAYS CONNECTOR
2-WAYS CONNECTOR
2-WAYS CONNECTOR
9-WAYS CONNECTOR MARK
16-WAYS CONNECTOR FKI INSTRUMENT
5-WAYS CONNECTOR
2-WAYS CONNECTOR DEUTSCH
4-WAYS CONNECTOR
4-WAYS CONNECTOR
1-WAY CONNECTOR
4-WAYS CONNECTOR
FUSES:
FU2 FUSE 3A
(BUZZER - STARTER RELAY - INSTRUMENT)
FU9 FUSE 7.5 A
(ALTERNATOR - TRAVEL INCREMENT
SOLENOID VALVE)
FUG GENERAL FUSE 60A
10-75
10-76
PC35R-8 PC45R-8
1
1.19
1.19
10
11
12
13
14
15
16
17
18
19
20
A2.5
A2.5
A2.5
A2.5
3.1
3.1
R1.5
G1
1.3
FU1
7.5 A
XS5
FU6
30 A
10 A
XS5
XS6 XS6
2 1
XS6
R - N1
S5 A
XS5
X5
E
6
S6
XS6
XS5
XS6
FU11
FU7
7.5A
7.5A
FU8
FU4
7.5A
10A
G - N1.5
FU10
G/R1
B - R1
R - N1.5
V4
R1.5
S8
1.12
G1
N1
V - N1
R - V1
S7
H - G1.5
C - L1
A - N1.5
G - N1.5
X5
1
B - R1.5
X13
X7
X7
M - B1
R1.5
Y3
S10
H10
V3
X17
HA2
X20
X21
2
N1
N1
N1
N1
N1
N1
N1.5
N1
XP
V5
2
1.19
X20
X13
X23 X23 X23
X21
M2
X13
Y4
X14
X19
S9
X14
X19
S - G1
X19
V - N1
X16
X17
N1.5
KT2
N1.5
R - V1
L - R1.5
L - N1.5
L - N1
R - N1.5
V - N1
X16 X16 X16

4
S - G1
M - B1
C - L1
H -R1
H -L1
X4
H - N1
X4
3.0
B - R1.5
X4
X6
X25 X25
X5
K2
X6
L - R1.5
L - N1.5
K3
31
31
3.1
RKP06580
COMPONENTS:
H10
HA2
K2
K3
M2
S5
S6
S7
S8
S9
S10
PC35R-8 PC45R-8
WORKING BEAM
HORN
STOP MOTOR RELAY
HORN RELAY
FUEL PUMP
OPTIONAL SWITCH (TBG)
LIGHT SWITCH
PUSH-BUTTON
HAMMER SOLENOID VALVE
PUSH-BUTTON
N.A. PUSH-BUTTON
PRESSOSTAT
V3
V4
V5
XP
Y3
Y4
STOP MOTOR DIODE

WARNING LIGHT DIODE
HAMMER SOLENOID VALVE DIODE
ELECTRICAL SOCKET
HAMMER SOLENOID VALVE
STOP MOTOR
CONNECTORS:
X4
X5
X6
X7
X13
X14
X16
X17
X19
X20
X21
X23

16-WAYS CONNECTOR FKI INSTRUMENT
3-WAYS CONNECTOR
2-WAYS CONNECTOR
4-WAYS CONNECTOR
2-WAYS CONNECTOR
X25 2-WAYS CONNECTOR

XS5 CONNECTOR FOR SWITCH MERIT
XS6 CONNECTOR FOR SWITCH MERIT
FUSES:
FU1
FU4
FU6
FU7
FU8
FU10
FU11
FUSE 30A (STOP MOTOR)

FUSE 10A (CAR RADIO)
FUSE 10A (FUEL PUMP - HORN - TBG)
FUSE 7.5 A (HAMMER SOLENOID VALVE OPTIONAL)
FUSE 7.5A (ELECTRICAL SOCKET - 30 + CABIN)
FUSE 7.5A (STOP MOTOR COIL)
FUSE 7.5A (WORKING BEAM)
10-77
10-78
PC35R-8 PC45R-8
2.19
2.19
10
11
12
13
14
15
16
17
18
19
20
A2.5
A2.5
XS11
0
XS11
XS14
FU5
0
7.5A
B - R1.5
XS11
X5
2 1
XS14
FU3
15A
S14
XS14
S12
XS14
B1.5
B1.5
N1
S - N1.5
S11
XS11
S - N1.5
R - G1
R - G1
2.19
R - G1
X5
B - N1
B - N1
1.12
S13
A/R1
B - N1
C1.5
X19
L1.5
A/R1
X19
X24
Y2
X26
M3
X26
X27
R3
V7
2.19
X27
3
N1
N1.5
X26
1
N1
X24
2
31
RKP06590
COMPONENTS:
M3
R3
S11
S12
S13
S14
V7
Y2
PC35R-8 PC45R-8
VENTILATOR
FUEL LEVEL INDICATOR
ROTATING BEAM SWITCH
ARM REST MICRO
SERVOCONTROL MICRO
SWITCH A VENTILATOR
SERVOCONTROL SOLENOID VALVE DIODE
SERVOCONTROL SOLENOID VALVE
CONNECTORS:
X5
X19
X24
X26
X27
XS11
XS14

4-WAYS CONNECTOR
3-WAYS CONNECTOR
CONNECTOR FOR SWITCH MERIT
CONNECTOR FOR SWITCH MERIT
FUSES:
FU3 FUSE 15A (VENTILATOR)

FU4 FUSE 10 (CAR RADIO)
10-79
10-80
PC35R-8 PC45R-8
GROUP
20
TESTING AND ADJUSTMENTS
Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2

Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24
Checking the engine speed . .. . . . . .. . . . .. . . . . .. . . . .. . 25
Adjustment of valve clearance . . . . .. . . . .. . . . . .. . . . .. . 26
Measurement of the compression pressure .. . . . .. . 27
Control and adjustment of the tension of
the fan belt . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 28
Control and adjustment of the injection timing . . .. . 29
Control and adjustment of the accelerator stroke . . 31
Adjustment of the stroke of the blade
command lever . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32
Adjusting the flexible cables .. . . . . .. . . . .. . . . . .. . . . .. . 33
Control and adjustment of the stroke of the
travel lever . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 34
Adjustment of the stroke of
the boom swing command pedal . .. . . . .. . . . . .. . . . .. . 35
Adjustment of the PPC valve clearances . . . .. . . . .. . 36
Adjustment of the rubber pad and safety
microswitch for servo-control engagement . .. . . . .. . 37
Control and adjustment of the track-shoe tension. . 38

Control and regulation of the pressures in the
hydraulic circuits .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
Control and regulation of the LS differential
pressure and adjustment of the ls valve . . .. . . . .. . . . 42
Regulation of the PC valve .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
Control and regulation of the servo-control
power supply . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Elimination of residual pressures - pressurisation
of the tank . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Bleeding air from the hydraulic circuits . . . .. . . . .. . . . 47
Control of hydraulic drifts - analysis of the causes
of a drift . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 49
Checking for any leakages inside the working
equipment cylinders. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Checking for any leakages inside the
swing motor .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Methods for testing for leakages inside the
swivel joint . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 57
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 undergoing 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).
PC35R-8 PC45R-8
20-1
NORMAL OR STANDARD TECHNICAL DATA

. FOR THE ENGINE
Machine model
PC35R-8
Engine
3D84E-3FA
Check item
Test condition
Unit
Standard
value
Permissible
value
Engine speed
High idling
Low idling
Rated speed
rpm
rpm
rpm
2700
1150
2500
2675 2725
1125 1175
Exhaust gas
colour
At sudden acceleration
At high idling speed
Bosch
Index
Max. 3.5
Max. 1.5
Max. 6.0
Max. 3.0
Valve clearance
Intake valve (20C)

Exhaust valve (20C)
mm
mm
0.20
0.20
0.20
0.20
Compression
pressure
(SAE30 oil)
Oil temperature 40-60C

(Engine speed)
kg/cm2
rpm
33w1
(250)
26w1
(250)
Blow-by
pressure
(SAE30 oil)
Water temperature in operating range

At high idling speed
mm H2O
Engine oil
pressure
(Water temperature in operating range)

At high idling speed (SAE30)
At low idling speed (SAE30)
At low idling speed (SAE10W)
kg/cm2
kg/cm2
kg/cm2
3.0 3.5
1.5
1.5
Min. 2.0
Min. 1.0
Min. 1.0
Engine oil
temperature
Whole speed range
Max. 120
Max. 120
Fuel injection
timing
Before top dead center (BTDC)
Degree
14w1
14w1
Fan-belt tension
Deflection when pressed with finger

force of approx. 6 Kg
mm
10 15
20-2
PC35R-8 PC45R-8
. FOR THE ENGINE

PC45R-8
4D84E-3FA
Standard
value
Permissible
value
2700
1150
2500
2675 2725
1125 1175
Max. 3.5
Max. 1.5
Max. 6.0
Max. 3.0
0.20
0.20
0.20
0.20
33w1
(250)
26w1
(250)
3.0 3.5
1.5
1.5
Min. 2.0
Min. 1.5
Min. 1.5
Max. 120
Max. 120
14w1
14w1
10 15
PC35R-8 PC45R-8
20-3
. FOR THE MACHINE

Machine model
Classification
Check item
PC35R-8
Test condition
Unit
Engine
.
.
.
.
Engine speed with
one pump at max.
pressure
Boom circuit: max. pressure

Hydraulic oil temperature: 45 55C
Cooling circuit: in correct range
Engine oil pressure: in correct range
H Measure when pressure has stabilised
Boom and swing circuit:

max. pressure
. Hydraulic oil temperature: 45 55C
. Cooling circuit: in correct range
. Engine oil pressure: in correct range
H Measure when pressure has stabilised
Boom control
Permissible
value
2600
2550 2650
2580
2530 2630
rpm
Arm control
Standard
value
<
<
30
30
20
20
Control valve
Bucket control
Swing control
RKP01970
Work equipment control
mm
Blade control
Boom swing control

Travel control
Boom control
lever
Raise
Lower
60
50 70
Open
Curled
60
50 70
Open
Curled
60
50 70
Neutral
Swing RH
Swing LH
60
50 70
Blade control lever
Neutral
Raise
Lower
75
60 90
Boom swing
pedal
Neutral
Swing RH
Swing LH
20
15 25
Travel control
lever
Neutral
Forward
Backward
90
80 100
130
110 150
Work equipment,
swing
Max. 15
Travel
10
Max. 25
Arm control
lever
Stroke of levers and pedals
Bucket control lever

Swing control lever
Accelerator lever
Play of control lever
20-4
RKP01980
.
.
.
.
.
Neutral
At centre of
lever knob
Reading at
end of travel Neutral
Equipment
on the ground
Neutral
Engine
stopped
Tip of pedal
Min.
Max.
mm
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
2550
2500 2600
2540
2490 2590
<
<
30
30
20
20
60
50 70
60
50 70
60
50 70
60
50 70
80
65 95
20
15 25
90
80 100
130
110 150
Max. 15
10
Max. 25
PC35R-8 PC45R-8
20-5
. FOR THE MACHINE

Machine model
Operating force for control of levers and pedals
Classification
Standard
value
Permissible
value
2.1
1.7 2.5
2.1
1.7 2.5
1.9
1.5 2.3
1.9
1.5 2.3
5.0
4.0 6.0
Blade lever
3.0
2.2 3.8
Travel control lever
1.8
1.4 2.3
Check item
Test condition
Arm lever
Bucket lever
Swing lever
.
.
.
.
.
Engine speed: high idling

Instrument coupling at centre
of control lever knob
Instrument coupling on outside
edge (for pedal control)
Reading at end of travel
kg
Boom swing pedal
Travel accelerator
lever
.
.
.
.
Min.
Max.
2.0
1.5 2.5
Max.
Min.
1.8
1.3 2.3
35
30 40

All levers at HOLD
Relieve pump outlet pressure
kg/cm2
Boom
250
10
250
10
Arm
250
10
250
10
Bucket
250
10
250
10
Servocontrol
Boom swing
.
.
.
.

Check one circuit at a time
Relieve pump outlet pressure
30
30
250
10
250
10
250
10
250
10
Travel
250
10
250
10
Swing
168
168
kg/cm2
Blade
.
LS differential
pressure
.
.
Hydraulic oil temperature:

All levers at HOLD
45 55C
Engine speed: max.
Differential pressure=
Travel rotating freely,
pump delivery
pressure LS pressure travel lever at half-way
position
20-6
Unit
Boom lever
Unload pressure
Circuit pressure
PC35R-8
35
30 40
16
16w1
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
2.1
1.7 2.5
2.1
1.7 2.5
1.9
1.5 2.3
1.9
1.5 2.3
5.0
4.0 6.0
3.0
2.2 3.8
1.8
1.4 2.3
2.0
1.5 2.5
1.8
1.3 2.3
35
30 40
250
10
250
10
250
10
250
10
250
10
250
10
30
30
250
10
250
10
250
10
250
10
250
10
250
10
200
200
35
30 40
16
16w1
PC35R-8 PC45R-8
20-7
. FOR THE MACHINE

Machine model
Classification
Check item
PC35R-8
Test condition
Unit
Standard
value
Permissible
value
mm
(Degree)
430
(40)
540
(50)
2.3w0.3
Max. 2.9
3.8w0.5
Max. 4.5
sec
33w3
Max. 38
mm
160
(15)
270
(25)
Work equipment at max. reach
Braking angle
.
.
.
.
RKP01840
No load in bucket
Make centering marks on the outer swing
circle rings. Rotate the revolving frame
360 and lock in position. Measure the difference between the marks after stopping.

90
Time taken to start swing
RKP01840
.
.
.
.
No load in bucket
Hydraulic oil temperature: 45 55C 180
Measure the time taken for swings
to start from positions at 90 and
180.
Swing
Time taken for to swing
RKP01840
.
.
.
.
.
No load in bucket
Make one turn to settle machine
Measure the time taken to make 5 full
swings.
15
Hydraulic drift of swing
.
.
.
.
.
20-8
sec
135
RKP01990
Load in bucket: PC35R: 176 kg

(Degree)
PC45R: 270 kg
Engine switched off
Park the machine on a 15 slope and position the boom at 135 with respect to
the ground surface.
On the outer swing circle, mark the position between revolving frame and track frame. After 15 minutes measure the drift.
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
475
(40)
595
(50)
2.5w0.3
Max. 3.0
4.3w0.5
Max. 5.0
33.0w3
Max. 40
240
(20)
360
(30)
PC35R-8 PC45R-8
20-9
. FOR THE MACHINE
Standard
value
Permissible
value
,/min
30
25 35
High speed
Internal leakage from

swing motor
Unit
19
16 22
Low speed
Check item
25.5
(26.3)
21 30
(22 31)
High speed
Swing
Classification
PC35R-8
15.5
(16.0)
12 19
(12.5 19.5)
Low speed
Machine model
Max. 500
Max. 550
Max. 300
Max. 330
Test condition
.
.
.
.
.

Swing lock: engaged
Measure the leakage
Pressurize circuit.
Travel motor swing

speed (1)
(no-load)
Low speed
Measuring posture
sec
RKP01950

. Rest the bucket on the ground, raise one track-shoe, rotate one turn,
then measure time taken for next.
Measuring posture
45
Travel speed (2)

.
.
.
.
Travel
sec
RKP01850

On flat ground
Travel for at least 10 metres and
then check on the time needed to
cover 20 metres
45
RKP01850
.
.
mm
High speed
Travel deviation

45 55C
. Travel 20 metres on flat ground
and measure the deviation.
H The surface must be firm and horizontal.
20m
X
10m
RKP01830
20-10
Measure dimension X
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
35
30 40
22
18 26
25.5
(26.3)
21 30
(22 31)
15.5
(16.0)
12 19
(12.5 19.5)
Max. 500
Max. 550
Max. 300
Max. 330
PC35R-8 PC45R-8
20-11
. FOR THE MACHINE

Machine model
Classification
Check item
PC35R-8
Unit
Standard
value
Permissible
value
mm
Max. 300
Max. 350
,/min
Short arm
Max. 300
Max. 300
Long arm
Max. 300
Max. 350
Short arm
14
Max. 25
18
Max. 25
Short arm
20
Max. 25
Long arm
22
Max. 25
15
Max. 25
Max. 15
Max. 25
Max. 20
Max. 30
Test condition
Measuring posture
Travel
30
Hydraulic drift of
travel motors
RKP02000
.
.
.
.
Leakage of travel motor
Engine stopped.
Hydraulic oil temperature: 45 55C.
Machine parked on sloping ground.
Measure the drift after 5 minutes
. Engine speed: high idling

. Lock shoe
Measuring posture
Total work equipment

(Downward movement
of tips of bucket teeth)
RKP01860
Hydraulic drift of working equipment
Boom cylinder
(Retraction)
Arm cylinder
(Extension)
Bucket cylinder
(Retraction)
.
.
.
.
.
.
Bucket: rated load:

PC35R: 176 kg
PC45R: 270 kg
In this position, measure extension or retraction of each
cylinder, and any leakages occurring when a load is applied
to the tips of the bucket teeth.
Horizontal and level ground
Levers: neutral
Engine: switched off
Oil temperature: 45 55C.
Take measurements as soon
as the engine stops.
Measure the variations every 5
minutes and check the total
variation after 15 mins.
Long arm
mm
Short arm
15
Boom swing
.
.
.
.
20-12
135
RKP01990
Bucket: rated load:

PC35R: 176 kg
PC45R: 270 kg
Engine stopped.
Hydraulic oil temp.: 45 55C
In the same position as above, Long arm
stop the machine on a 15 slope and position the revolving
frame at 90. Measure the extension and retraction of the
cylinder after 15 minutes.
mm
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
Max. 330
Max. 400
Max. 300
Max. 300
Max. 300
Max. 350
15
Max. 25
20
Max. 25
22
Max. 25
22
Max. 25
15
Max. 25
Max. 20
Max. 30
Max. 25
Max. 40
PC35R-8 PC45R-8
20-13
. FOR THE MACHINE

Machine model
Internal cylinder
leakage
Hydraulic drift of working equipment
Classification
Check item
PC35R-8
Test condition
Blade
(measure the downward
movement of the edge
of the blade)
RKP01870
.
.
.
Engine stopped
Raise the blade to its maximum height and
measure the height of the edge from the
ground.
Measure the downward after 15 mins.
.
.
.

Check leakages: on the cylinder on the side opposite to the one under pressure.
Unit
Standard
value
Permissible
value
mm
Max. 30
Max. 45
Max. 2.0
Max. 5.0
Max. 2.0
Max. 5.0
Max. 2.0
Max. 5.0
Boom
Arm
Bucket
20-14
cm3/
min
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
Max. 35
Max. 50
Max. 2.0
Max. 5.0
Max. 2.0
Max. 5.0
Max. 2.0
Max. 5.0
PC35R-8 PC45R-8
20-15
. FOR THE MACHINE
Standard
value
Permissible
value
Raise
3.0
2.6 3.4
Lower
3.0
2.6 3.4
Closed
3.3
2.9 3.7
Inout
2.7
2.4 3.0
Dump
3.3
2.9 3.7
Curled
2.1
1.8 2.4
L.H.
7.5
6.5 8.5
R.H.
Check item
7.5
6.5 8.5
Raise
Classification
PC35R-8
1.2
1.0 1.4
Lower
Machine model
1.2
1.0 1.4
Test condition
.
Unit
Measuring posture
Boom
Bucket teeth on the ground
RKP01820
Cylinder fully extended
.
.

45 55C
Measuring posture
Arm
Cylinder fully retracted
RKP01880
.
.

45 55C
Measuring posture
Bucket
Speed
Work equipment

sec.
RKP01890
.
.

45 55C
Measuring posture
Boom swing
RKP01960
.
.

45 55C
Measuring posture
Blade
Blade on the ground
RKP01900
Blade raised to
max. height
20-16
.
.

45 55C
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
3.0
2.6 3.4
3.0
2.6 3.4
3.0
2.6 3.4
3.1
2.7 3.5
3.3
2.9 3.7
2.5
2.2 2.9
7.5
6.5 8.5
7.5
6.5 8.5
1.2
1.0 1.4
1.2
1.0 1.4
PC35R-8 PC45R-8
20-17
. FOR THE MACHINE

Machine model
Classification
Check item
PC35R-8
Test condition
Unit
Standard
value
Permissible
value
Max. 2.0
Max. 2.5
Max. 1.0
Max. 1.2
Measuring posture
Boom
RKP01910
.
.
.
Engine speed: low idling

With the work equipment fully extended,
lower the boom and measure the time taken to raise the machine from when the
bucket reaches the ground.
Measuring posture
Arm
RKP01920
Time lags
Work equipment
.
.
.

Bring the boom into a horizontal position.
Retract the arm cylinder completely and
then extend it. Measure the time elapsing
from when the arm stops at dead centre
until it starts to move again.
Measuring posture
Bucket
RKP01930
.
.
.
sec.

Bring the boom into a horizontal position.
Retract the bucket cylinder completely,
then extend it. Measure the time elapsing
from when the bucket stops at dead centre
until it starts to move again.
Measuring posture
Blade
RKP01940
.
.
.
20-18

Raise the blade to its max. height, then lower it. Measure the time that it takes to raise the machine after the blade touches the
ground.
PC35R-8 PC45R-8
. FOR THE MACHINE

PC45R-8
Standard
value
Permissible
value
Max. 2.0
Max. 2.5
Max. 1.0
Max. 1.2
PC35R-8 PC45R-8
20-19
. FOR THE MACHINE

Machine model
Classification
Unit
Standard
value
Theoretical flow
cm3
8.4
Motor speed
rpm
2500
Test pressure
kg/cm2
165
Nominal capacity
. Hydraulic oil temperature: 45 55 C
,/min
19.5
Check item
Test condition
Gear pump P2
Permissible
value
Delivery piston pump P1

Pump speed: 2500 rpm
Gear pump P2: without load
Q (/min)
.
.
.
.
PC35R-8
Pump characteristics
100
0 bar
92.5 /min
113.7 bar
91 /min
90
109.8 bar
79 /min
80
70
13.2 bar
66.3 /min
0 bar
82.5 /min
60
245 bar
32.4 /min
50
137.2 bar
58.4 /min
40
30
245 bar
24.3 /min
20
10
49
(50)
98
(100)
147
(150)
196
(200)
245 P(bar)
(250) (kg/cm2)
RKP06711
20-20
PC35R-8 PC45R-8
Machine model

Gear pump P2: at max. pressure
Q (/min)
Classifi- .
cation
.
.
.
PC35R-8
100
0 bar
92.5 /min
90
51 bar
92 /min
39.2 bar
81 /min
80
70
76.4 bar
67.5 /min
0 bar
82.5 /min
60
50
60,7 bar
62.5 /min
40
245 bar
16 /min
30
20
10
245 bar
6 /min
49
(50)
98
(100)
147
(150)
196
(200)
245 P(bar)
(250) (kg/cm2)
RKP06721
H When measuring deliveries with the pumps mounted on the machine, it is difficult to use the accelerator
to count the precise number of revs needed for this test.
Make delivery measurements with the engine running at a speed close to the test speed and then make
a proportional calculation.
Example:
MEASUREMENT
. Engine speed: 2450 rpm
. Delivery: 42 ,/min
PROPORTIONAL DELIVERY AT 2500 rpm
(42x2500)/2450= 42.8 ,/min
PC35R-8 PC45R-8
20-21
. FOR THE MACHINE

Machine model
Classification
Unit
Standard
value
Theoretical flow
cm3
10.5
Motor speed
rpm
2500
Test pressure
kg/cm2
200
Nominal capacity
. Hydraulic oil temperature: 45 55 C
,/min
24.5
Check item
Test condition
Gear pump P2
Permissible
value

Gear pump P2: without load
Q (/min)
.
.
.
.
PC45R-8
130
0 bar
118 /min
122.5 bar
116.6 /min
120
110
100
0 bar
107.8 /min
117.6 bar
104 /min
90
162.7 bar
81.2 /min
80
245 bar
49 /min
70
162.7 bar
72.3 /min
60
50
245 bar
40.2 /min
40
30
20
10
49
(50)
98
(100)
147
(150)
196
(200)
245 P(bar)
(250) (kg/cm2)
RKP06731
20-22
PC35R-8 PC45R-8
Machine model

Gear pump P2: at max. pressure
Q (/min)
Classifi- .
cation
.
.
.
PC45R-8
130
0 bar
118 /min
120
53.9 bar
117 /min
33.3 bar
107 /min
110
100
90
0 bar
107.8 /min
84.2 bar
82.5 /min
80
70
60
71.5 bar
72.9 /min
50
245 bar
23 /min
40
30
20
245 bar
12 /min
10
49
(50)
98
(100)
147
(150)
196
(200)
245 P(bar)
(250) (kg/cm2)
RKP06741
H When measuring deliveries with the pumps mounted on the machine, it is difficult to use the accelerator
to count the precise number of revs needed for this test.
Make delivery measurements with the engine running at a speed close to the test speed and then make
a proportional calculation.
Example:
MEASUREMENT
. Engine speed: 2450 rpm
. Delivery: 42 ,/min
PROPORTIONAL DELIVERY AT 2500 rpm
(42x2500)/2450= 42.8 ,/min
PC35R-8 PC45R-8
20-23
SPECIAL TOOLS
Measurement check points
Symbol
Valve clearance
Compression pressure
Engine speed
Hydraulic pressure
Track shoe tension
20-24
Code
Name
Q.ty
Remarks
Feeler gauge
Commercially
available
ATR800090
Compression gauge
ATR800130
Adapter
ATR800070
Multi-scale tachometer
20 - 4000 rpm
ATR800060
Stroboscopic tachometer
6 - 30000 rpm
ATR800170
Compression gauge
Scale 60 bar
ATR800140
Compression gauge
Scale 400 bar
ATR800010
Compression gauge
Scale 600 bar
ATR800200
Servocontrol kit
(Differential pressure)
823001135
Grease nipple
0-70 kg/cm2
Included in the
machine tool kit
PC35R-8 PC45R-8
CHECKING THE ENGINE SPEED
CHECKING THE ENGINE SPEED

When checking the engine rpm , always be very
careful not to touch parts that reach high temperatures and not to get entangled in rotating elements.
H Check the engine speed after the following conditions
have been reached:
. Temperature of engine cooling water: 68 80 C.
. Temperature of hydraulic oil: 45 55 C.
C1
1 - Mount and connect the tachometer C1.

H If the stroboscopic tachometer C2 is used, make a
distinct mark on the engine pulley to facilitate the
reading.
RKPA3880
2 - Start the engine and check:

. Low idling without load (accelerator lever in "minimum" position).
. High idling without load (accelerator lever in
"maximum" position).
H Low idling: 1150w25 rpm
H High idling: 2700w25 rpm
H If the minimum and maximum speeds do not fall
within permissible limits when the engine is without load, check the position locks of the accelerator lever, and the sheathing of the accelerator
well, before carrying out any tests under load.
(See ADJUSTMENT OF THE ACCELERATOR
LEVER).
. Engine rpm with the pumps under load.
H Boom at max. pressure: PC35R: 2600w50 rpm
PC45R: 2550w50 rpm
MAX
MIN
RKPA3890
H Boom and swing at max. pressure:

PC35R: 2580w50 rpm
PC45R: 2540w50 rpm
H If engine efficiency does not fall within permissible limits, have the engine checked by an
authorised workshop.
PC35R-8 PC45R-8
20-25
ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE

.
Adjust the clearance between valve and rockers to the

following values:
Unit: mm
With
engine
cold
Suction valves
Exhaust valves
0.20
0.20
2
1
1 - Remove the intake filter and the valve cover.
2 - Turn the drive shaft in the normal direction of rotation

until the line (1) marked as no. 1 on the flywheel is in
alignment with the reference notch (2) on the flywheel
housing.
H If the cylinder is in a compression stroke, the
valves do not move when the drive shaft is rotated
slightly.
If the valves do move, rotate the drive shaft by one
turn and realign the reference marks (1) and (2).
3 - Loosen the lock nut (3) and unscrew the adjustment
screw (4) by approximately 1 turn.
H Check that the valve cap (5) is lying flat on the
valve stem and that there is no lop-sided wear.
1 - If the valve caps (5) are damaged, replace
them with new ones.
2 - Make sure that the valve caps fit perfectly and
are lying flat on the valve stem.
RKP06440
4
3
4 - Insert the feeler gauge A1 between the rocker (6) and

the valve cap (5).
Rotate the adjusting screw (4) until it rubs against the
feeler gauge A1.
Secure this position with the nut (3).
Lock nut: 25.5w2.5 Nm
H After locking the nut (3), check the valve clearance again.
Assembly of the valve cover
RKP06450
5 - PC35R
After adjusting the No. 1 cylinder, rotate the drive
shaft 240 each time and adjust the valve clearance
of the other cylinders according to the ignition sequence.
H Ignition sequence: 1 - 3 - 2.
After adjusting the No. 1 cylinder, rotate the drive
shaft 180 each time and adjust the valve clearance
of the other cylinders according to the ignition sequence.
H Ignition sequence: 1 - 3 - 4 - 2.
NO
NO
YES
SI
A1
RKP06530
10
1 - Check the condition of the gasket (7) of the valve

cover (8), and the O-rings (9). Thoroughly clean
the contact surface on the cylinder heads.
2 - Replace the valve cover (8) and mount the O-rings
(9) and the lock nuts (10).
Lock nuts for cover: 25w3 Nm
20-26
RKP06560
PC35R-8 PC45R-8
MEASUREMENT OF THE COMPRESSION PRESSURE
MEASUREMENT OF THE COMPRESSION PRESSURE

While measuring the compression, take care not
to get entangled in the cooling fan, the alternator
belt, or in other rotating parts.
. Check all cylinders.
H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45 55 C.
. Battery: fully charged.
. Valve clearance: adjusted
(See ADJUSTMENT OF VALVE CLEARANCE).
. Air filter functioning properly.
.
1
RKPA3900
1 - Remove the clamp (1) and disconnect the high-pressure tube (2).
2 - Remove the nozzle holder (3) of the cylinder to be
checked.
3 - Disconnect the connector (4) of the engine-stopping

solenoid and close the fuel cock (5).
4 - Turn the engine over a few times, using the starting
motor.
4
RKPA3910
5 - Mount the adapter B2 and connect the test pressure

gauge B1.
H Check that the seal is mounted in the adapter,
and that it is undamaged.
7 - After the reading, re-assemble the nozzle holder (3),

and reconnect the high- pressure tube (2) and the
connector (4).
Nut that secures the nozzle: 7.84w0.98 Nm
High-pressure coupling: 31.85w2.45 Nm
B2
B1
RKP06370
Compression pressure (kg/cm2)
6 - Turn the engine using the starting motor and read the
compression value.
H Read the compression value when the pressure
gauge has stabilised.
H While reading the compression, also check the
engine rpm using the tachometer C1 or C2. If
the speed does not correspond with the control
value, check it against the diagram.
H Compression value:
Normal: 33w1 kg/cm2 a 250 rpm
Minimum permissible: 26w1 kg/cm2 a 250 rpm
H Maximum difference between the cylinders:
2 3 kg/cm2
C1
40
35
30
25
20
200
250
300
350
400
Engine speed (rpm)

RKP06751
PC35R-8 PC45R-8
20-27
CONTROL AND ADJUSTMENT OF THE

TENSION OF THE FAN BELT
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT

1. Checking the tension
1 - Depress the belt (1) at the centre of the section between the alternator (2) and the pulley (3) that
drives the water pump. Check the flexion.
At a pressure of 10 kg (98 N) the flexion should be
10 15 mm. If this value is not found, adjust the
belt tension.
H With a new belt the flexion should be 7 9 mm.
RKPA3920
2. Adjusting the belt tension

1 - Loosen the screws (4) that secure the alternator
(2) and the screw (5) that secures the belt-tightening stop.
3
10
15 mm
mm
1015
2 - Rotate the alternator (2) to give the belt (1) the correct tension and tighten the screws (4) and (5).
3 - Check the belt (1) tension.
H If the belt has been replaced with a new one,
check the tension again after about 20 hours of
operation.
Screws fastening the alternator to the timing
system cover: 45 54 Nm
Screws locking the support: 25 32 Nm
20-28
2
1
Puleggia
Crankshaft
albero
motore
pulley
RKP04800
PC35R-8 PC45R-8
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING

H Check the injection timing of the No.1 cylinder by
means of the No.1 union of the injection pump.
H PC35R
The cylinders are numbered 1-2-3 counting from the
flywheel side.
PC45R
The cylinders are numbered 1-2-3-4 counting from the
flywheel side.
H The spark advance notches of 0-10-15-20; are
also marked on the flywheel. In order to read the intermediate values, sub-divide the sections between the
two marks into equal lengths.
RKPA3930
1 - Remove the cap (1) of the flywheel casing.

2 - Pass a screwdriver between the teeth and rotate the
flywheel in a counter-clockwise direction (as seen
from the flywheel side) until the 1/3 notch of PC35R
and 1/4 notch for PC45R of the flywheel is aligned
with the notch (2) marked inside the hole in the casing.
H In this position, the piston of the No. 1 cylinder is
at the top dead centre (B.T.D.C.). Check that the
cylinder is in a compression stroke, i.e. that both
valves are closed.
H Once the B.T.D.C. has been ascertained, rotate
the drive shaft in a clockwise direction (seen from
the flywheel side) for about 25 teeth.
RKPA0060
3 - Take off the clamp (3) and disconnect all the fuel delivery tubes (4) from the injection pump.
4 - Rotate the flywheel slowly in a counter-clockwise direction (seen from the flywheel side), checking carefully the level of the fuel in the No. 1 union of the injection pump. Stop the rotation when the fuel level
starts to rise.
3
5 - Check the position of the notches at 15 and 10 that
appear in the hole in the casing and, in function of the
position, establish the true fuel injection timing.
H In order to determine the degrees of intermediate
fuel injection timing, sub-divide the space between 10 and 15.
H Normal fuel injection timing: 14w1
RKPA3901
15
20
10
15
10
1/3
Notch
2
RKPA0011
PC35R-8 PC45R-8
20-29
6 - Rotate the injection pump (5) towards the outside or

towards the motor, after having loosened the pump
(6) retaining nuts.
. To BRING FORWARD the injection, rotate the
pump (5) towards the outside.
. To DELAY the injection rotate the pump (5) towards the cylinder block.
H Check the extent of the movement on the scale
(7).
7 - Lock the nuts (6) that fasten the pump to its block.
Pump fastening nuts: 25 35 Nm
7
5
RKPA3940
H After adjustment of the fuel injection timing:

8 - Connect the fuel delivery tubes (4) to the pump and
replace the clamp (3).
Delivery tube couplings: 31.85w2.45 Nm
9 - Bleed any air from the fuel circuit.
20-30
PC35R-8 PC45R-8
CONTROL AND ADJUSTMENT

OF THE ACCELERATOR STROKE
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE

H Test conditions:
. Engine: switched off.
. Working equipment: resting on the ground.
H If the sheathing (1) is to be substituted, before
proceeding with the adjustments, secure the
pump side of the sheathing (1) in the intermediate
position.
RKPA3950
1 - Loosen the screws (2) and (3) by a few turns.
MAX
2 - Push the accelerator control lever (4) to the end of its

stroke, in the minimum position, until the lever (5)
rests against the minimum-adjustment screw (6).
H If the lever (4) touches the housing (7), loosen the
inside nut (8) and tighten the nut (9) sufficiently to
bring the lever back to a distance of 3-4 mm from
the edge of the housing (7).
7
MIN
2
9
3 - Tighten the screw (2) until it is 0.1 mm from the lever

(4) and tighten the lock-nut.
8
1
RKPA4731
4 - Push the accelerator control lever (4) to the end of its

stroke in the maximum position, until the lever (5)
rests against the maximum-adjustment screw (10).
5 - Tighten the screw (3) until it is 0.1 mm from the lever
(4) and then tighten the lock-nut.
10
RKPA3951
PC35R-8 PC45R-8
20-31
ADJUSTMENT OF THE STROKE OF THE

BLADE COMMAND LEVER
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER

H Test conditions:
The adjustment, carried out on the power train, is aimed at
restoring the position of the command lever, keeping the
neutral position of the valve block spool.
The procedure is as follows:
1 - Move the operator's cab forwards complete.
2 - Loosen the nuts (1) and unscrew the screws (2) by a

few turns.
2
RKPA3960
3 - Adjust the centering of the lever (3) with respect to the

housing (4) by loosening the outside nut (5) of one of
the sheathings and tightening the inside nut (6) of the
other by the same amount.
3
4
4 - Secure the position with the nuts (7) and (8).

5 - Execute a full stroke in one of the two directions with
the lever (3).
H Make sure that the valve block spool executes the
full stroke.
6 - Tighten the lock-screw (2) until it rests on the lever
and then turn it for another half turn. Secure the position with the nut (1).
7
5
6
8
RKPA3961
7 - Repeat this lever adjustment (3) for the other direction.

Before starting the engine to check the adjustment, make sure that the valve block spool returns to its neutral position each time the lever
(3) is released.
20-32
PC35R-8 PC45R-8
ADJUSTING THE FLEXIBLE CABLES
ADJUSTING THE FLEXIBLE CABLES

H Test conditions:
All adjustments that can be made to the flexible cables are
for the purpose of restoring the correct positions of the
control levers, while maintaining the neutral positions of
the control valve spools.
The procedure is as follows:
Controls for boom swing and travel
1 - Remove the footboard (1) from the platform.

2 - Loosen the nut (2) in the sheath of the drive (3) to be
adjusted.
RKPA2220
Travel
3 - Adjust the locknuts of the sheath until the position of

the lever or pedal has been corrected.
H When the position of the lever or pedal concerned
is absolutely correct, the locknuts of the sheath
should be behind the bracket (4).
Boom swing
4 - Firmly tighten the nuts (2).
3
3
RKPA4930
ALIGNAMENT ERROR
BETWEEN LEVER
IN NEUTRAL POSITION
0 3 mm
TRAVEL
LEVERS
BOOM SWING
CONTROL PEDAL
3
2
[ A= for canopy: 200 mm
for cabin 220 mm
PC35R-8 PC45R-8
4
RKP06630
20-33
CONTROL AND ADJUSTMENT OF THE STROKE

OF THE TRAVEL LEVER
CONTROL AND ADJUSTMENT OF THE STROKE OF THE

TRAVEL LEVER
H Test conditions:
1 - Remove the cab floor (1) to gain access to the lever
stroke lock-screws.
1
RKPA2220
2 - Loosen the nuts (2) and unscrew the lock-screws (3)

by a few turns.
3 - Loosen the nuts (4) and tighten the lock-screws (5) by
a few turns.
4 - Pull one of the levers (6) towards the operator's seat.
Keep this position and tighten the corresponding
lock-screw (3) until it touches the lever. Tighten the
screw (3) by another half turn.
5 - Keeping the position of the lever (4), tighten the nut
(2).
6 - Repeat the same operations for the other direction
and for the other lever.
3
2
4 5
RKPA4940
Before starting the engine, check that the levers

and the valve block spools return to their neutral
position.
20-34
PC35R-8 PC45R-8
ADJUSTMENT OF THE STROKE OF

THE BOOM SWING COMMAND PEDAL
ADJUSTMENT OF THE STROKE OF

THE BOOM SWING COMMAND PEDAL
H Test conditions:
1 - Remove the cab floor (1).
1
RKPA2220
2 - Remove the caps (2) and loosen the nuts (3) and
screws (4).
3 - Push the pedal (5) to the end of its stroke in one direction. Keep this position and tighten the screw (4) until
it touches the support. Tighten the screw (4) by a final
half-turn.
4 - Hold the pedal (5) in position and lock the nut (3).
5 - Repeat the same operations for the other working direction of the pedal.
Before starting the engine, check that the pedal
and control valve spools return to their neutral
positions.
RKPA3970
6
4
3
4
3
RKP06640
PC35R-8 PC45R-8
20-35
ADJUSTMENT OF THE PPC VALVE CLEARANCES
ADJUSTMENT OF THE PPC VALVE CLEARANCES

The clearance of the PPC valve (hand and foot) levers is
adjusted as follows.
Lower the working equipment to the ground and stop
the engine.
Turn the ignition key to the I position and move the
command levers in all directions in order to release
all pressure in the hydraulic circuits.
Return the ignition key to the O (OFF) position and
remove it.
Push the lever of the safety device into the
LOCKED position.
Slowly loosen the oil-tank refuelling cap to eliminate
residual pressure.
2
1
3
4
1 - Remove cap (1).

2 - Loosen the nut (2) that retains the disc (3).
3 - Tighten the disc (3) until it makes light contact with
the 4 push-rods (4).
H During this adjustment, take care not to activate any of the push-rods (4) individually.
4 - Secure this position by tightening the retaining nut
(2) to the specific torque.
Retaining nut: 113w15 Nm
RKP06380
20-36
PC35R-8 PC45R-8
ADJUSTMENT OF THE RUBBER PAD AND SAFETY

MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH

FOR SERVO-CONTROL ENGAGEMENT
H Test conditions:
1 - Remove the cover (1).
1
RKPA3220
2 - Loosen the nut (2) and tighten the rubber pad (3) in
the lower plate (4) by several turns.
3 - Lower the servo-control engagement lever until the
pitch point of the roller (5) is roughly 3 mm from the
starting point of the cut-off slot.
4 - Keep this position and bring the rubber pad into contact with the console (6).
6
4
2
RKPA3230
5 - Release the servo-control engagement lever and secure the rubber pad (3) with the nut (2).
3 mm
3
2
5
RKP06620
Adjustment of the microswitch

1 - Disconnect the connectors (7).
2 - Loosen the nut (8) and unscrew the microswitch (9) by
a few turns.
3 - Lower the console (6) into its working position.
4 - Tighten the microswitch (9) until it depresses the

push-button by 3w0.5 mm.
5 - Put the console (6) into its 'safe' position and lock the
nut (8).
6 - Connect the connectors (7) and replace the cover (1).
PC35R-8 PC45R-8
RKPA3240
20-37
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION

1. Test
H Test conditions:
. Solid, flat ground.
1 - Only for machines with rubber track-shoes
Move the machine backwards and forwards until
the track-shoe joint (mark M) is uppermost and
halfway between the sprocket wheel and the
track-shoe stretcher wheel.
150
mm
100100
150
mm
2 - Rotate the revolving frame 90 towards the side of

the track-shoe to be checked.
RKP04690
3 - Close the bucket, bring the arm perpendicular to

the ground and rest the bucket on the ground.
4 - Force the boom downwards until the track-shoe to
be checked is completely raised.
5 - Measure the distance A between the 3rd sprocket track roller and the track shoe.
H Standard measurements
rubber shoe: A=10 15 mm
steel shoe: A=30 50 mm
2. Adjustment
If the track-shoe tensions do not fall within permissible
limits, adjust them as follows:
RKPA3980
H On completion of the adjustment and before engaging the greasing pump G1, thoroughly clean
the grease nipple and surrounding area.
1 - If the tension is too low.
Inject grease through the grease nipple (1) using
the grease pump G1.
H If difficulties are found when injecting the
grease, move the machine slowly backwards
and forwards over a short distance.
"A"
2 - If the tension is too high.

Slowly loosen the union (2) in order to let grease
out of the valve.
RKPA3990
The grease in the stretcher cylinder is under

pressure and could seriously injure the operator. For this reason the valve should not
be loosened for more than one turn.
H If the grease does not come out easily,
move the machine slowly backwards
and forwards over a short distance.
1
2
RKPA4000
20-38
PC35R-8 PC45R-8
CONTROL AND REGULATION OF THE PRESSURES

IN THE HYDRAULIC CIRCUITS
CONTROL AND REGULATION OF THE PRESSURES IN THE

HYDRAULIC CIRCUITS
H Test conditions:
. MIN and MAX. engine speeds: within permissible limits.
Before removing the plugs in order to measure the
pressures, release the residual pressures in the
circuits (see ELIMINATION OF THE RESIDUAL
PRESSURES IN THE CIRCUITS AND IN THE

TANK) and place the safety engagement levers
into their locked positions.
After having connected the pressure gauges, pressurise the tank. For details, see PRESSURISATION OF THE TANK.
OIL COOLER
TANK
DIESEL
P1
P2
RKP06761
The control valve consists of the spools that command:
Command
Ports
Arm (Close - Open)
A1 - B1
Travel motor L.H.

(Backwards - Forwards)
A2 - B2
Travel motor R.H.

(Backwards - Forwards)
A3 - B3
Boom (Raise - Lower)
A4 - B4
Bucket (Dump - Curl)
A5 - B5
Boom swing (R.H. - L.H.)
A6 - B6
Blade (Lower - Raise)
A7 - B7
Swing (R.H. - L.H.)
A8 - B8
Hammer (Suction - Delivery)
A9 - B9
PC35R-8 PC45R-8
8 10
RKP06770
20-39

1. Control of operating pressure (unloading valve)

1 - Remove the plug (1) of pump P1 and mount a
pressure adapter.
E1
2 - Connect a pressure gauge E1 (60 bar).
3 - Start the engine and bring it up to high idling with

all levers in neutral position.
4 - Check the pressure.
H Normal pressure:
35w5 kg/cm2 (34.3w4.9 bar)
The unloading valve cannot be re-adjusted. If
the pressure differs from the normal value the
valve must be substituted.
RKPA4010
2. Control the operating pressures of the working

equipment and machine travel
1 - Remove the plug (1) of pump P1 and mount a
pressure adapter.
E3
1
2 - Connect a pressure gauge E2 (400 bar) or E3

(600 bar).
3 - Start the engine and bring it up to high idling.
4 - Check the pressure for each movement with the
command lever at the end of its stroke and with
the pressure stabilised.
To check the pressure of the working equipment, push the piston to the end of its stroke.
To check the pressure of machine travel, insert a block "A" between the chassis and
the sprocket wheel.
RKPA4020
H Normal pressures:
Working equipment and travel:
250 10 kg/cm2 (245 9.8 bar)
3. Check the operating pressure of the turret

swing
1 - Remove the caps (1) of the swing motor and
mount the pressure adapters.
2 - Connect a pressure gauge E2 (400 bar) or E3 (600
bar).
Insert the turret swing locking-pin.
RKPA4030
3 - Start the engine and bring it up to high idling.

4 - Check the pressure for a swing to the right and a
swing to the left, bringing the lever of the left-hand
PPC valve to the end of its stroke and with the
pressure stabilized.
H Normal pressure:
PC35R: 168 5 kg/cm2 (165 5 bar)
PC45R: 200 5 kg/cm2 (196 5 bar)
E3
1
RKPA4040
20-40
PC35R-8 PC45R-8

Valve adjustment
H The unloading valve cannot be re-adjusted, only substituted.
1. Adjustment of the main relief valve
If the pressures measured for the working equipment

and machine travel do not fall within normal values,
adjust the main relief valve (1) as follows:
2 - Loosen the lock nut (2) and rotate the adjusting
screw (3).
. To INCREASE pressure, turn in a CLOCKWISE direction.
. To DECREASE pressure, turn in a COUNTER-CLOCKWISE direction.
H Each turn of the adjusting screw (3) varies the
pressure by about 125 bar (128 kg/cm2).
RKPA4050
3 - Lock the nut (2).

Nut: 69w10 Nm
H After adjustment, check the adjustment of the
main relief valve with the same procedures as
used for the measurements.
3
RKP06360
2. Adjustment of the safety valve of the swing motor

Do not calibrate the valves when the circuits are
under pressure.
H To perform these adjustments, follow the procedures described in the calibration control section.
If the pressures measured for the swings to the right
and to the left do not come within the normal values,
adjust the safety valve (1) of the swing motor as follows:
1 - Loosen the lock nut (2) and turn the adjusting
screw (3).
. To INCREASE pressure, turn in a CLOCKWISE direction.
. To DECREASE pressure, turn in a COUNTER-CLOCKWISE direction.
RKPA4060
3
2

Nut: 8.8w1 Nm
RKP06430
PC35R-8 PC45R-8
20-41
CONTROL AND REGULATION OF THE LS DIFFERENTIAL

PRESSURE AND ADJUSTMENT OF THE LS VALVE

Test
1. Test method with differential pressure gauge E3
1 - Remove the plugs (1) and (2) and mount two pressure adapters.
2 - Connect the differential pressure gauge E4.
H Connect the high-pressure side to the adapter
(2) and the low-pressure side to the adapter
(1).
E4
3 - Start the engine and use the working equipment

to raise one track-shoe.
4 - Bring the engine up to high idling and check the
LS differential pressure according to the test conditions in Table 1.
RKPA4070
Table 1
Position of
the travel
lever
Neutral
LS differential2 pressure in kg/cm (bar)
NOTES
35w5 (34.3w4.9)
The LS differential pressure

is equal to the pressure given by the unloading valve
Half the
stroke (Swing
without load)
2. Test method with pressure gauges E2 or E3

H The differential pressure is 34.3 bar (35 kg/cm2).
For a precise check use the same pressure gauge
together with a decimal scale.
1 - Remove the plugs (1) and (2) and mount two
pressure adapters.
2 - Connect pressure gauge E2 or E3 to the pressure adapter (2).
3 - Start the engine and use the working equipment
to raise one track-shoe.
4 - Bring the engine up to high idling and measure
the delivery pressure of pump (PP) in the conditions shown in Table 1. Make a note of the values
read.
H Check the instrument by reading it from the
front and making sure that the reading is correct.
5 - Disconnect the pressure gauge E2 or E3 from the
pump delivery and connect it to the pressure
adapter (1).
6 - Measure the LS pressure in the same conditions
indicated at point 4. Make a note of the value read.
7 - Subtract the LS pressure from the delivery pressure of the pump (PP) in order to obtain the differential pressure value DPLS (PP LS=DPLS)
H DPLS normal= 34.3 bar (35 kg/cm2)
20-42
E3
RKPA4080
E3
RKPA4090
PC35R-8 PC45R-8

LS valve adjustment
If the DPLS value is not the one indicated, adjust the LS
valve (1) as follows:
1 - Disconnect the tube (2).
2 - Loosen the lock nut (3) and turn the adjusting screw
(4).
. To INCREASE pressure, turn in a CLOCKWISE
direction.
. To DECREASE pressure, turn in a COUNTERCLOCKWISE direction.
Nut: 31w3.5 Nm
H After the adjustment, check the setting of the LS
valve (1) following the procedure used for the test.
RKP06780
RKP06510
PC35R-8 PC45R-8
20-43
REGULATION OF THE PC VALVE
REGULATION OF THE PC VALVE

H If the engine speed decreases when an increase in
pressure or delivery is requested, or when the speed
of the working equipment is low, even though the engine speed, the delivery pressure and the LS differential pressure are all normal, the PC valve (1) should be
regulated as follows:
1 - Loosen the check-nut (2).

2 - Turn the adjustment screw (3).
. If the working equipment speed is low, turn the
screw (3) in a CLOCKWISE direction to INCREASE
the torque absorption of the pump.
. If the engine rpm suffer an abnormal drop, turn
the screw (3) in a COUNTER-CLOCKWISE direction to DECREASE the torque absorption.
3 - After adjustment, tighten the check-nut (2).
RKPA4100
RKP06500
20-44
PC35R-8 PC45R-8
CONTROL AND REGULATION OF THE

SERVO-CONTROL POWER SUPPLY
CONTROL AND REGULATION OF THE SERVO-CONTROL

POWER SUPPLY
H Test conditions:
. Hydraulic oil temperature: 45 55 C.
E1
Before removing the cap to measure the pressure,

release the residual pressures from the circuits
(See ELIMINATION OF RESIDUAL PRESSURES
OF THE CIRCUIT AND THE TANK) and put the
safety device engagement levers into their locked
position.
After connecting the pressure gauge, pressurise the
tank. For details see PRESSURISATION OF THE
TANK.
RKPA4110
1. Checking the pressure of the servo-controls

1 - Remove the cap (1) of servocontrol delivery pipe
and a pressure adapter.
2 - Connect the pressure gauge E1 (60 bar).
3 - Start the engine and bring it up to high idling with
all leers in neutral position.
4 - Check the pressure.
H Normal pressure: 29
bar (30
kg/cm2)
2. Regulating the servo-control valve

If the pressure value does not fall within the tolerances, regulate the valve (2) as follows:
1 - Loosen the lock nut (3) and turn the adjusting
screw (4).
. To INCREASE pressure, rotate in a CLOCKWISE direction.
. To DECREASE pressure, rotate in a COUNTER-CLOCKWISE direction.
H Each turn of the screw (4) varies the pressure
by 56 kg/cm2 (55 bar).
RKPA4120
3
4

Nut: 22w2.5 Nm
RKP07150
PC35R-8 PC45R-8
20-45
ELIMINATION OF RESIDUAL PRESSURES PRESSURISATION OF THE TANK
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION

OF THE TANK
1. Elimination of pressures from the hydraulic circuits.
1 - Rest the working equipment on the ground and
stop the engine.
2 - Turn the ignition key to the position I and move
the command lever in all directions to release all
pressure in the main hydraulic circuits and the
servo-controls .
3 - Return the ignition key to the position O (OFF)
and remove it.
4 - Put the safety device lever into its LOCKED position.
2. Elimination of pressure in the tank
The hydraulic oil tank is of the sealed and pressurised type.

When tubes are to be removed or disconnected
for controls or repairs, or when caps are removed, tank pressure must be eliminated using
the following method:
1 - Rest the working equipment on the ground and

stop the engine.
2 - Slowly loosen the oil-refuelling cap in order to release residual pressure.
RKPA4130
3. Pressurising the tank

H This operation should be performed every time
the oil-refuelling cap is moved for removal of the
tubes or other hydraulic equipment.
1 - Start the engine and position the machine as in
the figure.
2 - Stop the engine, loosen the tank cap (1) and then
close it again.
H This operation lets air into the tank when the
level of the remaining oil is at minimum.
RKP04720
3 - Start the engine and lower the working equipment

to the ground.
20-46
PC35R-8 PC45R-8
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS

Sequence of operations or procedures for bleeding the air
Procedures for bleeding air
. Substitution of hydraulic oil
Bleeding air
from pumps
Starting
engine
Bleeding
air from
cylinders
. Cleaning tank filter
pump
. Removal of suction tube
. Substitution - repair
control valve
. Repair-Substitution
cylinders
. Removal of cylinders tube

. Repair - substitution
swing motor
. Removal of tubes
Bleeding air Bleeding air Pressurisfrom swing from travel

ing tank
motor
motor
,1
,1
. Substitution filter
Starting
tasks
from swing motor
travel motor - joint
. Removal of tubes
from travel motor - joint
,1: Only bleed air from the swing and travel motors if the engine oil (casing) is to be drained.
1. Bleeding air from the pump
1 - Loosen and remove the cap (1) from the pump
body (2).
2 - Pour hydraulic oil through the hole until the entire

casing is full.
3 - Replace the cap (1).
Cap: 17.2w2.45 Nm
H After filling the casing, start the engine and allow it to run at low idling for about 10 minutes
before proceding to bleed the air from the circuits.
PC35R-8 PC45R-8
2
RKPA4101
20-47
2. Bleeding air from the cylinders
BOOM CYLINDER
1 - Start the engine and let it run at low idling for

about 5 minutes.
2 - Lower and raise the boom 4-5 times.
H Lower and raise the piston of the boom up to
about 100 mm of the end of its stroke.
Every care must be taken to avoid pressurising the circuits.
3 - Bring the engine up to high idling and repeat the
operations described in point 2. Return the engine
to low idling and pout the piston through its entire
stroke until it reaches max. pressure in both directions.
4 - Repeat the operation (starting from point 2) for the
arm, bucket, arm swing, and blade cylinders.
RKP04940
33 Giri
Turns
3. Bleeding air from the swing motor

Make sure that the swing-locking pin is not engaged.
1 - With the engine at low idling, rotate the revolving
frame three turns towards the left.
2 - Repeat the same manoeuvre, rotating the revolving frame to the right.
Turns
33Giri
4. Bleeding air from the travel motors
RKP04700
1 - With the engine at low idling, use the working

equipment to raise the left-hand track-shoe from
the ground.
2 - Let the track-shoe turn for about 30 seconds.
3 - Repeat points 1 and 2 for the right-hand trackshoe.
H Engage the travel increment for about 10 seconds.
100150
150 mm
mm
100
5. Bleeding air from any optional equipment

H This method must be used for all the optional
working equipment, unless otherwise indicated.
RKP04690
1 - Each time an item of optional working equipment

is installed, operate the equipment repeatedly,
with the engine at low idling, until all air has been
completely eliminated.
20-48
PC35R-8 PC45R-8
CONTROL OF HYDRAULIC DRIFTS ANALYSIS OF THE CAUSES OF A DRIFT
CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES

OF A DRIFT
H Test conditions:
. Machine: in the conditions indicated in the NORMAL TECHNICAL DATA.
1. Test
To check on the extent of the hydraulic drifts of
individual components and the total hydraulic
drift, position the machine and follow the procedures indicated in the NORMAL TECHNICAL
DATA.
2. Analysis of the causes of hydraulic drifts

Before disconnecting the tubes, release hydraulic pressures in the circuits (see ELIMINATION
OF THE RESIDUAL PRESSURES).
1. Boom test
1 - Position the machine with the arm vertical and
with the back of the bucket resting on the ground.
2 - Stop the engine and release the residual hydraulic pressures.
3 - Disconnect the hoses (1) and (2) that supply the
cylinder on the head side and on the base side.
4 - Plug the two hoses to prevent entry of impurities.
5 - Plug the rigid tube (3) that supplies the cylinder
on the base side.
6 - In order to catch any oil leakages, attach a tube
to the pipe (4) that supplies the head side of
the cylinder.
7 - Start the engine and extend the arm completely.
8 - Stop the engine and check the position of the
boom for 15 minutes.
. If the boom moves downwards the drift is due
to the cylinder gaskets.
. If the boom does not move, the drift is due to
the control valve.
PC35R-8 PC45R-8
4
RKPA4950
RKP04990
20-49
2. Arm test
1 - Position the machine with the arm completely extended and with the bucket teeth on the ground.
RKP05000
3 - Disconnect the hose (1) from the arm cylinder

and plug them to prevent the entry of impurities.
4 - Plug the hole of the arm cylinder on the head
side and attach a provisional tube on the base
side to catch any oil leakages.
RKPA4960
5 - Start the engine and raise the boom.

arm for 15 minutes.
. If the arm moves downwards the drift is due to
the cylinder gaskets.
. If the arm does not move, the drift is due to the
control valve.
RKP05010
RKP04940
20-50
PC35R-8 PC45R-8
3. Bucket test
1 - Position the machine with the arm vertical and
the bucket resting on the ground in a horizontal
position. Put a weight in the bucket, or fill it with
earth.
3 - Disconnect the bucket cylinder hoses (1) and (2)
and plug them to prevent the entry of impurities.
4 - Plug the hole of the bucket cylinder on the base
side and attach a provisional tube on the head
RKP05020
1
RKPA4970
5 - Start the engine and raise the boom.

bucket for 15 minutes.
. If the bucket makes an opening movement the
drift is due to the cylinder gaskets.
. If the bucket does not move, the drift is due to
the control valve.
50 cm
RKP05030
PC35R-8 PC45R-8
20-51
4. Boom swing test

1 - Position the machine with the boom, arm and
bucket raised and with the revolving frame
turned 135 to the left.
RKP05040
3 - Disconnect from control valve the pipe (1) and

plug it.
H Plug the control valve union to prevent entry
of impurities
RKPA4140
4 - Disconnect the boom swing cylinder hose (2) and

plug it.
5 - Attach a provisional tube on the head side to
catch any oil leakages.
RKPA4150
6 - Start the engine and move the machine to a 15

slope.
boom for 15 minutes.
. If the boom makes a rotating movement
the drift is due to the cylinder gaskets.
. If the boom does not move, the drift is due
to the control valve.
15
135
RKP05050
20-52
PC35R-8 PC45R-8
5. Blade test
1 - Position the machine with the arm resting vertically on the ground and with the bucket resting
on its back.
2 - Raise the blade completely and support it on a
centrally-positioned block.
RKP04930
4 - Disconnect the hoses (1) and (2) of the blade cylinder (3) and plug them.
5 - Plug the hole of the blade cylinder on the head
side and attach a provisional tube on the base
6 - Start the engine and force the boom down to
raise the machine in order to remove the block
on which the blade is resting.
7 - Lower the blade and stop the engine.
8 - Check the position of the blade for 15 minutes.
. If the blade moves downwards the drift is due
to the cylinder.
. If the blade does not move downwards, the
drift is due to the safety valve.
H In order to check whether the drift is due to the
swivel joint, see: CHECKING LEAKAGES INSIDE THE SWIVEL JOINT.
RKPA4160
6. Swing motor test

1 - Position the machine with boom, arm and bucket
raised as in the figure and with the revolving
frame turned 135 to the left.
RKP04980
PC35R-8 PC45R-8
20-53
3 - Disconnect the hoses (1) and (2) from the motor

and plug them to prevent entry of impurities. Attach provisional tubes to the motor to catch any
oil leakages.
4 - Start the engine, move the machine to a 15
slope, and stop the engine.
5 - Mark the position between revolving frame and
lower track-frame on the swing circle and for 15
minutes check whether or not the revolving frame
rotates.
. If the revolving frame rotates the drift is due to
either the safety valve or the control valve.
H To establish the cause of the drift, install a
new safety valve.
2
RKPA4170
15
135
RKP05050
20-54
PC35R-8 PC45R-8
CHECKING FOR ANY LEAKAGES INSIDE

THE WORKING EQUIPMENT CYLINDERS
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING

EQUIPMENT CYLINDERS
H Test conditions:
POSITION FOR THE BOOM TEST
1 - Fully extend the rod of the cylinder to be checked and

stop the engine.
2 - Disconnect the tube from the head side of the cylinder and bind it to the structure.
Take great care not to disconnect the tube on
the base side of the cylinder.
3 - Start the engine, bring it up to high idling and bring
the base side of the cylinder up to maximum pressure.
4 - After 30 seconds, wait for a full minute to collect any
leakages from the free tube.
RKP04720
POSITION FOR THE ARM AND BUCKET TEST
RKP04710
TUBE HEAD
SIDE
DELIVERY
BOTTOM SIDE
MAXIMUM
PRESSURE
RKP04751
PC35R-8 PC45R-8
20-55
CHECKING FOR ANY LEAKAGES INSIDE

THE SWING MOTOR
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR

H Test conditions:
. Hydraulic oil: 45 55C.
. Turret: locked in place with the swing-locking pin.
1 - Disconnect the drainage tube (1) of the motor (2) and
plug it.
2
1
2 - Attach a provisional tube to catch the drainage oil.

3 - Start the motor and bring it up to maximum swing.
4 - Make sure that the turret is locked in place and push
the swing command lever to the end of its stroke.
RKPA4171
5 - Hold it in this position for 15 seconds and then measure the leakage for the next full minute.
6 - Bring the motor back to low speed and repeat the
reading for the other direction of swing.
7 - Check that the average between the two readings
falls within normal values (See TECHNICAL DATA).
8 - Re-assemble the hydraulic drainage circuit.
20-56
PC35R-8 PC45R-8
METHODS FOR TESTING FOR LEAKAGES

INSIDE THE SWIVEL JOINT
METHODS FOR TESTING FOR LEAKAGES INSIDE THE

SWIVEL JOINT
H Test conditions:
. Hydraulic oil: 45 55C.
1. Functionality test
1 - When a lower actuator (blade, travel motor, travel
increment) is found to be defective, one of the
possible causes of failure is the swivel joint.
2 - In order to ascertain the cause of the defect it is
sufficient to by-pass the joint by connecting (using
a length of additional tubing) the input and output
tubes of the joint of the line to be checked.
If this corrects the defect, it is certainly due to the
swivel joint.
If the defect persists, it can be ascribed to other
causes, but definitely not to the swivel joint.
F Blade cylinder, head side - Rise

G Blade cylinder, base side - Descent
B Travel motor to the left - Forward
D Travel motor to the right - Forward
E Travel speed increment
A Travel motor to the left - Reverse
2. Looking for a defective seal

These controls are to be carried out only on
those lines subjected to working pressures.
The drainage line is therefore not included in
these tests.
C Travel motor to the right - Reverse
The test method consists of pressurising the line to be

checked and measuring any leakages from the adjacent lines according to the following tables:
RKP06790
TABLE A
Symbol
Line to be controlled (under pressure)
Blade cylinder, head side - Rise
Blade cylinder base side - Descent
Travel motor to the left - Forward
Travel motor to the right - Forward
Travel speed increment
Travel motor to the left - Reverse
Travel motor to the right - Reverse
Adjacent line (possible leakages)
Sym.
External leak (visible)
Blade cylinder, head side - Rise
Travel motor to the right - Reverse
External leak (visible)
The symbols correspond to the symbols stamped onto the input and output ports of the swivel joint.
PC35R-8 PC45R-8
20-57
METHODS FOR TESTING FOR LEAKAGES

INSIDE THE SWIVEL JOINT
3. Preparation for the testing:

.
.
Travel motor
Travel increment
1 - Release all residual hydraulic pressures.

(See ELIMINATION OF THE RESIDUAL PRESSURES FROM THE CIRCUITS).
2 - Disconnect from the travel motor (1) the tube (2)

corresponding to the line to be checked and seal
it. Also plug the motor to prevent entry of impurities.
3 - Disconnect from the relative actuators the tubes
that correspond to the lines adjacent to the one
being checked. Plug the disconnected tubes to
prevent entry of impurities.
H To identify the lines adjacent to the line being
checked, please refer to Table A.
RKPA4180
4 - Wait a few minutes to give the oil in the tubes time

to drain out.
4. Preparation for testing the blade

1 - Release all residual hydraulic pressures.
(See ELIMINATION OF THE RESIDUAL PRESSURES FROM THE CIRCUITS).
2 - Disconnect from the blade cylinder (3) the tube (4)
corresponding to the line to be checked and seal
it. Also plug the holes in the actuators to prevent
entry of impurities.
3
4
3 - Disconnect from the relative actuators the tubes

that correspond to the lines adjacent to the one
being checked. Plug the disconnected tubes to
H To identify the lines adjacent to the line being
tested, please refer to Tables A and B.
RKPA4161
4 - Wait a few minutes to give the oil in the tubes time

to drain out.
5. Checking the leaktightness

1 - Start the motor and bring it up to the testing speed
for each group of components.
2 - Pressurise the line to be tested.
3 - After 30 seconds, then for the next full minute
check to see if there are any leakages.
H
If oil leaks out of one of the two tubes of the
actuators (adjacent lines), it means that there
is a leakage of the intermediate gasket between the high pressure line and the adjacent line.
20-58
Lines adjacent
Line to be
tested
RKP04761
PC35R-8 PC45R-8
GROUP
30
REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3

PRECAUTIONS TO BE TAKEN
WHILE WORKING .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
SPECIAL TOOLS . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5
STARTER MOTOR
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7
ALTERNATOR
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
INJECTION PUMP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
NOZZLE HOLDER
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
WATER COOLANT PUMP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 13
CYLINDER HEAD
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
OIL COOLER
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17
OIL COOLER - RADIATOR GROUP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19
ENGINE HOOD
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20
CANOPY
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 21
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 21
CAB
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
HEATING FAN
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 23
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24
COUNTERWEIGHT
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25
PC35R-8 PC45R-8
FUEL TANK
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 26
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 27
HYDRAULIC TANK
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 28
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
ENGINE-PUMP GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 30
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 33
PUMP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
ENGINE-PUMP COUPLING
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 35
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 35
CONTROL VALVE
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 37
LEFT-HAND PPC VALVE (ARM-BUCKET)
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
RIGHT-HAND PPC VALVE (BOOM-BUCKET)
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
SERVOCONTROL SOLENOID GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40
PLATFORM
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
SWIVEL JOINT
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
SWING MACHINERY
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
REVOLVING FRAME
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 48
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 49
SWING CIRCLE
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 50
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 50
30-1
RUBBER TRACK SHOES

Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
STEEL TRACK-SHOES
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
SPROCKET WHEEL
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
FINAL DRIVE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
IDLER AND RECOIL SPRING
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
SPRING RECOIL AND THRUST
CYLINDER GROUPS
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
IDLER
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
TRACK ROLLERS
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
BOOM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
ARM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
BUCKET CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . .
30-2
51
51
52
52
53
53
54
54
55
55
56
57
59
60
61
61
62
63
64
64
BOOM SWING CYLINDER

Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
BLADE CYLINDER
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
WORK EQUIPMENT CYLINDERS
Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
UPPER WORK EQUIPMENT
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
BUCKET
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
ARM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
ARM ASSEMBLY
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
BOOM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
BOOM SWING SUPPORT
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
BLADE
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .
66
67
68
68
69
71
75
76
77
77
78
79
80
80
81
82
83
83
84
84
65
65
PC35R-8 PC45R-8
HOW TO READ THE MANUAL
HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are
given in the removal procedure. The sequence of operations is not repeated in the installation procedure.
(2) Information needed for installation is marked with the symbol
. 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
:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions to be followed when carrying
out the operation.
1 - Remove XXXX (1):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing XXXX (1)
2 - ~ ~ ~ (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This sign means that information is given for

the installation procedure
3 - Remove &&&& (3):

........... ,: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recovery of oil or water, and the quantity to be recovered.
INSTALLATION GROUP *** : . . . . . . . . . . . . . . . . . . . . . Title of operation.
.
To install, reverse removal procedure.

: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing ~ ~ ~ (2).
Addition of water or oil: . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.

H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil.
2.
To the precautions to be taken during the removal or installation of the groups, must be added the specific
PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS.
Always make sure that these precautions are taken.
3. List of special tools.

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational
procedures, see the list SPECIAL TOOLS supplied in this section.
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
represent the values of TIGHTENING TORQUES, WEIGHT OF PARTS OR GROUPS, QUANTITIES
OF OIL OR LIQUIDS TO BE INTRODUCED, SCREW LOCKING MATERIAL, SEALANTS AND LUBRICATION, LUBRICATING GREASE.
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
PC35R-8 PC45R-8
30-3
PRECAUTIONS TO BE TAKEN WHILE WORKING
PRECAUTIONS TO BE TAKEN WHILE WORKING

H When dismantling or installing a part, always take the following general precautions.
1. Precautions for removal operations

.
.
.
.
.
.
.
.
.
.
.
.
If not otherwise indicated, lower the work equipment until it rests on the ground.
If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
After having removed flanges and tubes, insert plugs to prevent impurities from entering.
Before removing a cylinder, fully retract the piston and tie it with wire.
Use a sufficiently large container to collect the oil.
Before removing a part from the machine, check the alignment reference marks which show the correct installation position. If necessary add further marks to avoid incorrect installation.
While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
Check the number and height of the adjustments to a given clearance and store them in a safe place.
When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or
dust from gaining entrance.
2. Precautions to be taken during installation

.
.
.
.
.
.
.
.
.
.
.
.
Tighten nuts and screws with the specified tightening torques.

Install the flexible hoses, taking care not to entangle or twist them.
Bend the cotter pins and stops in such a way as to secure them.
When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough
adhesive to cover the threading in a uniform manner.
When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there
are no dents or dirt, then apply the liquid sealant in a uniform manner.
Clean all the parts, remove dirt, rust, burrs, or dents.
Apply a film of engine oil over all the moving parts.
Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking.
After having mounted the snap-rings, check that they are firmly positioned in their seatings.
When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them,
then connect them firmly.
If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoisting hook.
Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive
pull on one side only.
3. Precautions to be taken on completion of removal and installation operations.

.
.
.
30-4
If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level.
Start the engine to circulate the liquid throughout the cooling system and then top up the level once more.
When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the engine to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves,
are removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the
machine.
H For details, see 20. TESTING AND ADJUSTMENTS.
After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.
PC35R-8 PC45R-8
SPECIAL TOOLS
SPECIAL TOOLS
Nature of work
Symbol
Code
Description
Q.ty
Removal - installation
of steel track shoe
Disassembly - assembly
recoil spring
ATR200460
Equipment
For master pin
ATR200720
Equipment
Removal - installation
recoil spring
ATR200620
Equipment for disassembly

- assembly cylinders
All cylinders
ATR800190
Dynamometric wrench
with multiplier
Max. 400 kg (400 dNm)
ATR200730
Pliers for mounting gaskets
All cylinders
ATR200740
Plunger i 30
ATR200750
Plunger i 35
Wrench for cylinder 65
6-point socket wrench (30)
Plunger for piston rod 30
Plunger for piston rod 35
Plunger for cylinder 50
Gauge for cylinder 50
ATR200990
ATR201000
Bushing for piston rod

30
Bushing for piston rod

35
6
cylinders
ATR200870
7
10
ATR201150
PC35R-8 PC45R-8
Notes
Mounting bushings on
cylinders and piston rod
Removal - installation of
head
Removal - installation of
piston
Mounting ring on
the head
Mounting piston gasket
Gauging piston gasket
Mounting head
30-5
SPECIAL TOOLS
SPECIAL TOOLS
Nature of work
cylinders
Assembly of idler
30-6
Symbol
Code
Description
Q.ty
Bushing for piston 50
ATR201190
ATR201200
Plunger
Plunger
11
Notes
Assembling
piston - cylinder
PC35R-8 PC45R-8
STARTER MOTOR
REMOVAL OF THE STARTER MOTOR

Disconnect the negative terminal cable () from the
battery.
1 - Remove cabin.
(For details, see REMOVAL OF CABIN).

3 - Loosen bolts (1) and remove the cover (2).
RKPA4190
3 - Disconnect cable (3) and connector (4).

4 - Loosen bolts (5) and remove starter motor (6).
RKPA4200
INSTALLATION OF THE STARTER

MOTOR
.
To install, reverse the removal procedure.
Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
5
RKPA4210
PC35R-8 PC45R-8
30-7
ALTERNATOR
REMOVAL OF THE ALTERNATOR

battery.
1 - Remove cabin.
(For details, see REMOVAL OF CABIN).

3 - Loosen bolts (1) and remove the cover (2).
RKPA4190
4 - Disconnect cable (3) and connectors (4) and (5).
5 - Loosen bolts (6) and (7) sufficiently to allow the alternator to be rotate.
6 - Free the pulley (8) from the fan-belt and remove alternator (9).
5
6
RKPA4220
INSTALLATION OF THE
ALTERNATOR
.
H Adjust the tension of the fan belt. (For details, see 20.
CONTROLS AND ADJUSTMENTS).
RKPA3921
30-8
PC35R-8 PC45R-8
INJECTION PUMP
REMOVAL OF INJECTION PUMP

.
Disconnect the negative terminal cable () from

the battery.
Close the cock of separator to prevent fuel leakage.
1 - Remove oil-cooler - radiator group.

(For details, see REMOVAL OF THE OIL-COOLER RADIATOR GROUP).
2 - Disconnect connector (1) and accelerator cable (2).
2
RKPA4230
7
3 - Disconnect from injection pump (3) fuel feeding pipes
(4) and return pipes (5).
4 - Disconnect injection pump (3) lubricating pipe (6).

5 - Disconnect high pressure pipes (7) from injection
pump (3).
5
6
RKPA4240
9
6 - Remove the inlet cover (8) to ignition gear system.
7 - Loosen and remove nut (9) and lock washer (10) of
pump driving gear.
H Be careful not let nut (9) and lock washer drop in
the housing.
10
RKPA4250
8 - Remove pump (10) driving gear (3).

H Before removing pump driving gear, mark position compared to idling gear.
H For removal, use a puller (X1) and tighten its
screws (X2) directly in the gear (10).
H During removal be careful not let key drop (11) in
the housing.
13
X2
11
10
X1
X2
RKP06390
PC35R-8 PC45R-8
30-9
9 - Loosen nuts (12) (No. 3) and remove injection pump

(3) with O-rings (13).
INJECTION PUMP
12
RKPA4260
INSTALLATION OF INJECTION
PUMP
.
H Check accelerator stroke lever.

(For details, see 20. CONTROLS AND ADJUSTMENTS).
Feed and return pipes: 31.85w2.45 Nm
H Align marks among gears before to install pump
and nut.
Nuts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
Pump lock nuts: 25.5 Nm
1 - Check fuel injection timing.
30-10
PC35R-8 PC45R-8
NOZZLE HOLDER
REMOVAL OF THE NOZZLE HOLDER

1 - Remove the suction filter (1) and the supporting bracket (2).
RKPA4270
2 - Remove the high-pressure pipes (3) and the fuel return tubes (4).
4
RKPA3902
3 - Loosen nuts (5) and remove clips (6).

4 - Remove the complete injection nozzles.
RKPA4280
INSTALLATION OF THE
NOZZLE HOLDER
.

High-pressure pipe union: 31.85w2.45 Nm
Nuts: 7.84w0.98 Nm
PC35R-8 PC45R-8
30-11
WATER COOLANT PUMP
REMOVAL OF WATER COOLANT PUMP

battery.
H Drain the engine coolant.
Coolant: Approx. 8 ,
1 - Remove the engine hood (1) and R.H. lateral counterweight (2).
R.H. lateral counterweight: 45 kg
RKPA4290
2 - Disconnect the air intake tube (3) and remove the

coolant tank (4).
RKPA4300
3 - Disconnect the tube (5) and (6).

H Only for cabin version. Disconnect the heating
circuit tube (7).
4 - Disconnect the connectors (8).
5 - Remove from the radiator the fan cover (9) and disconnect the fan-cooling conveyor (10).
10
8
6
7
RKPA4310
6 - Loosen the screws (11), remove the cooling fan (12)

and the spacer (13). Take out the fan-cooling conveyor (10).
Loosen the alternator drive belt and disengage the
pulley of the water pump.
13
12
11
RKP06800
30-12
PC35R-8 PC45R-8
WATER COOLANT PUMP
7 - Loosen the screws (14) and remove the complete

pump (15), gasket (16) and O-ring (17).
17
15
16
14
RKP06810
INSTALLATION OF WATER
COOLANT PUMP
.
1 - Fill up the cooling circuit.

Coolant: approx. 8 ,
2 - Start the engine to circulate the liquid through all circuits. Stop the engine and check the level.
H Only for cabin version. Make sure that the heating cock is open.
R.H. lateral counterweight screws: . . . . . . . . Nm
1 - To install the engine hood.
(For details, see REMOVAL OF ENGINE HOOD).
H Adjust belt tension. (For details, see 20. CONTROLS
AND ADJUSTMENTS - Control and adjustments of
the fan belt).
Fan screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
H Check the gaskets:
Pump screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
PC35R-8 PC45R-8
30-13
CYLINDER HEAD
REMOVAL OF THE CYLINDER HEAD

battery.

1 -Remove the water coolant pump. (For details, see
REMOVAL OF WATER COOLANT PUMP).
2 - Remove filter (1) and bracket (2).
RKPA4270
3 - Remove the fuel filter (3) without disconnecting the

tubes. Put it to rear side of machine.
4 - Remove nozzle holder (4). (For details, see REMOVAL OF THE NOZZLE HOLDER).
5 - Remove the valves cover (5).

6 - Disconnect the pre-heater cable (6).
6
3
RKPA3903
7 - Remove the rocker-arm shaft (7).

H Loosen the lock nuts and unscrew the valve tappets by 2-3 turns.
7
7
8 - Take out the rocker-arm control rods (8).
RKP06820
9 - Loosen clips (9) and disconnect exhaust pipe from

muffler (10) .
10 - Loosen the screws (11) from support (12) and nuts
(13) from muffler.
Remove muffler (10).
10
13
12
11
RKPA4980
30-14
PC35R-8 PC45R-8
CYLINDER HEAD
11 - Take out the screws (14) in the sequence indicated

and remove the complete cylinder head (15).
H The cylinder head gasket (16) must be substituted
every time it is dismantled.
14
15
16
RKP06830
PC35R
Flywheel side
Exhaust side
14
8
12
2
4
5
9
10
11
13
Intake side
RKP06841
PC45R
Flywheel side
Exhaust side
18
11
5
14
16
7
1
12
10
17
13
15
Intake side
RKP06851
PC35R-8 PC45R-8
30-15
CYLINDER HEAD
INSTALLATION OF THE CYLINDER HEAD

PC35R
.

Exhaust side
Flywheel side
1 - Fill up the cooling circuit.

2 - Start the engine to circulate the liquid through all circuits. Stop the engine and check the level.
H Only for cabin version. Make sure that the heating cock is open.
7
3
13
11
10
6
12
14
Intake side
Nuts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
RKP07161
PC45R
Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
Screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
Nuts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
H Raise the cylinder head, keeping it horizontal, and
place it on the gasket without shifting anything.
H Lubricate the screw-threadings with engine oil.
H Tighten the screws in the sequence indicated.
(See figure).
Cylinder head screws: 88.2w2.94 Nm
30-16
Exhaust side
Flywheel side
H Adjust valve clearance. (For details, see 20. CONTROLS AND ADJUSTMENTS - Adjusting valve clearance).
12
16
14
2
6
13
3
10
18
15
9
4
17
11
Intake side
RKP07171
PC35R-8 PC45R-8
OIL COOLER
REMOVAL OF THE OIL COOLER

Completely lower the working equipment until it is resting on the ground and stop the engine.
Release all residual pressures from the circuits and
the tank. (For details, see 20. CONTROLS AND ADJUSTMENTS).
H Drain the hydraulic oil.
Oil cooler: Approx. 33 ,

1 - Remove R.H. lateral counterweight (1) and R.H. lateral cover (2).
R.H. lateral counterweight PC35R: 32 kg
PC45R: 46 kg
RKPA4291
2 - Remove the intake tube (3) and tube (4).
RKPA4320
3 - Remove the panel (5), disconnect the tubes (6) and

(7) and plug them to prevent entry of any impurities.
4 - Take out the screws (8) and remove the oil-cooler (9).
9
5
INSTALLATION OF THE
OIL COOLER
.
RKPA4330
H Fill the hydraulic oil tank with oil up to its maximum level.
Hydraulic oil required: approx. 33 ,
Lateral counterweight screws:. . . . . . . . . . . . . Nm
1 - Start the engine at low idling to circulate the oil throughout the system.
2 - Pressurise the tank and bleed air from all circuits.
PC35R-8 PC45R-8
30-17
REMOVAL OF THE OIL COOLER - RADIATOR GROUP

1 - Remove the engine hood (1), R.H. lateral counterweight (2) and R.H. lateral cover (3).
R.H. lateral counterweight 45 kg
RKPA4292
2 - Drain the coolant and hydraulic oil.
Hydraulic oil: Approx. 33 ,

3 - Remove the suction pipe (3) and disconnect the coolant delivery tubes (4) and return pipes (5).
4 - Remove the fan guard (6).
RKPA4301
5 - Remove the panel (7) and disconnect the exchange

delivery tube (8).
H Plug tube (8) to prevent entry of any impurities.
8
9
6 - Remove the bracket (9).
RKPA4340
7 - Disconnect the exhaust tube (10) and remove the

cock (11).
8 - Loosen the radiator-group screws and remove it.
10
11
RKPA4350
30-18
PC35R-8 PC45R-8
INSTALLATION OF THE OIL COOLER - RADIATOR GROUP

.

R.H. lateral counterweight screws: . . . . . . . . Nm
1 - To install the engine hood.
(For details, see REMOVAL OF ENGINE HOOD).
H Fill the hydraulic oil tank with oil up to its maximum level.
H Fill the coolant up to its maximum level.
H During the installation of the oil cooler - radiator
group, make sure that the fan put out approx. 1/3 of
its width from conveyor and make sure that it is centered in the conveyor seat.
1 - Start the engine to circulate the coolant throughout
the system.
H Make sure that the heating cock is fully open in
the cab version.
2 - Pressurise the tank and bleed air. (For details, see
20. CONTROLS AND ADJUSTMENTS).
3 - Stop the engine, check the level and, if necessary,
top it up.
PC35R-8 PC45R-8
30-19
ENGINE HOOD
REMOVAL OF THE ENGINE HOOD

1 - Block the engine hood (1) in its raised position, take

out the screws (2) that fasten the hinge (3) to the frame and remove the hood.
RKPA4360
INSTALLATION OF THE
ENGINE HOOD
.
H Check the alignment of the outside edges, the centering and the adjustment of the closing mechanism (4).
RKPA4370
30-20
PC35R-8 PC45R-8
CANOPY
REMOVAL OF CANOPY
Completely lower the working equipment until it is resting on the ground and stop the engine and take out
the ignition key.
1 - Attach the canopy (1) to some hoisting tackle.
2 - Loosen and remove the screws (2) and (3).
3 - Remove the canopy.
Canopy: 73 kg
RKPA4380
INSTALLATION OF CANOPY
.

Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
RKPA2760
RKPA2770
PC35R-8 PC45R-8
30-21
CAB
REMOVAL OF CAB
the ignition key.
1 - Loosen the clamp (1) and disconnect the heating pipe
(2).
2 - Remove the cover (3).
RKPA2780
3 - Attach the cab (4) to some hoisting tackle.

4 - Loosen the cab lock crews (No. 10).
5 - Take out the cab (4).
Cab: 208 kg
INSTALLATION OF CAB
.

Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
RKPA4390
30-22
PC35R-8 PC45R-8
HEATING FAN
REMOVAL OF THE HEATING FAN

the ignition key.
1 - Remove the floor mat.
2 - Remove screws (1).
3 - Loosen screws (2) and take out the cover (3).
4 - Remove the travel increment pedal (4).
RKPA2800
5 - Remove the L.H. lower cover (for details, see REMOVAL OF THE L.H. LOWER COVER) and remove the
swivel pin (5).
6 - Disconnect the return tube (6) and delivery tube (7) to
heating fan.
H Plug the tubes to prevent entry of impurities.
6
RKPA4311
7 - Loosen screws (8) (No. 2), remove cover (9) and remove the complete fan (10).
H Accompany the tubes (6) and (7) to avoid to damage them.
H Take care not to take out completely the tube (6)
and (7) from engine box.
10
8 - Disconnect the connector (11).
RKPA2820
9 - Loosen the clips (12) and take out the tubes (6) and
(7).
11
13
10 - Remove the heating fan (13).
6
7
12
RKPA2830
PC35R-8 PC45R-8
30-23
HEATING FAN
INSTALLATION OF THE HEATING FAN

.
1 - Make sure that the heating cock is fully open.

2 - Fill up the coolant circuit.
3 - Start the engine to circulate the coolant and check
that there are no leaks.
4 - Stop the engine and top up the level.
30-24
PC35R-8 PC45R-8
COUNTERWEIGHT
REMOVAL OF THE COUNTERWEIGHT

1 - Remove the lateral counterweight (1) and (2).
R.H. counterweight: 45 kg
L.H. counterweight: 32 kg
RKPA4293
2 - Remove the hood fastener (3).
RKPA4371
3 - Loosen the counterweight screws (4) to eliminate the

tightening torque.
4 - Attach the counterweight (5) to some hoisting tackle,
remove the screws, and pull out the counterweight
(5).
INSTALLATION OF THE
COUNTERWEIGHT
.
4
5
RKPA4400

Lateral counterweight screws:. . . . . . . . . . . . . Nm
Counterweight screws: . . . . . . . . . . . . . . . . . . . . . . .
Counterweight screws: . . . . . . . . . . . . . . . . . . . . Nm
PC35R-8 PC45R-8
30-25
FUEL TANK
REMOVAL OF FUEL TANK

H Drain the fuel.
Fuel: max. 51.5 ,

1 - Remove R.H. lateral counterweight (1) and R.H. lateral cover (2).
R.H. counterweight: 45 kg
RKPA4291
2 - Remove the panel (3).

3 - Remove the hood (4).
(For detail, see LATERAL LOWER COVER).
RKPA4410
4 - Disconnect from the fuel tank the tubes (5) and (6).
H Mark the tubes to avoid exchanging them during
re-assembly.
RKPA4420
5 - Loosen nuts (7) and remove the fuel tank (8).

H Disconnect the fuel level connector (9).
RKPA4430
30-26
PC35R-8 PC45R-8
FUEL TANK
INSTALLATION OF THE FUEL TANK

.

Nut: 5.9w0.49 Nm
H Tighten before external nut (10) and then nut (11).
10
11
1 - Fill up the tank.

Tank: max. 51.5 ,
2 - Bleed the air from the fuel pipes and start the engine.
PC35R-8 PC45R-8
RKPA4440
30-27
HYDRAULIC TANK
REMOVAL OF THE HYDRAULIC TANK

H Drain out the hydraulic oil.
2
3
Hydraulic oil: 33 ,
1 - Remove the engine hood (1) and the L.H. lateral
counterweight (2).
(For details, see the single removal)
2 - Only for cab version.
Remove the cab. (For details, see REMOVAL OF
CAB).
RKPA4450

4 - Remove the exhaust tubes (4) and (5).
RKPA4460
5 - Remove the exhaust tube (6) and the intake tube (7).
7
RKPA4990
6 - Attach the tank (8) to some hoisting tackle, remove

the screws (9) and take out the tank (8).
Hydraulic tank: 40 kg
RKPA4470
30-28
PC35R-8 PC45R-8
HYDRAULIC TANK
INSTALLATION OF THE HYDRAULIC TANK

.
1 - Fill the hydraulic oil tank to maximum level.

Hydraulic oil needed: approx. 33 ,
PC35R-8 PC45R-8
30-29
ENGINE-PUMP GROUP
REMOVAL OF THE ENGINE-PUMP GROUP

Hydraulic oil: approx. 33 ,

H Drain the coolant.
H Drain the fuel.
RKPA4294
Fuel: max. 51.5 ,

1 - Remove the engine hood (1).
(For detail, see REMOVAL OF ENGINE HOOD).
2 - Remove the rear counterweight (2) and (3). (For detail, see REMOVAL OF COUNTERWEIGHT).
3 - Remove the R.H. hood (5) and the panel (4).
RKPA4411
4 - Disconnect the tubes (6) and (7) from the fuel tank.
re-assembly.
5 - Disconnect the fuel level connector (8).
RKPA4480
6 - Remove the cab or the canopy.


8 - Loosen the screws (10) and remove the fixed hood
support (11).
10
11
10
RKPA5000
30-30
PC35R-8 PC45R-8
ENGINE-PUMP GROUP
9 - Remove the oil cooler - radiator group (12).

(Fro details, see REMOVAL OF OIL COOLER - RADIATOR GROUP).
12
10 - Only for cab version

Disconnect the tubes (13).
13
RKPA4302
11 - Attach the fixed hood (14) to some hoisting tackle.

12 - Remove the screws (15).
Loosen the screws (no. 5) and remove the fixed hood
with fuel tank.
H Check that the fixed hood completely free while it
is being raised, and that no other parts are damaged.
15
14
Fixed hood: 60 kg
RKPA5010
13 - Remove the hydraulic tank (16).

(For detail, see REMOVAL OF HYDRAULIC TANK).
14 - Remove the brackets (17).
16
17
17
RKPA4461
15 - Disconnect the delivery tubes (19), the Load Sensing

tube (20) and (21) from the pump (18).
18
21
19
PC35R-8 PC45R-8
20
19
RKPA5020
30-31
ENGINE-PUMP GROUP
15 - Disconnect the fuel delivery tube (22) and fuel return

tube (23).
16 - Disconnect the control accelerator cable.
23
22
18 - Disconnect the support (25) and move away it from

the engine.
RKPA5030
19 - Disconnect the pre-heater wiring (26), the engine stop

connector (27) and the oil pressure connector (28).
27
20 - Disconnect the ground (29).
26
24
29
28
25
RKPA5040
21 - Disconnect the water temperature connectors (30).

22 - Disconnect the alternator connector (31) and starting
motor connector (32).
30
31
32
RKPA5050
23 - Attach the engine hoisting hook to some hoisting

tackle and apply a slight tension to the cable.
24 - Take out the nuts (33) and the four washers, raise the
engine slowly and lift it out.
H Check that the motor swings completely free while it is being raised, and that no other parts are damaged.
33
Engine -pump group: PC35R: 210 kg

PC45R: 260 kg
RKPA4850
30-32
PC35R-8 PC45R-8
ENGINE-PUMP GROUP
INSTALLATION OF THE ENGINE-PUMP GROUP

.
H Adjust the accelerator stroke. (For details, see 20.

Vibration-damping nuts:. . . . . . . . . . . . . . . . . . . Nm
1 - Fill the tank with hydraulic oil up to the maximum level.
While filling the tank, bleed air from the pump.
2 - Fill the cooling circuit up to its maximum level.
2 - Fill the fuel tank and bleed air from the circuit.
Fuel: max. 51.5 ,
4 - Start the engine to circulate the oil and coolant and
check that there are no leaks.
5 - Stop the engine, check the levels and, if necessary,
top them up.
6 - Bleed air from the hydraulic circuits and pressurise
PC35R-8 PC45R-8
30-33
PUMP
REMOVAL OF THE PUMP

Lower the working equipment until it is resting on the
ground and stop the engine.
1 - Remove the hydraulic oil tank. (For detail, see REMOVAL OF HYDRAULIC TANK).
6
3
4
2 - Disconnect the delivery tubes (1) and (2) and the

Load Sensing tube (3) and (4) from the pump.
3 - Attach the pump to some hoisting tackle and apply a
slight tension to the cable.
RKP06881
6 - Loosen the screws (5) (no. 2) and remove the pump

(6).
Pump: 30 kg
INSTALLATION OF THE PUMP

.

Pump screws: Loctite . . . . . . . . . . . . . . . . . . . . . . . .
Pump screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
6
RKPA4102
1 - Lubricate the shaft.

Shaft: ASL800040
2 - Fill the hydraulic oil tank to maximum level.
Bleed the air from the pump. (For details, see 20.
3 - Start the engine to circulate the oil and check that
there are no leaks.
4 - Stop the engine, check the oil level and, if necessary,
top it up.
30-34
PC35R-8 PC45R-8
REMOVAL OF ENGINE-PUMP COUPLING

ground and stop the engine.
1 - Remove the pump. (For details, see REMOVAL OF
THE PUMP).
2 - Remove the flywheel cover (1). (8 screws).

3 - Take out the screws (2) and remove the coupling (3).
RKPA4490
INSTALLATION OF THE
.
2
3
Flywheel cover screws: Loctite . . . . . . . . . . . . . . .

Flywheel cover screws: . . . . . . . . . . . . . . . . . . . Nm
Coupling screws: Loctite . . . . . . . . . . . . . . . . . . . . .
Coupling screws: . . . . . . . . . . . . . . . . . . . . . . . . . Nm
RKPA4500
1 - Fill the tank up to its maximum level.

Bleed the air from the pump. (For details, see 20.
there are no leaks.
top it up.
4 - Bleed the air from the hydraulic circuits and pressurise the tank. (For details, see 20. CONTROLS AND
ADJUSTMENTS).
PC35R-8 PC45R-8
30-35
CONTROL VALVE
REMOVAL OF THE CONTROL VALVE



1 - Remove control valve cover (1), lateral lower cover
(2).
RKPA4295
2 - Disconnect all the servo-control, function, delivery

and exhaust pipes (4) from control valve (3).
re-assembly.
3 - Disconnect the cylinder (6) from inner control valve
box cover (6).
3
4
RKPA4141
4 - Remove the floor mat (7) and the covers (8).
8
7
RKPA3061
5 - Disconnect the lever command cable from the cables

(9).
RKPA3962
30-36
PC35R-8 PC45R-8
CONTROL VALVE
6 - Disconnect the cables (10) and (11) from travel control lever, from boom swing control pedal and from
bracket.
11
10
RKPA4931
7 - Put a sling around the control valve group (13) and

connect it to some hoisting tackle.
8 - Take out the screws (12) and remove the control valve group complete with its support.
Accompany the command cable.
H Mark the cable to avoid exchanging them during
re-assembly.
Control valve group: 50 kg
12
RKPA5060
INSTALLATION OF THE
CONTROL VALVE
.

H Adjust the travel control lever, blade control lever
and boom swing control pedal stroke.
(For detail, see 20. CONTROLS AND ADJUSTMENTS).
PC35R-8 PC45R-8
30-37
LEFT-HAND PPC VALVE (ARM-BUCKET)
REMOVAL OF LEFT-HAND PPC VALVE (ARM-BUCKET)

ground, stop the engine and remove the ignition key.
1
2
Release all residual pressures from all circuits and

from the tank. (For details, see 20. CONTROLS
AND ADJUSTMENTS).
1 - Take off the arm-rest (1).

2 - Disconnect cap (2).
H Take great care not to damage the frame (3).
3
5
RKPA3090
3 - Take out the screws (4) and remove the L.H. cover
(5).
4 - Remove the hose-clamp (6), remove the screws (7)

and remove the PPC valve (8).
RKPA4860
5 - Disconnect the six PPC valve tubes (9) and plug them
to prevent entry of impurities.
H Check that the tubes are marked to avoid exchanging them during re-assembly.
8
9
INSTALLATION OF LEFT-HAND
PPC VALVE (ARM-BUCKET)
.
RKPA3110
H Check carefully the positions for re-connecting

the tubes.
Position
P
P1
P2
P3
P4
White
S
White
M
Green
A
Green
C
Blue
L
Blue
R
If the couplings are removed from the PPC valves,

make sure that the coupling with a filter is mounted
on input P.
30-38
P2
P4
P3
P1
RKPA3120
PC35R-8 PC45R-8
RIGHT-HAND PPC VALVE (BOOM-BUCKET)
REMOVAL OF RIGHT-HAND PPC VALVE (BOOM-BUCKET)

ground, stop the engine and remove the ignition key.

AND ADJUSTMENTS).

2 - Disconnect cap (2).
3 - Take out the screws (4) e overturn the cover toward
engine hood.
3
RKPA3130
4 - Disconnect the horn connector (5).
RKPA3140
5 - Take out the screws (6) and remove the PPC valve
(7).
6 - Disconnect the six PPC valve tubes (7) and plug them
to prevent entry of impurities.
H Check that the tubes are marked to avoid exchanging them during re-assembly.
INSTALLATION OF RIGHT-HAND
PPC VALVE (BOOM-BUCKET)
.
RKPA3150
H Check carefully the positions for re-connecting

the tubes.
Position
P
P1
P2
P3
P4
White
M
White
S
Red
D
Red
S
Yellow
C
Yellow
A
P2
P4
If the couplings are removed from the PPC valves,
make sure that the coupling with a filter is mounted
on input P.
PC35R-8 PC45R-8
P3
P1
RKPA3160
30-39
REMOVAL OF THE SERVOCONTROL SOLENOID GROUP

ground, and stop the engine.
AND ADJUSTMENTS).
1 - Remove the L.H. side lower panels (1).
(For details, see REMOVAL OF THE SIDE LOWER
PANELS).
RKPA4451

H Mark the connectors to avoid exchanging them
during re-assembly.
3 - Disconnect in sequence:
- the travel increment control pipe (3);
- the union (4);
- the solenoid valve pipe (5);
- the union (6).
4 - Take out the screws (7) and remove the solenoid
group (8) complete with accumulator.
5
6
RKPA4720
INSTALLATION OF THE
.
30-40
PC35R-8 PC45R-8
PLATFORM
REMOVAL OF THE PLATFORM

AND ADJUSTMENTS).
1 - Remove the canopy or the cab.
(For details, see the removal of the each component).
RKPA4451
2 - Remove the R.H. lateral cover (1), the lateral lower

covers (2).
3 - Disconnect the servo-controls tubes (3) (No. 10).

re-assembly.
H Plug the tubes and raccords to prevent entry of
impurities.
RKPA5070
4 - Disconnect (4) and (5) from EV solenoid valve (6).
6
RKPA4721
5 - Disconnect the delivery and exhaust tubes (8) from

attachment PPC valve (7).
6 - Disconnect the connectors (9) travel increment pedal
control.
9
7
RKPA5080
PC35R-8 PC45R-8
30-41
PLATFORM
7 - Disconnect the cables (10) and (11) of travel command.
11
10
RKPA5090
8 - Disconnect the cables (12) and (13) of accelerator

and blade command.
13
12
RKPA4730
15
10 - Disconnect cup (15).

14
18
11 - Take out the screws (17) overturn the cover (18) toward engine hood.
17
16
RKPA3132
12- Disconnect the connectors (19) and ground cables

(20).
19
20
RKPA4870
30-42
PC35R-8 PC45R-8
PLATFORM
13 - Only for cabin version.

H Drain the coolant.
14 - Disconnect the return and delivery pipes (21) to the
heating fan.
15 - Only for canopy version. Loosen the screws (22)
and remove the cover (23).
21
16 - Attach the platform (24) to some hoisting tackle and

apply a slight tension to the cables.
RKPA4303
17 - Loosen lock platform screws (25) and remove it.

H Accompany the tubes and wiring harness to avoid
damaging them.
H Check that the platform completely free while it is
being raised and that no other parts are damaged.
23
22
Platform: 40 kg
RKPA4880
24
25
RKPA5100
PC35R-8 PC45R-8
30-43
PLATFORM
INSTALLATION OF THE PLATFORM

.
H Fill the tank with hydraulic oil up to the maximum level.

Only for cabin version.
H Fill the tank with coolant.
H Make sure that the fan cock is fully open.
1 - Start the engine to circulate the oil and coolant and
check that there are no leaks.
top it up.
4 - Bleed the air from the hydraulic circuits and pressurise the tank. (For details, see 20. CONTROLS AND
ADJUSTMENTS).
H Adjust the travel control lever and boom swing control
pedal stroke (For details, see 20. CONTROLS AND
ADJUSTMENTS).
H Adjust accelerator control lever and blade control
lever stroke (For details, see 20. CONTROLS
AND ADJUSTMENTS).
Platform screws: . . . . . . . . . . . . . . . . . . . . . . . . . Nm
30-44
PC35R-8 PC45R-8
SWIVEL JOINT
REMOVAL OF THE SWIVEL JOINT


AND ADJUSTMENTS).
1 - Remove the floor-mat (1) and the cover (2).
RKPA3061
2 - Disconnect the upper tubes (3) (No. 8).

re-assembly.
3 - Remove the stopper (4).
RKPA4740
4 - Remove the protective cover (5) from the lower trackframe.
RKPA4750
5 - Disconnect the tubes (6) from the swivel joint (7).

re-assembly.
6 - Loosen the screws (8) and remove the swivel joint (7).
6
8
RKPA4760
PC35R-8 PC45R-8
30-45
SWIVEL JOINT
INSTALLATION OF SWIVEL JOINT

H Make sure that the swivel joint is correctly positioned
and that the rotor pin is engaged properly in the pin.
Bracket screws: . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
1 - Start the engine to circulate the oil, bleed air from the
lower circuits and check that tubes are leaktight.
2 - Stop the engine and check the level of the tank.
3 - Pressurise the tank.
30-46
PC35R-8 PC45R-8
SWING MACHINERY
REMOVAL OF SWING MACHINERY

insert the locked swing, lower the working equipment
until it is resting on the ground, and stop the engine.
AND ADJUSTMENTS).
2
1

1 - Remove the canopy or the cab. (For details, see the
removal of the each component).
2 - Remove the floor-mat (1) and the covers (2).
RKPA3061
3 - Disconnect the delivery pipe (3), the exhaust pipe (4)

and the drainage pipe (5).
re-assembly.
4 - Take out the screws (6) (No. 8) and remove the swing
machinery (7).
Swing machinery: 37 kg
INSTALLATION OF SWING
MACHINERY
.
3
4
7
5
RKPA4770

Swing machinery screws: 130 Nm
Swing machinery screws: Loctite 262
there are no leaks.
3 - Stop the engine, check the oil hydraulic level and, if
necessary, top it up.
PC35R-8 PC45R-8
30-47
REVOLVING FRAME
REMOVAL OF REVOLVING FRAME

Fully extend the arm and open completely the bucket, lower the equipment until it rests on the ground;
stop the engine.

AND ADJUSTMENTS).
H Drain the hydraulic oil and the fuel.

Fuel: max. 51.5 ,
1 - Remove the work equipment.
(For details, see REMOVAL OF THE WORK EQUIPMENT).
RKPA4741
2 - Removal the boom cylinder. (For details, see REMOVAL OF BOOM CYLINDER).
3 - Remove the cab or the canopy.
4 - Remove the rear counterweight. (For details, see
REMOVAL OF THE REAR COUNTERWEIGHT).
5 - Remove the swing machinery. (For details, see REMOVAL OF SWING MACHINERY).
6 - Disconnect the upper tubes (1) (No. 8) from the swivel
joint.
re-assembly.
5
4
RKPA5110
7 - Remove the bracket (2) of the joint.

8 - Disconnect the swing circle lubrication tube (3) and
remove the coupling (4).
9 - Loosen and remove the screws that secure the revolving frame.
H Leave two opposite screws in position for safety.
10 - Attach the revolving frame (5) to some hoisting tackle
and apply a slight tension to the cables.
H Adjust the length of the cables to balance the
group.
11 - Loosen and remove the two turret screws left in position for safety.
RKP07180
12 - Remove the revolving frame (5).

Revolving frame: PC35R: 1500 kg
PC45R: 1550 kg
30-48
PC35R-8 PC45R-8
REVOLVING FRAME
INSTALLATION OF REVOLVING FRAME

.

Turret screws: Loctite 262
Turret screws: 130 Nm
H Take great care not to damage the reference pins and

the swivel joint.
Swing circle lubrication: ASL800050
1- Refill the hydraulic oil tank.
2 - Refill the fuel tank.
Fuel tank: max. 51.5 ,
3 - Start the engine to circulate the oil and check that tubes are leaktight.
H Only for cab version.
Make sure that the heating cock is fully open.
4 - Bleed air from the hydraulic circuits. (For details, see
5 - Stop the engine, check the levels and cooling circuit
and eventually top them up.
6 - Pressurise the hydraulic oil tank. (For details, see
PC35R-8 PC45R-8
30-49
SWING CIRCLE
REMOVAL OF THE SWING CIRCLE

1 - Remove the evolving frame (For details, see REMOVAL OF THE REVOLVING FRAME).
2 - Take out the screws (1) that secure the swing circle
(2).
3 - Remove the swing circle (2).

Swing circle: PC35R: 35 kg
PC45R: 55 kg
2
RKPA4890
INSTALLATION OF THE
SWING CIRCLE
.
H Before attaching the swing circle, check that the area

marked with an S is placed to the right of the frame.
Screws: Loctite 262
Screws: 130 Nm
Swing circle: ASL800050
30-50
PC35R-8 PC45R-8
RUBBER TRACK SHOES
REMOVAL OF RUBBER TRACK SHOES

1 - Rotate the turret by 90 to the side of the track-shoe
to be removed and rest the back of the bucket on the
ground with the arm perpendicular to the ground.
2 - Slowly loosen the grease nipple (1) to let out the grease and release the tension of the track-shoe (2).
The grease contained in the idler cylinder is under

pressure and could seriously injure the Operator.
For this reason the valve should never be loosened
by more than one turn.
H If the grease does not run out easily, move the
machine slowly backwards and forwards.
RKPA4001
3 - Force the boom downwards to raise the machine.

4 - Insert three steel pipes into the track-shoe and then
reverse the track-shoe until the first pipe is above
the idler.
5 - Push the track-shoe (2) outwards and remove it.
Track-shoe: PC35R: 160 kg
PC45R: 240 kg
Direction
Steel tube
RKP05171
INSTALLATION OF RUBBER
TRACK-SHOES
.

H Adjust the track-shoe tension. (For details, see
PC35R-8 PC45R-8
30-51
STEEL TRACK-SHOES
REMOVAL OF STEEL TRACK-SHOES

1 - Rotate the track-shoe until the connecting pin (1) is
above the horizontal axis of the idler (2).
2 - Slowly loosen the grease nipple to let out the grease

and release the tension of the track-shoe.
The grease contained in the idler cylinder is under
pressure and could seriously injure the Operator.
For this reason the valve should never be loosened
by more than one turn.
H If the grease does not run out easily, move the
machine slowly backwards and forwards.
3 - Using the tool A1, remove the connecting pin (1).

H First remove the safety cotter-pin.
H While dismantling the track-shoe, support the part
of the track-shoe that is wound round the idler
with a block placed under the shoe-ribbing. Once
the track shoe has been unfastened, lay it on the
ground.
4 - Keeping the horizontal end-piece of the track-shoe
raised, move the machine in order to remove the
track-shoe (3) and lay it on the ground.
5 - Push down with the boom in order to raise the lower
track-frame and pull out the track-shoe (3).
Track-shoe: PC35R: 180 kg
PC45R: 294 kg
RKPA4900
2
3
RKP06650
INSTALLATION OF
STEEL TRACK-SHOES
.

H Adjust the track-shoe tension. (For details, see
1 - Rotate the turret 90 towards the side on which the

track-shoe is to be installed. Push down with the
boom to raise the lower track-frame.
2 - Arrange the track-shoe on the ground beneath the
bottom rollers. Lower the track-frame.
3 - Attach the first articulated joint of the sprocket wheel
and move the machine forwards until the articulated
joint is close to the sprocket wheel.
4 - Keeping the track-shoe raised, travel in order to bring
the end-piece above the idler.
5 - Install the connecting-pin using the tool A1.
6 - Install the safety cotter pin.
30-52
PC35R-8 PC45R-8
SPROCKET WHEEL
REMOVAL OF THE SPROCKET WHEEL

1 - Remove the track-shoe. (For details, see REMOVAL
OF TRACK-SHOES).
2 - Rotate the turret 90 away from the side of the wheel
to be removed.
3 - Push down with the boom perpendicular to the
ground and raise the lower track-frame.
BLOCK
Insert safety blocks underneath the track-frame.

4 - Take out the screws (1) and their washers.
5 - Remove the sprocket wheel (2).
RKP05241
Sprocket wheel: PC35R: 6 kg

PC45R: 13 kg
INSTALLATION OF THE
SPROCKET WHEEL
.

Screws: Loctite 262
Screws: PC35R: 120 Nm
PC45R: 190 Nm
PC35R-8 PC45R-8
RKPA4780
30-53
FINAL DRIVE
REMOVAL OF THE FINAL DRIVE

1 - Remove the sprocket wheel. (For details, see REMOVAL OF THE SPROCKET WHEEL).
2 - Remove the protective cover (1).
3 - Disconnect the tubes (2) from the travel motor. Plug
the tubes and the motor fittings to prevent entry of impurities.
4 - Take out the screws (3).
5 - Remove the final drive (3).

Complete final drive: PC35R: 40 kg
PC45R: 61 kg
RKPA4790
INSTALLATION OF THE
FINAL DRIVE
.
Final drive screws: Loctite 262

Final drive screws: PC35R: 120 Nm
PC45R: 190 Nm
1 - Start the engine and bleed air from the travel motors.
30-54
RKPA4800
PC35R-8 PC45R-8
IDLER AND RECOIL SPRING
REMOVAL OF IDLER AND RECOIL SPRING

1 - Remove the track-shoe (For details, see REMOVAL
OF RUBBER TRACK-SHOES or REMOVAL OF
STEEL TRACK-SHOES).
2 - Pull the idler (2) and recoil spring (3) out of the lower
track-frame (1).
1
RKPA4910
3
RKPA4920
INSTALLATION OF IDLER AND

RECOIL SPRING
.
H Restore tension to the track-shoe. (For details, see

PC35R-8 PC45R-8
30-55
SPRING RECOIL AND THRUST CYLINDER GROUPS
DISASSEMBLY OF THE SPRING RECOIL AND

THRUST CYLINDER GROUPS
1 - Remove valve (2) and piston (3) from thrust cylinder
group (1).
1
RKPA4810
2 - Using tool B1 press spring (4). Loosen screw (6) and

nut (5).
H Installed load of spring:
Model
Rubber shoe
Steel shoe
PC35R
3151 kg
2008 kg
PC45R
4326 kg
2748 kg
B1
4
8
3 - Release the spring (4) slowly.
RKP06890
4 - Remove the stopper (7) and spring (4) from cylinder

(8).
H Free length of spring: PC35R: 275 mm
PC45R: 302 mm
7
4
8
RKP06900
5 - Remove the ring (9), the spacer (10), the gasket (11),
the ring (12) and the O-ring (13).
8
13
11
9
12
10
RKP06910
30-56
PC35R-8 PC45R-8
ASSEMBLY OF THE SPRING RECOIL AND

THRUST CYLINDER GROUPS
1. Cylinder
.
8
13
11
9
12
10
RKP06910
2. Recoil spring
1 - Mount the spring (4) and stopper (7) on the cylinder.
4
8
RKP06900
2 - Using tool B1, set recoil spring (4) to press.

Put the tool B1 and the cylinder (8) correctly under the press.
3 - Press the spring (4) slowly until reaching the size "A".
H Size "A":
Model
Rubber shoe
Steel shoe
PC35R
188.1 mm
213.1 mm
PC45R
202.2 mm
238.2 mm
H Installed load of spring:

Model
Rubber shoe
Steel shoe
PC35R
3151 kg
2008 kg
PC45R
4326 kg
2748 kg
F
B1
6
4
8
H The hole "a" shows the correct position for steel shoe
version; the hole "b" shows the correct position for
rubber shoe version.
RKP06920
PC35R-8 PC45R-8
30-57
H After assembling the recoil spring, check that the outof-parallel between surface "c" of the cylinder (8) and
surface "d" of stopper (7) is less than 0.5 mm.
d
RKP06940
3. Piston
1 - Tighten valve (2) completely and then turn back it approx. 2 turns.
2 - Add approx. 120 cc of grease inside the cylinder.

Grease: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - Assemble cylinder (8) and push in until grease comes
out from grease hole "e".
4 - Tighten valve (2).
H Check that the grease fitting is facing the outside
of the chassis.
30-58
RKP06930
PC35R-8 PC45R-8
IDLER
DISASSEMBLY OF THE IDLER

1 - Remove cover (1) and bracket (2).
2 - Loosen screws (3) and remove support (4) and shaft
(5).
4
1
2
5
3
RKP06950
3 - Remove O-ring (6) from shaft (5).

4 - Remove floating seal (7) from supports (4).
RKP06960
5 - Remove floating seals (9) from idler (8).
9
8
RKP06970
6 - Remove bushings (10) from idler (8).
10
8
RKP06980
PC35R-8 PC45R-8
30-59
IDLER
ASSEMBLY OF THE IDLER

1 - Using tool D1, insert bushings (10) in the idler (8).
D1
10
8
RKP07000
2 - Using tool D2, insert the floating seals (9) in the idler
(8).
H Wash and remove all grease and oil from the floating seals and their contact surface, then dry the
parts.
H Coat the sliding surface of the oil seal with engine
oil and be careful not to let any dirt or dust stick to
it.
D2
RKP07010
3 - Using tool D2, insert the floating seals (7) in supports

(4).
H Wash and remove all grease and oil from the floating seals and their contact surface, then dry the
parts.
H Coat the sliding surface of the oil seal with engine
oil and be careful not to let any dirt or dust stick to
it.
D2
6
4 - Mount O-rings (6) on shaft (5).
RKP06990
5 - Mount shaft (5) in support (4) and tighten screw (3).

Screw: Loctite 242
6 - Insert support (4) in the idler (8).
7 - Fill inside idler (89 with engine oil.
Idler: approx. 70 cc
8 - Mount 2nd support (4) e tighten screw (3).
Screw: Loctite 242
9 - Mount bracket (2).
Screw: 110.5w12.5 Nm
Screw: Loctite 242
10 - Mount cover (1).
30-60
4
1
2
5
3
RKP06950
PC35R-8 PC45R-8
TRACK ROLLERS
REMOVAL OF THE TRACK ROLLERS

1 - Slowly loosen the grease nipple (1) to let out the grease and release tension in the track-shoe.
The grease contained in the cylinder is under

pressure and could seriously injure the Operator. For this reason, the valve should not be loosened for more than one turn.
H If the grease does not come out easily, move
the machine slowly backwards and forwards.
2
2 - Rotate the turret 90 towards the removal side and
force the boom down to raise the lower track-frame
(2).
RKPA4820
3 - Loosen the screws (3) and remove the rollers (4).
INSTALLATION OF THE
TRACK ROLLERS
.
4
RKPA4830
H With the lower track-frame (2) raised, install the

idler rollers (4), and slightly tighten the screws (3).
H Slowly lower the lower track-frame (2) until the rollers (4) rest fully on the track-shoe, then finish
tightening the screws (3).
Roller screws: Loctite 262
Roller screws: PC35R 190 Nm
PC45R 270 Nm
H Restore the track-shoe tension. (For details, see
PC35R-8 PC45R-8
30-61
BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

Fully extend the arm and open the bucket completely. Lower the equipment until it rests on the ground.
1 - Remove the pin (1).
RKPA4610
2 - Lower the cylinder (2) until it rests on a stand A.

3 - Start the engine to retract the piston (3).
H Bind the piston rod with wire to secure the fully retracted position.
4 - Stop the engine and release the residual hydraulic

pressures. (For details, see 20. CONTROLS AND
ADJUSTMENTS).
5 - Disconnect the tubes (4) and plug them. Also plug the
holes in the cylinder to prevent entry of impurities.
RKPA4621
7 - Remove the cylinder (2).

Boom cylinder: PC35R: 30 kg
PC45R: 40.5 kg
2
5
RKPA4840
30-62
PC35R-8 PC45R-8
BOOM CYLINDER
INSTALLATION OF THE BOOM CYLINDER

.
3
H Adjust the shim thickness so that the clearance between cylinder (3) and swing bracket (6) is below 1
mm.
When aligning the positions between the hole and

the pin, turn the engine over at low idling.
Do not insert fingers in the holes to check alignment.
MAX. 1 mm
RKP07020
H Adjust the shim thickness so that the clearance between cylinder (3) and boom (7) is below 1 mm.
3
7
Internal bushings: ASL800050

1 - Start the engine and bleed the air from the cylinder.
H After bleeding the air, check the level of oil in the
tank.
MAX. 1 mm
RKP07030
PC35R-8 PC45R-8
30-63
ARM CYLINDER
REMOVAL OF THE ARM CYLINDER

Lower the working equipment to the ground with all
safety devices engaged. Rest the back of the bucket
on the ground with the arm in a vertical position.
2
1
1 - Stop the engine and release the pressures from the

cylinder by moving the left-hand PPC valve lever several times.
2 - Place a block A beneath the cylinder (1).
4 - Start the engine and retract the piston rod (3).
H Bind the piston rod with wire to secure the fully retracted position of the piston.
RKPA4510
5 - Stop the engine and release any residual hydraulic

ADJUSTMENTS).
holes in the cylinder to prevent the entry of impurities.

Arm cylinder: PC35R: 28 kg
PC45R: 37 kg
RKPA4520
INSTALLATION OF THE
ARM CYLINDER
.

H Adjust the shim thickness so that the clearance between cylinder and arm is below 1 mm.
MAX. 1 mm
RKP07040

.
Start the engine and bleed the air from the cylinder.
H After bleeding the air, check the oil level in the
tank.
MAX. 1 mm
RKP07050
30-64
PC35R-8 PC45R-8
BUCKET CYLINDER
REMOVAL OF THE BUCKET CYLINDER

Completely open the front equipment. Make the necessary movements to rest the bucket teeth on the
ground with the arm supported on a block A.
1 - Stop the engine and release the pressures from the

cylinder (1) by moving the right-hand PPC valve lever
several times.
A
RKPA4530
2 - Place a block B beneath the cylinder (1) and remove the pin (2).
3 - Start the engine and retract the piston rod (3).
4 - Stop the engine and release any residual hydraulic
ADJUSTMENTS).
5 - Disconnect the hoses (4) and plug them. Also plug
the holes in the cylinder to prevent the entry of impurities.
B
3
5
4
A
RKPA4540
6 - Put a sling round the cylinder (1).

Bucket cylinder: PC35R: 20 kg
PC45R: 31 kg
INSTALLATION OF THE
BUCKET CYLINDER
.
MAX. 1 mm

the pin, do not insert fingers in the holes to check
alignment.
RKP07060
H Adjust the shim thickness so that the clearance between cylinder and bucket link and between arm and
bucket link is below 1 mm.
.
tank.
PC35R-8 PC45R-8
MAX. 1 mm
RKP07070
30-65
BOOM SWING CYLINDER
REMOVAL OF THE BOOM SWING CYLINDER

Swing the work equipment approx. 45 to the left
and extend completely the boom swing cylinder. Lower the working equipment to the ground with all safety devices engaged. Rest the back of the bucket on
the ground with the arm in a vertical position.
1 - Stop the engine and move the command pedal boom
swing cylinder several times to release residual pressures.
2 - Remove the pin (1) and disengage the piston rod (2)
from swing support (3).
3 - Start the engine and retract the piston rod (4) completely.
RKPA4550
4 - Stop the engine and move the command pedal boom

swing cylinder several times to release residual pressures. (For details, see 20. CONTROLS AND ADJUSTMENTS).
RKPA4560
5 - Remove the fuel tank (4).

(For details, see REMOVAL OF FUEL TANK).
6 - Remove accumulator (5).
H Disconnect first the negative terminal () and then
the positive terminal (+).
RKPA4570
7 - Disconnect the hoses (6) and (7) plug them. Also plug
the holes in the cylinder to prevent the entry of impurities.
RKPA4580
30-66
PC35R-8 PC45R-8
BOOM SWING CYLINDER
8 - Disconnect the tube (8).

9 - Loosen the screws (9) and remove the plate (10).
8
9
10 - Put a sling round the cylinder (11) and apply a slight

tension to the cables.
11 - Take out the pin (12) and remove the cylinder (11).
12
10
Boom swing cylinder: PC35R: 28 kg

PC45R: 40 kg
11
RKPA4121
INSTALLATION OF THE
BOOM SWING CYLINDER
.
MAX. 1 mm
H Adjust the shim thickness so that the clearance between cylinder and swing bracket is below 1 mm.
RKP07080
H Adjust the shim thickness so that the clearance

between cylinder and revolving frame is below 1
mm.
MAX. 1 mm
1 - Start the engine and bleed the air from the cylinder.
RKP07090
PC35R-8 PC45R-8
30-67
BLADE CYLINDER
REMOVAL OF THE BLADE CYLINDER

safety devices engaged. Rest the back of the bucket
on the ground with the arm in a vertical position.
1 - Remove the protection (1).

H Place a supporting block A beneath the cylinder.
2 - Stop the engine, release the pressures in the cylinder
(2) by moving the command lever several times in
both directions.
RKPA4590

ADJUSTMENTS).
2
4
holes in the cylinder to prevent entry of impurities.

RKPA4600
Blade cylinder: PC35R 20 kg

PC45R 24 kg
INSTALLATION OF THE
BLADE CYLINDER
.

tank.
30-68
PC35R-8 PC45R-8
DISASSEMBLY OF THE WORK EQUIPMENT CYLINDERS

1 - Take off the guard rings (1) from both sides of the cylinder and from the piston rod.
H Make sure that the tube unions are not plugged.
1
RKP05230
2 - Place the cylinder (2) on the apparatus C1. Engage

the cylinder in the tools C4, having the same bushing
diameter.
C4
2
C1
RKPA1392
3 - Attach the special wrench C5 (adjusted to fit the cylinder) to the head (3) and apply the dynamometric tool
C2.
C5
C2
RKPA1400
4 - Unscrew the head (3) and extract it completely from

the cylinder (2).
2
RKPA1410
PC35R-8 PC45R-8
30-69
5 - Raise the cylinder and hook the piston rod to the mobile group of the tool C1.
6 - Extract the piston rod group (4) from the cylinder.
7 - Remove the cylinder (2) and the piston rod group.
C1
2
RKPA1420
8 - Lock the complete piston rod (4) onto the apparatus

C1.
9 - Attach the socket wrench C6 to the lock nut (5) of the

piston (6) and, using the dynamometric tool with a
multiplier C2, remove the nut.
H Socket wrench measurement:
Unita di misura: mm
Cylinder
Boom
Arm
Bucket
Boom
swing
Blade
PC35R
46
50
46
46
50
PC45R
55
55
50
55
55
Model
C6
C2
RKPA1430
10 - Take all the groups to pieces and remove all the

seals, guard rings and guide rings.
The seals, guard rings, and guide rings cannot
be used again.
30-70
PC35R-8 PC45R-8
ASSEMBLY OF THE WORK EQUIPMENT CYLINDERS

H Take great care not to damage the seal and the sliding surfaces.
H Prepare each individual component before commencing the final assembly.
1. Assembly of the cylinder head
C7
1 - Position the guard ring (7) and, using a press and the
push rod C7, press it home in the head (3).
H Check the orientation carefully.
3
RKPA1440
2 - Mount the snap ring (8).
3 - Using the tool C3, mount the lip-seal (9).

H Check that the lips face into the cylinder.
C3
9
RKPA1450
4 - Mount the O-ring (10), the anti-extrusion ring (11) and

the O-ring (12) onto the cylinder head (3).
H Only for the boom cylinders.
In sequence mount the anti-extrusion ring (17),
the O-ring (18) and the 2nd anti-extrusion ring
(17).
10
11 12
17 18 17
8
7
9
RKZ05260
PC35R-8 PC45R-8
30-71
2. Piston assembly
1 - Using the tool C8, mount the piston seal. Mount in sequence the rubber ring (13), the outer seal (14) and
the anti-extrusion rings (15).
C8
13 14 15
RKPA1460
2 - Mount the guide ring (16).
3 - Calibrate the diameter of the gasket (14) of the piston

(6), mounting the group beneath the press and using
the calibrating ring C9 adapted to fit the piston diameter.
15 14 15 16
C9
13
RKPA1470
3. Piston rod group assembly

1 - Using a press and the tool C4 adapted to the diameter, insert the bushing (17) into the piston rod (4).
17
2 - Insert the support A beneath the piston rod.
C4
A
RKPA1480
3 - Mount the pilot boss C10 adapted to the diameter onto the extremity of the piston rod.
4 - Slide the head (3) onto the piston rod (4).
C10
5 - Remove the pilot boss C10 from the extremity of the

piston rod.
RKPA1490
30-72
PC35R-8 PC45R-8
6 - For the boom cylinders.

Mount the brake bushing (19).
H Carefully check the orientation of the chamfer on
the brake bushing.
19
Bevel
Smusso
RKP07140
7 - Mount the complete piston (6).
RKPA1500
8 - Mount the nut (5) that secures the piston and tighten
it with the socket wrench C6 and the dynamometric
tool with a multiplier C2.
Nut: Loctite 262
Nut:
Unita di misura: mm
Cylinder
Model
Boom
Arm
Bucket
Boom
swing
Blade
C6
C2
PC35R 1520w152 2060w206 1520w152 1520w152 2060w206

PC45R 2845w285 2845w285 2060w206 2845w285 2845w285
RKPA1431
4. Cylinder assembly
1 - Mount the tools C4 onto the apparatus C1.
2 - Position the bushing (20) and mount it onto the cylinder (2).
H Leave the cylinder in position, ready for the next
assembly operation.
C4
2
C1
20
RKPA1393
PC35R-8 PC45R-8
30-73
3 - Lubricate the threading and the first part of the cylinder (2).
Cylinder: ASL800050
C11
4 - Mount the two halves of the tool C11, adapted to the

diameter, onto the mouthpiece of the cylinder (2).
RKPA1510
5 - Mount the piston rod group (4) onto the tool C1 and
raise the mobile part up to the end of its stroke.
6 - Put the cylinder (2) into a vertical position and guide
the piston into the tool C11.
7 - Lower the apparatus supporting the piston rod (4) in

order to insert the piston into the cylinder liner (2).
8 - Remove the tool C11 from the cylinder and then lower
the apparatus C1 even further, until the head (3) and
the piston rod approach the cylinder.
C1
C11
9 - Place the cylinder (2) in position for screwing in the

head (3).
10 - Insert the head into the cylinder and screw it in by
hand for a few turns.
RKPA1421
11 - Attach the special wrench C5 to the dynamometric

tool C2 and screw the head (3) fully home.
Head:
Unita di misura: mm
Cylinder
Boom
Arm
Bucket
Boom
swing
Blade
PC35R
588w59
677w68
490w49
637w64
677w68
PC45R
677w68
863w86
677w68
735w74
942w94
Model
12 - Mount the guard rings (1) on both sides of the cylinder and the piston rod.
30-74
C5
2
C2
RKPA1401
PC35R-8 PC45R-8
REMOVAL OF THE UPPER WORK EQUIPMENT

Fully extend the arm and open the bucket completely. Lower the equipment until it rests on the ground.
battery.
1 - Stop the engine, release the pressures in the cylinder

by moving the PPC valve lever several times.
3 - Lower the cylinder (2) until it rests on a stand A.
RKPA4610

ADJUSTMENTS).
A
RKPA4620
6 - Disconnect the hoses (4) (No. 10); plug the tubes to

H Disconnect the connector (5) and remove the fixed working beam clips (6).
6
4
RKPA4630
7 - Put a sling around the work equipment (7) and apply

a slight tension to the cables.
load.
RKPA4640
PC35R-8 PC45R-8
30-75
8 - Take away the pin (8). Remove the working equipment (7).
H Check and make a note of the position of the
shim.
Working equipment: PC35R: 320 kg

PC45R: 450 kg
RKPA4650
INSTALLATION OF THE UPPER

WORK EQUIPMENT
.
H Adjust the shim thickness so that the clearance between cylinder and boom is below 1 mm.
MAX. 1 mm
RKP07100
H Adjust the shim thickness so that the clearance between boom and swivel joint is below 0.5 mm.
. Start the engine to circulate the oil and bleed the air
from the cylinder.
H After bleeding the air, stop the engine and check
the oil level in the tank.
MAX. 0,5 mm
RKP07110
30-76
PC35R-8 PC45R-8
BUCKET
REMOVAL OF THE BUCKET

Position the bucket on the ground on a flat surface,
and resting on its back.
1 - Take out the safety pin (1) and remove the connecting
pin (2) between the bucket (3) and the tie-rods (4).
7
4
6
2
5
2 - Take out the safety pin (5) and remove the pin (6) that
connects the bucket (3) to the arm (7).
3 - Remove the bucket (3).

RKPA4660
Bucket: PC35R: 68 kg
PC45R: 105 kg
INSTALLATION OF THE BUCKET

.

3
H Insert O-ring (8) on both sides between the bucket (3)
and the arm (7).
H Check size "A".
If the size is below of limit size, replace O-rings.
Standard size
Limit size
85 mm
83.5 mm
Size A
RKPA4670
RKP07120
PC35R-8 PC45R-8
30-77
ARM
REMOVAL OF THE ARM

1 - Remove the bucket. (For details, see REMOVAL OF
THE BUCKET).
2 - Remove the pin (1) and completely retract the piston

rod (2).
3 - Put the arm (2) into a vertical position and rest the
boom on a block.
RKPA4680
4 - Disconnect the R.H. and L.H. brackets (3).

5 - Disconnect the tubes (4) of bucket cylinder command
(5).
H Plug the tubes and the holes on the cylinder to
4
3
6 - Put a sling round the cylinder (5).
7 - Remove the cylinder (5) completely of levels.

(For details, see REMOVAL OF THE BUCKET CYLINDER).
Complete cylinder: PC35R: 55 kg
PC45R: 65 kg
RKPA4690
8 - Position a block A beneath the arm cylinder command (6).

9 - Remove the pin (7) completely retract the piston rod
(8).
A
RKPA4700
10 - Put a sling round the arm (9) and apply a slight tension to the cables.
10
11 - Remove the pin (10) and take out the arm (9).
Arm: PC35R: 69 kg
PC45R: 95 kg
Long arm: PC35R: 88 kg
PC45R: 119 kg
RKPA4710
30-78
PC35R-8 PC45R-8
ARM
INSTALLATION OF THE ARM

.
H Insert shims between link and arm.

alignment.
H Insert shims on base sides of the piston rod.
H Insert the shims on both sides of the piston rod.
H Adjust the shim thickness so that the clearance between arm and boom is below 1 mm.
alignment.
.
Start the engine to circulate the oil and bleed the air
from the cylinder.
PC35R-8 PC45R-8
RKP07130
30-79
ARM ASSEMBLY
REMOVAL OF THE ARM ASSEMBLY

safety devices engaged with the arm in a vertical position and the bucket curled.
1 - Stop the engine and release the pressures from bucket cylinder and from optional working equipment circuit.
2 - Attach a block a beneath the cylinder (1) and remove the pin (2).
3 - Start the engine and retract the piston (3).
ADJUSTMENTS).
5 - Disconnect the tubes (4) of bucket cylinder command.
H Plug the tube and the holes on the cylinder to prevent entry of impurities.
RKPA3750
6 - Disconnect the delivery and exhaust equipment tubes (5).

7 - Remove the pin (6) and take out the arm complete (7).
A
5
Arm complete: PC35R: 185 kg

PC45R: 270 kg
RKPA3572
INSTALLATION OF THE
ARM ASSEMBLY
.

RKPA3760
H Insert the shims on both sides of the arm.

alignment.
.
from the cylinder.
30-80
PC35R-8 PC45R-8
BOOM
REMOVAL OF THE BOOM

battery.
1 - Remove the arm assembly. (For details, see REMOVAL OF THE ARM ASSEMBLY).
1
2
2 - Remove the arm cylinder. (For details, see REMOVAL OF THE ARM CYLINDER).
3 - Remove the working beam (1).
H Remove the wiring harness lock clips.
4 - Stop the engine, and rest the boom (2) on a block A.
RKPA3511
5 - Stop the engine and move the PPC valve several times to release pressures in the cylinder.
6 - Place a stand B beneath the cylinder (3).
7 - Remove the pin (4) and rest the cylinder on a stand.
2
8 - Start the engine and completely retract the piston rod
(5).
ADJUSTMENTS).
B
A
10 - Put a sling round the boom (2) and apply a slight tension to the cables.
RKPA3770
11 - Disconnect the hoses (6) (No. 10); plug the tubes to

12 - Remove the pin (7) and remove the boom (2).
Boom: PC35R: 135 kg
PC45R: 180 kg
4
5
RKPA3522
6
7
RKPA3780
PC35R-8 PC45R-8
30-81
BOOM
INSTALLATION OF THE BOOM

.

H Insert the shims on both sides of the arm.
alignment.
.
from the cylinder.
30-82
PC35R-8 PC45R-8
BOOM SWING SUPPORT
REMOVAL OF THE BOOM SWING SUPPORT

Extend the working equipment completely and rest it
on the ground.
1 - Remove the front working equipment. (For details,
see REMOVAL OF THE UPPER WORKING EQUIPMENT).
2 - Remove the boom cylinder. (For details, see REMOVAL OF THE BOOM CYLINDER).
3 - Disconnect the boom swing cylinder from swing support (4). (For details, see REMOVAL OF THE BOOM
SWING CYLINDER).
RKPA3790
4 - Remove the protection (2).

5 - Disconnect the bracket (3) from the boom swing support.
6 - Attach the boom swing support (4) to some hoisting

tackle and apply a slight tension to the cable.
7 - Take out the bracket (5), remove the pin (6) and remove the boom swing support (4).
H Make a note of the position and the quantity of
shims (7).
Boom swing support: PC35R: 70 kg

PC45R: 93 kg
RKPA3830
INSTALLATION OF THE BOOM

SWING SUPPORT
.
5
4

alignment.
Pins: ASL800050
H Adjust the shim thickness so that the clearance between swing bracket (4) and frame (8) is below 0.5 mm.
Supporting surfaces and shims: ASL800050
RKPA3820
6
8
MAX.0,5mm
RKP06351
PC35R-8 PC45R-8
30-83
BLADE
REMOVAL OF THE BLADE

1 - Rotate the turret 90 and rest the working equipment
on the ground.
2 - Disconnect the cylinder from the blade. (For details,
see REMOVAL OF THE BLADE CYLINDER).
3 - Attach the blade to some hoisting tackle, using the lateral holes provided (1) and the cylinder attachment
(2).
group.
4 - Take out the pin (3).
5 - Remove the blade (4).
RKPA3800
Blade: PC35R: 154 kg

PC45R: 235 kg
INSTALLATION OF THE BLADE

.

RKPA3810

30-84
PC35R-8 PC45R-8
GROUP
40
STANDARD MAINTENANCE
Swing circle . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3
Final drive . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
Sprocket . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5
Idler .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6
Steel shoe . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7
Carrier roller. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Track roller . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Rubber shoe . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Track frame . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
PC35R-8 PC45R-8
Hydraulic pump . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
Control valve. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
Swivel joint. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
Swing motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
PPC Valve . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
PPC Valve (hammer). .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
Cylinder . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
Work equipment . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .
14
15
21
22
24
28
29
30
32
40-1
SWING CIRCLE
130 Nm
with Loctite 262
130 Nm
with Loctite 262
RKP02730
Unit: mm
No.
1
40-2
Check item
Axial bearing clearance
Criteria
Remedy
Standard clearance
Clearance limit
0.2 0.3
1.5
Replace
PC35R-8 PC45R-8
SWING MACHINERY
1
42 Nm
25 Nm
2
3
4
750 850 Nm
6
20 30 Nm
130 Nm
with Loctite 262
ASL800050
RKP02650
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.10
0.30
Backlash between
No. 1 planetary gear and
No. 1 gear ring
0.15
0.35
Backlash between
No. 2 sun gear and
0.10
0.30
Backlash between
No. 2 planetary gear and
No. 2 gear ring
0.15
0.35
Size of pinion in the zone

of contact with the sealing ring
Standard size
Repair limit
50 0.020
49.750
0.05 0.10
+0.010
Backlash between
No. 1 sun gear and
Preload bearings
PC35R-8 PC45R-8
Replace
Repair or
replace
40-3
FINAL DRIVE
PC35R: 120 Nm
PC45R: 190 Nm
with Loctite 262
3
4
25 Nm
RKP02660
Unit: mm
No.
Check item
Backlash between No. 2

planetary gear and housing
Criteria
Remedy
Standard clearance
Clearance limit
PC35R
0.15
0.35
PC45R
0.18
0.40
PC35R
0.15
0.35
PC45R
0.18
0.40
Backlash between No. 1

planetary gear and housing
Backlash between
No. 2 sun gear and
PC35R
0.10
0.30
PC45R
0.12
0.35
Backlash between
No. 1 sun gear and
PC35R
0.10
0.30
PC45R
0.12
0.35
Backlash between
No. 1 sun gear and disc
PC35R
0.5 1.5
2.5
PC45R
0.5 1.5
2.5
40-4
Replace
PC35R-8 PC45R-8
SPROCKET
4
3
PC35R: 120 Nm
PC45R: 190 Nm
with Loctite 262
2 1
RKP02670
Unit: mm
No.
Check item
Wear at roots of
sprocket teeth
Wear at tips of
sprocket teeth
Face width at tips of

sprocket teeth
Face width at base

of sprocket teeth
PC35R-8 PC45R-8
Criteria
Remedy
Standard size
Tolerance
Repair limit
PC35R
344.3
+1
2
332
PC45R
380.37
+1
2
368
PC35R
386.2
w1.5
374
PC45R
423.99
+0
3
412
PC35R
20
18
PC45R
26
24
PC35R
27
+0.5
1
24
PC45R
33
+0.5
1
30
Build up by
solder or
replace
40-5
IDLER
4
3 5
7
2 1
RKP02480
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
PC35R
338w1
330
PC45R
373w1
365
Outer diameter
of tread
PC35R
300w1
292
PC45R
335w1
327
Width of track
shoe guide
PC35R
28
20
PC45R
37
29
Total width
PC35R
64
59
PC45R
75
70
Width of tread
PC35R
18
22
PC45R
19
23
Clearance between
shaft and support
PC35R
0.25
1.0
PC45R
0.25
1.0
Thickness of metal on PC35R

idler tread
(centre of tread width) PC45R
8.6
4.6
10.3
6.3
Outer diameter of
track shoe guide
Standard size
8
40-6
Clearance between
idler shaft and
bushing
Tolerance
Shaft
Hole
Build up by
welding or
replace
Standard Clearance Replace

clearance
limit
PC35R
35
0.025
0.064
+0.142
+0.080
0.105
0.206
1.5
PC45R
35
0.025
0.064
+0.142
+0.080
0.105
0.206
1.5
PC35R-8 PC45R-8
STEEL SHOE
PC35R
3
6
8
RKP03800
Unit: mm
No.
Check item
Criteria
Standard size
Link pitch
Grouser height
Link height
Interference between
regular pin and link
Repair limit
Rotate pin
or replace
101.6
Outer diameter
of bushing
Remedy
104
Replace
30
Rotate
bushing or
replace
28
Replace
16.5
8.5
61
Build up by
welding or
replace
32
Standard
size
Tolerance
Standard Interference
interference
limit
Shaft
Hole
32
+0.22
+0.12
0
+0.05
0.07
0.22
pin and link
19
+0.15
+0.12
0
+0.05
0.07
0.15
master pin and link
19
0.02
0.07
0
+0.05
0.02
0.12
Clearance between
link joint faces
PC35R-8 PC45R-8
Standard size
Clearance limit
0.6
1.2
Replace
40-7
PC45R
1
4
3
116w1 Nm
2
RKP02461
Unit: mm
No.
Check item
Criteria
Standard size
Link pitch
Outer diameter
of bushing
Remedy
Repair limit
135
35.05
137.3
Rotate pin
or replace
139.3
Replace
33.05
Rotate
bushing or
replace
31.05
Replace
Grouser height
18
Link height
65
60
regular pin and link
Standard
size
Tolerance
Shaft
35.05 (Shaft)
35.00 (Hole)
0.1
Hole
Build up by
welding or
replace
Standard Interference
interference
limit
0.09
0.15
0.09
0.16
pin and link
22.53 (Shaft)
22.00 (Hole)
+0.04
0.04
+0.352
+0.3
0.13
0.27
master pin and link
22.53 (Shaft)
22.00 (Hole)
0.03
0.07
+0.352
+0.3
0.078
0.17
Clearance between
link joint faces
40-8
Standard size
Clearance limit
0.6
1.2
Replace
PC35R-8 PC45R-8
CARRIER ROLLER
2
270 Nm
RKP02471
Unit: mm
No.
Check item
Outer diameter of tread
Width of tread
Axial play of roller
PC35R-8 PC45R-8
Criteria
Remedy
Standard size
Repair limit
70
60
100
Standard tolerance
Clearance limit
0 0.5
1.0
Replace
Replace
40-9
TRACK ROLLER
5
2 1
PC35R: 190 Nm
PC45R: 270 Nm
with Loctite 262
RKP02521
Unit: mm
No.
Check item
Outer diameter
of thread
Outer diameter
of protusion
Width of thread
Width of protusion
Criteria
Standard size
Repair limit
PC35R
112
106
PC45R
123
117
PC35R
85
77
PC45R
95
87
PC35R
34
37
PC45R
34.5
37.5
PC35R
26
20
PC45R
41
35
Standard size
5
Clearance between
shaft and bushing
Interference
between
roller and bushing
Axial play of roller
Thickness of metal on
idler tread
40-10
Remedy
Tolerance
Shaft
Hole
Build up by
welding or
replace
Standard Clearance
clearance
limit
PC35R
25
0
0.013
+0.183
+0.144
0.144
0.196
1.5
PC45R
35
0.025
0.054
+0.142
+0.080
0.105
0.192
1.5
PC35R
32
0.073
0.048
+0.030
+0
0.018
0.073
PC45R
42
0.079
0.054
+0.030
+0
0.024
0.079
Standard size
Clearance limit
PC35R
0.20
0.74
PC45R
0.25
0.81
Standard size
Repair limit
26.5
22.5
Replace
Replace
Replace
bushing
Build up or
replace
PC35R-8 PC45R-8
RUBBER SHOE
A
A
2
3
1
Section A
A-AA
Sezione
RKP02500
Unit: mm
No.
Check item
Wear of lug height
Wear of roller guard

portion
Wear of meshing
portion of sprocket
PC35R-8 PC45R-8
Criteria
Remedy
Standard size
Repair limit
PC35R
25
PC45R
25
PC35R
71
63
PC45R
85
67
Replace
Standard size
Tolerance
Repair limit
PC35R
25
w0.5
29
PC45R
25
w0.5
29
40-11
TRACK FRAME
Rubber shoe
RKP06670
Unit: mm
No.
Check item
Criteria
Item
Deformation of frame
Repair limit
Curvature
5 (for length of 1000 mm)
Twisting
Opening of idler
Vertical width of
idler guide
Horizontal width of
idler guide
Standard size
Repair limit
Track
frame
96
100
Idler
support
94
90
Build up by
welding or
replace
Track
frame
161
165
Build up by
welding
Idler
support
159
155
Build up by
welding or
replace
Standard size
4
Build up by
welding
Repair limit
Free
length
Preloaded
length
Installed
load
Free
length
Installed
load
PC35R
257
188.1
3151 kg
251.5
2899 kg
PC45R
302
202.2
4326 kg
294.0
3980 kg
Recoil spring
40-12
Correct
Item
2
Remedy
Replace
PC35R-8 PC45R-8
Steel shoe
RKP02740
Unit: mm
No.
Check item
Criteria
Item
Deformation of frame
Repair limit
Curvature
Twisting
Opening of idler
Vertical width of
idler guide
Horizontal width of
idler guide
Standard size
Repair limit
Track
frame
96
100
Idler
support
94
90
Build up by
welding or
replace
Track
frame
161
165
Build up by
welding
Idler
support
159
155
Build up by
welding or
replace
Standard size
4
PC35R-8 PC45R-8
Build up by
welding
Repair limit
Free
length
Preloaded
length
Installed
load
Free
length
Installed
load
PC35R
257
213.1
2008 kg
252.2
1787 kg
PC45R
238.2
238.2
3748 kg
295.0
2446 kg
Recoil spring
Correct
Item
2
Remedy
Replace
40-13
HYDRAULIC PUMP
17.2w2.45 Nm
(1.75w0.25 kgm)
24.5w4.9 Nm
(2.5w0.5 kgm)
30.9w3.43 Nm
(3.15w0.35 kgm)
23.5w3.92 Nm
(2.4w0.4 kgm)
68.6w9.81 Nm
(7.0w1.0 kgm)
Vista ZZ
View
40-14
RKP02081
PC35R-8 PC45R-8
CONTROL VALVE
9.8 12.7 Nm
(1 1.3 kgm)
9.8 12.7 Nm
(1 1.3 kgm)
9.8 12.7 Nm
(1 1.3 kgm)
C
29.4 34.3 Nm
(3 3.5 kgm)
9.8 12.7 Nm
(1 1.3 kgm)
View
Vista ZZ
A
9.8 12.7 Nm
(1 1.3 kgm)
B
C
RKP02351
PC35R-8 PC45R-8
40-15
39.2 49 Nm
(4 5 kgm)
39.2 49 Nm
(4 5 kgm)
SezioneAA-AA
Section
40-16
RKP02700
PC35R-8 PC45R-8
1
2
3
1
1
2
2
6.9 9.8 Nm
(0.7 1.0 kgm)
1
39.2 49 Nm
(4 5 kgm)
Sezione
Section
B BB- B
RKP02690
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Spool return spring

(boom, arm, bucket,
swing, hammer)
Free length
x .D.
Repair limit
Installed
length
Installed
load
Free
length
Installed
load
28.5
22.6N
(2.3 kg)
18.1 N
(1.8 kg)
29x17.5
2
Spool return spring

(blade, travel)
46.2x20
25.4
98 N
(10 kg)
78.4 N
(8.0 kg)
Spool return spring

(boom swing)
42x20
25.4
74.5 N
(7.6 kg)
59.6 N
(6.1 kg)
PC35R-8 PC45R-8
When
damage or
deformation
is found,
replace the
spring
40-17
1.3 1.7 Nm
(0.13 0.17 kgm)
47 58.8 Nm
(4.8 60 kgm)
2
117.6 161.8 Nm
(12 16.5 kgm)
117.6 161.8 Nm
(12 16.5 kgm)
4
117.6 161.8 Nm
(12 16.5 kgm)
Section
C
Sezione C
C - C
RKP02710
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Pressure compensation
valve spring
Repair limit
Free length
x .D.
Installed
length
Installed
load
Free
length
Installed
load
20x8.4
12
6.86N
(0.7 kg)
5.49 N
(0.56 kg)
154.6 N
(15.8 kg)
Unload valve spring
28.57x19.2
15
193.2 N
(19.7 kg)
Cooler check valve spring
27.2x13.2
21
78.8 N
(8.04 kg)
63 N
(6.43 kg)
Self-pressure reducing
valve sequence
valve spring
40.5x41.3
35.5
88.2 N
(9.0 kg)
70.6 N
(7.2 kg)
Spool return spring

(hammer)
29x17.5
28.5
22.6 N
(2.3 kg)
18.1 N
(1.8 kg)
40-18
When
damage or
deformation
is found,
replace the
spring
PC35R-8 PC45R-8
117.6 161.8 Nm
(12 16.5 kgm)
137 157 Nm
(14 16 kgm)
49 58.8 Nm
(5 6 kgm)
SezioneEE-EE
Section
2
1
19.6 24.5 Nm
(2 2.5 kgm)
Section
SezioneFF-FF
Section
H
Sezione H
H - H
RKP02680
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Check valve spring
Check valve spring
PC35R-8 PC45R-8
Repair limit
Free length
x .D.
Installed
length
Installed
load
Free
length
Installed
load
21.9x5
15.8
1.96N
(0.2 kg)
1.57 N
(0.16 kg)
13.7x7.6
9.8
13.83 N
(1.41 kg)
11.1 N
(1.13 kg)
When
damage or
deformation
is found,
replace the
spring
40-19
19.6 24.5 Nm
(2 2.5 kgm)
Sezione K
K - K
Section
K
Section
Sezione JJ -JJ
19.6 24.5 Nm
(2 2.5 kgm)
39.2 49 Nm
(4 5 kgm)
19.6 24.5 Nm
(2 2.5 kgm)
2
34.3 44.1 Nm
(3.5 4.5 kgm)
Section
SezioneN
N- N
N
Sezione
Section LL-LL
RKP02720
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Check valve spring

(Bucket, boom,
swing, hammer)
Check valve spring

(Blade)
40-20
Repair limit
Free length
x .D.
Installed
length
Installed
load
Free
length
Installed
load
21.9x5
15.8
1.96N
(0.2 kg)
1.57 N
(0.16 kg)
13.97x6.5
11.8
19.7 N
(2.01 kg)
15.8 N
(1.61 kg)
When
damage or
deformation
is found,
replace the
spring
PC35R-8 PC45R-8
SWIVEL JOINT
RKP02490
Unit: mm
No.
1
Check item
Clearance between
rotor and stator
PC35R-8 PC45R-8
Criteria
Standard size
60
Standard clearance
Remedy
Clearance limit
Replace
40-21
SWING MOTOR
39w2 Nm
177w10 Nm
3
2
157w10 Nm
8.8w1 Nm
Sezione A
Section
A -AA
RKP06700
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
Clearance between shoe

and piston
Clearance between piston

and cylinder
40-22
Remedy
Repair limit
Free length
x .D.
Installed
length
Installed
load
Free
length
Installed
load
30.1
15.7
2.3 N
25.5
1.6 N
Standard clearance
Clearance limit
0.03 0.15
0.4
0.01 0.02
0.4
When
damage or
deformation
is found,
replace
Replace
PC35R-8 PC45R-8
PC35R-8 PC45R-8
40-23
TRAVEL MOTOR
PC35R
63.7w4.9 Nm
1
A
3
B
34.5w5 Nm
B
A
240w5 Nm
31.9w2.5 Nm
2.5w0.5 Nm
2.5w0.5 Nm
10w1 Nm
Section
A -AA
Sezione A
40-24
RKP02601
PC35R-8 PC45R-8
53.7w5 Nm
53.7w5 Nm
Sezione
SectionBB- BB
RKP02622
Unit: mm
No.
1
2
Check item
Clearance between
piston and cylinder
Criteria
Standard clearance
Clearance limit
0.01 0.02
0.4
0.03 0.15
0.4
Clearance between
shoe and piston
Standard size
3
Travel increment
piston spring
Braking valve return spring
Travel increment
spool return spring
PC35R-8 PC45R-8
Remedy
Replace
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
23
15.6
7.8 N
21.5
6.2 N
32.8
24.7
113 N
31.2
90 N
36
29.5
68 N
34.7
54 N
When
damage or
deformation
is found,
replace the
spring
40-25
PC45R
2
1
A
3
B
34.5w5 Nm
B
A
63.7w4.9 Nm
240w5 Nm
31.9w2.5 Nm
2.5w0.5 Nm
10w1 Nm
Section A A
40-26
2.5w0.5 Nm
RKP06691
PC35R-8 PC45R-8
53.7w5 Nm
53.7w5 Nm
Section
B
Sezione B
B - B
6
RKP02623
Unit: mm
No.
Check item
Clearance between
piston and cylinder
Clearance between
shoe and piston
Criteria
Standard clearance
Clearance limit
0.01 0.02
0.4
0.03 0.15
0.4
Standard size
3
Travel increment
piston spring
Remedy
Replace
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
23
15.6
7.8 N
21.5
6.2 N
32.8
24.7
113 N
31.2
90 N
Braking valve return spring
Brake spring
23
20
205 N
22.4
164 N
Travel increment
spool return spring
36
29.5
68 N
34.7
54 N
PC35R-8 PC45R-8
When
damage or
deformation
is found,
replace the
spring
40-27
PPC VALVE
FOR BOOM, ARM, BUCKET, SWING
112.8w14.7 Nm
(11.5w1.6 kgm)
13.2w1.5 Nm
(1.35w0.15 kgm)
1
44.1w4.9 Nm
(4.5w0.5 kgm)
Section
B -BB
Sezione B
Section
A
Sezione A
A
-A
8.33w2.45 Nm
(0.85w0.25 kgm)
2
SezioneDD- D
D
Section
6.37w2.45 Nm
(0.65w0.25 kgm)
Section
C
Sezione C
C - C
Sezione EE- E
E
Section
RKP01330
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Centering spring
(P3 and P4 port)
Repair limit
Free length
x .D.
Installed
length
Installed
load
Free
length
Installed
load
38.7x15.5
34
9.8 N
(1.0 kg)
7.8 N
(0.8 kg)
Centering spring
(P1 and P2 port)
42.5x15.5
34
17.7 N
(1.8 kg)
14.1 N
(1.44 kg)
Metering spring
26.5x9.2
24.9
16.7 N
(1.7 kg)
13.7 N
(1.4 kg)
40-28
When
damage or
deformation
is found,
replace the
spring
PC35R-8 PC45R-8
PPC VALVE
FOR HAMMER
13.23w1.47 Nm
(1.35w0.15 kgm)
RKP01710
Unit: mm
No.
Check item
Criteria
Standard size
Centering spring
Metering spring
PC35R-8 PC45R-8
Remedy
Repair limit
Free length
x .D.
Installed
length
Installed
load
Free
length
Installed
load
54.4x21.2
40.5
308.7 N
(31.5 kg)
53.1
277.5 N
(28.3 kg)
25.9x11.0
25.0
24.5 N
(2.5 kg)
25.8
21.6 N
(2.2 kg)
Replace
40-29
CYLINDERS
PC35R
Boom:
Arm:
Bucket:
Boom swing:
Blade:
588w59
677w68
490w49
637w64
677w68
Nm
Nm
Nm
Nm
Nm
Boom:
Arm:
Bucket:
Boom swing:
Blade:
1520w152
2060w206
1520w152
1520w152
2060w206
Nm
Nm
Nm
Nm
Nm
(Wrench
(Wrench
(Wrench
(Wrench
(Wrench
size:
size:
size:
size:
size:
46
50
46
46
50
mm)
mm)
mm)
mm)
mm)
RKP03830
Unit: mm
No.
Check item
Criteria
Cylinder
Clearance
between
piston rod and
cylinder head
Clearance
between
cylinder head
bushing and pin
Clearance
between
cylinder bottom
bushing and pin
40-30
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard
Limit
clearance clearance
Boom
45
0.025
0.087
+ 0.152
+ 0.007
0.032
0.239
0.551
Arm
45
0.025
0.087
+ 0.152
+ 0.007
0.032
0.239
0.539
Bucket
40
0.025
0.087
+ 0.132
+ 0.006
0.031
0.219
0.551
Boom swing
45
0.025
0.087
+ 0.152
+ 0.007
0.032
0.239
0.551
Blade
45
0.025
0.087
+ 0.152
+ 0.007
0.032
0.239
0.551
Boom
40
0.025
0.087
+ 0.142
+ 0.080
0.105
0.229
1.0
Arm
40
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0
Bucket
35
0.170
0.232
+ 0.142
+ 0.080
0.250
0.374
1.0
Boom swing
45
0.025
0.064
+ 0.128
+ 0.075
0.100
0.192
1.0
Blade
50
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0
Boom
45
0.025
0.064
+ 0.128
+ 0.075
0.100
0.192
1.0
Arm
40
0.025
0.087
+ 0.142
+ 0.080
0.105
0.229
1.0
Bucket
35
0.025
0.087
+ 0.142
+ 0.080
0.105
0.229
1.0
Boom swing
45
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0
Blade
50
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0
Replace
cylinder head
Replace
bushing
PC35R-8 PC45R-8
PC45R
Boom:
Arm:
Bucket:
Boom swing:
Blade:
677w68
863w86
677w68
735w74
942w94
Nm
Nm
Nm
Nm
Nm
Boom:
Arm:
Bucket:
Boom swing:
Blade:
2845w285
2845w285
2060w206
2845w285
2845w285
Nm
Nm
Nm
Nm
Nm
(Wrench
(Wrench
(Wrench
(Wrench
(Wrench
size:
size:
size:
size:
size:
55
55
50
55
55
mm)
mm)
mm)
mm)
mm)
RKP03830
Unit: mm
No.
Check item
Criteria
Cylinder
Clearance
between
piston rod and
cylinder head
Clearance
between
cylinder head
bushing and pin
Clearance
between
cylinder bottom
bushing and pin
PC35R-8 PC45R-8
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard
Limit
clearance clearance
Boom
50
0.025
0.087
+ 0.164
+ 0.007
0.032
0.239
0.551
Arm
45
0.025
0.087
+ 0.152
+ 0.007
0.032
0.239
0.539
Bucket
50
0.025
0.087
+ 0.164
+ 0.007
0.032
0.251
0.551
Boom swing
50
0.025
0.087
+ 0.164
+ 0.007
0.032
0.251
0.551
Blade
50
0.025
0.087
+ 0.164
+ 0.007
0.032
0.251
0.551
Boom
50
0.025
0.087
+ 0.142
+ 0.080
0.105
0.229
1.0
Arm
45
0.025
0.064
+ 0.128
+ 0.075
0.100
0.192
1.0
Bucket
45
0.180
0.242
+ 0.142
+ 0.080
0.260
0.384
1.0
Boom swing
50
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0
Blade
55
0.030
0.104
+ 0.124
+ 0.100
0.130
0.228
1.0
Boom
50
0.025
0.087
+ 0.142
+ 0.080
0.100
0.215
1.0
Arm
45
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0
Bucket
45
0.025
0.064
+ 0.128
+ 0.075
0.100
0.192
1.0
Boom swing
50
0.025
0.064
+ 0.142
+ 0.080
0.105
0.192
1.0
Blade
55
0.030
0.104
+ 0.174
+ 0.100
0.130
0.278
1.0
Replace
cylinder head
Replace
bushing
40-31
WORK EQUIPMENT
PC35R
H
C
I
D A
B
E
G
O
Q
L
RKP03840
M
1
Sezione B
B - B
Section
B
SezioneCC- C
C
Section
Sezione
Section AA-AA
Sezione
SectionDD-DD
Sezione EE- E
E
Section
Sezione FF - F
Section
F
Sezione
GG
SectionGG-
40-32
Sezione
Section HH-HH
Sezione
Section II-I I
RKP03810
PC35R-8 PC45R-8
6
4
Sezione J
Section
J -JJ
Sezione
Section LL-LL
Sezione K
Section
K -KK
Sezione N
Section
N -NN
SezioneM
M- M
M
Section
Sezione O
O - O
O
Section
Sezione Q
Section
Q -Q
Q
Sezione P
P - P
Section
P
RKP03820
Unit: mm
No.
Check item
Clearance between bushing

and mounting pin of boom
swing bracket and revolving
frame
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
100
0.036
0.090
+ 0.207
+ 0.120
0.156
0.297
1.0

swing bracket and boom
45
0.025
0.064
+ 0.128
+ 0.075
0.100
0.192
1.0

and mounting pin of arm
and boom
40
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0

and mounting pin of link and
arm
35
0.170
0.230
0.003
0.052
0.118
0.227
1.0

and mounting pin of bucket
and arm
35
0.170
0.230
0.003
0.052
0.118
0.227
1.0

link
35
0.170
0.230
0.003
0.052
0.118
0.227
1.0

and link
35
0.170
0.230
0.003
0.052
0.118
0.227
1.0

and mounting pin of track
frame and blade
35
0.025
0.087
+ 0.142
+ 0.080
0.105
0.229
1.0
PC35R-8 PC45R-8
Replace
40-33
PC45R
H
C
I
D A
B
E
G
O
Q
L
RKP03840
M
1
Sezione B
B - B
Section
B
SezioneCC- C
C
Section
Sezione
Section AA-AA
Sezione
SectionDD-DD
Sezione EE- E
E
Section
Sezione FF - F
Section
F
Sezione
GG
SectionGG-
40-34
Sezione
Section HH-HH
Sezione
Section II-I I
RKP03810
PC35R-8 PC45R-8
6
4
SezioneJJ-JJ
Section
SezioneLL- L
L
Section
SezioneKK-KK
Section
SezioneNN-NN
Section
Sezione
-M
Section
MM
M
SezioneOO -OO
Section
SezioneQQ-Q
Q
Section
SezionePP -PP
Section
RKP03820
Unit: mm
No.
Check item

swing bracket and revolving
frame
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+ 0.204
+ 0.128
0.164
0.294
1.0

swing bracket and boom
50
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0

and mounting pin of arm
and boom
50
0.025
0.064
+ 0.142
+ 0.080
0.105
0.206
1.0

arm
45
0.170
0.230
0.012
0.065
0.105
0.218
1.0

and arm
45
0.170
0.230
0.012
0.065
0.105
0.218
1.0

link
45
0.170
0.230
0.012
0.065
0.105
0.218
1.0

and link
45
0.170
0.230
0.012
0.065
0.105
0.218
1.0

and mounting pin of track
frame and blade
35
0.025
0.087
+ 0.142
+ 0.080
0.105
0.229
1.0
PC35R-8 PC45R-8
Replace
40-35
40-36
PC35R-8 PC45R-8

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CONTENTS

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

The affected pages are indicated by the use of the

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

PREPARATIONS FOR WORK

Mistakes in operation extremely dangerous.

1. Before carrying out any greasing or repairs, read

8. Before starting work, lower blade, bucket or any

2. When carrying out any operation, always wear

9. When disassembling or assembling, support the

PRECAUTIONS DURING WORK

13. Before starting work, remove the leads from the

24. Take sure when removing or installing tracks.

15. When removing covers which are under internal

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

In order to make the shop manual greatly chelpful,

DISTRIBUTION AND UPDATING

Special safety precautions are necessary when performing the

Item number (10. Structure

3. Additional pages: additional pages are indicated

Extra special safety precautions

Special technical precautions or

Weight of parts or systems.

Parts that require special attention

Parts to be coated with adhesives

Places where oil, water or fuel

Places where oil or water must be

REVISED EDITION MARK

Heavy parts (25 kg or more) must be lifted

ing, and a serious accident can result.

1. If a part cannot be smoothly removed from the

Allowable load (tons)

3) Do not sling a heavy load with one rope alone,

4) Do not sling a heavy load with ropes forming a

The allowable load value is estimated to be

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Width across flats

Used for sealing the union threads for hydraulic tubes.

Used for protecting battery electrode terminals from corrosion.

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

Warning light, light etc.

Working beam, solenoid valve,

Control panel, etc.

CLASSIFICATION BY COLOUR AND CODE

Light blue - Red

Light blue - Black