(Webm000300) Komatsu Pc35r-8

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
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table
below.
C Page to be newly Add
c Page to be replaced Replace
( ) Page to be delete Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGES
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
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10-26 10-67 20-28 30-10 30-51
PC35R-8 PC45R-8 00-2-1

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

13. Before starting work, remove the leads from the 24. Take sure when removing or installing tracks.
battery. Always remove the lead from the negative When removing the track, the track separates
( ± ) terminal first. suddenly, so never let anyone stand at either
end of the track.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, 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 ac-
curate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing 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 re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.
Symbol Item Remarks

DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will Special safety precautions are ne-
be sent to Komatsu Utility distributors. cessary when performing the
Get the most up-to-date information before you start work.
any work. Safety
Extra special safety precautions
are necessary when performing
the work because it is under inter-
FILING METHOD
nal pressure.
1. See the page number on the bottom of the page.
File the pages in correct order. Special technical precautions or
other precautions for preserving
2. Following examples show you how to read the Caution standards are necessary when
page number. performing the work.
Example Weight of parts or systems.

10 - 3 Caution necessary when selecting
Weight hoisting wire, or when working po-
sture is important, etc.
Item number (10. Structure
and function) Parts that require special attention
Tightening for the tightening torque during as-
torque
Consecutive page number for sembly.
each item
Parts to be coated with adhesives
Coat and lubricants etc.
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num- Places where oil, water or fuel
Oil, water must be added, and their quantity.
ber.
Fle as in the example.
Places where oil or water must be
Example:
Drain drained, and quantity to be drai-
10-4
ned.
10-4-1
10-4-2
] Added pages
10-5
REVISED EDITION MARK

(1 2 3 ....)
When a manual is revised, an edition mark is recor-
ded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVI-
SED PAGES between the title page and SAFETY pa-
ge.
00-6 PC35R-8 PC45R-8

HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
ing, and a serious accident can result.

Heavy parts (25 kg or more) must be lifted Hooks have maximum strength at the middle
with a hoist etc. In the Disassembly and As- portion.
sembly section, every part weighing 25 kg or
more is clearly indicated with the symbol
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. 3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
2. Wire ropes Slinging with one rope may cause turning of
1) Use adequate ropes depending on the weight the load during hoisting, untwisting of the ro-
of parts to be hoisted, referring to the table be- pe, or slipping of the rope from its original
low: winding position on the load, which can cau-
se dangerous accidents.
WIRE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
4) Do not sling a heavy load with ropes forming a
Rope diameter (mm) Allowable load (tons) wide hanging angle from the hook.
When hoisting a load with two or more ropes,
10 1.0 the force subjected to each rope will increase
with the hanging angles.
11.2 1.4 The table below shows the variation of allow-
able load (kg) when hoisting is made with two
12.5 1.6 ropes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
14 2.2 When two ropes sling a load vertically, up to
16 2.8 2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
18 3.6 make a 120ë hanging angle.
On the other hand, two ropes are subjected to
20 4.4 an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150ë.
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0
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 «Di-
sassembly and Assembly».
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Width across flat

Thread diameter Pitch of (mm)
of bolts bolts
(mm) (mm)
kgm Nm kgm Nm
6 1 10 5 0.96w0.1 9.5w1 1.3w0.15 13.5w1.5
8 1.25 13 6 2.3w0.2 23w2 3.2w0.3 32.2w3.5
10 1.5 17 8 4.6w0.5 45w4.9 6.5w0.6 63w6.5
12 1.75 19 10 7.8w0.8 77w8 11w1 108w11
14 2 22 12 12.5w1 122w13 17.5w2 172w18
16 2 24 14 19.5w2 191w21 27w3 268w29
18 2.5 27 14 27w3 262w28 37w4 366w36
20 2.5 30 17 38w4 372w40 53w6 524w57
22 2.5 32 17 52w6 511w57 73w8 719w80
24 3 36 19 66w7 644w70 92w10 905w98
27 3 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 4 55 27 230w25 2250w250 320w35 3150w350
39 4 60 Ð 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): 1 Nm = 0.102 kgm
00-8 PC35R-8 PC45R-8

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.
Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm
1/2" - 20 17 2.6w0.5 25.5w4.9

9/16" - 18 17 4w0.5 39.2w4.9
3/4" - 16 22 6.7w2 65.7w19.6
7/8" - 14 27 8w2 78.5w19.6
1.1/16" - 12 32 9.7w3 95.15w29.4
1.5/16" - 12 38 17w3 166.7w29.4
1.5/8" - 12 50 20w5 196.2w49
22 27 8w2 78.5w19.6
33 41 20w5 196.2w49
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Nomenclature Code Applications

Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270 bolts.
Adhesives
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573 dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601 only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675 and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself on mounting surface on the final drive and transmission cases.
Loctite 510 (Clearance between flange surfaces within 0.2 mm).
Gasket sealant
Used by itself on mounting flat surface
Loctite 518 (Clearance between surfaces within 0.5 mm)
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stick-
(Lubricant including ASL800040 ing, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease) ASL800050 facilitation of assembling work.
Vaseline ± Used for protecting battery electrode terminals from corrosion.
PC35R-8 PC45R-8 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
Copper wire
Nominal Cable O.D. Current rating
Number ù of strands Cross section Applicable circuit
number (mm) (A)
strands (mm) (mm2)
1 14 0.30 0.99 2.80 11 Warning light, light etc.
Working beam, solenoid valve,
1.5 21 0.30 1.48 3.35 14
etc.
2.5 35 0.30 2.47 3.80 20 Control panel, etc.
4 56 0.30 3.95 4.60 28 Pre-heating
6 84 0.30 5.93 5.20 37 Control panel
35 266 0.40 9.20 12.20 125 Battery - Ground
CLASSIFICATION BY COLOUR AND CODE

Primary Auxiliary
Code A A±R A/R A±V ± A±N ± ± ±
Colour Light blue Light blue - Red Light blue - Green Light blue - Black ±
Code B B±G ± B±N ± B±R ± ± ±
Colour White White ± Yellow White ± Black White ± Red ±
Code C C±N C/N C±L ± ± ± ± ±
Colour Orange Orange ± Black Orange ± Blue ± ±
Code G G±N ± ± G/R ± ± ± ±
Colour Yellow Yellow ± Black Yellow ± Red ± ±
Code H H±N ± H±L ± H±R ± H±G ±
Colour Gray Gray ± Black Gray ± Blue Gray Red Gray ± Yellow
Code L L±R ± L±N ± ± ± ± ±
Colour Blue Blue ± Red Blue ± Black ± ±
Code M M±V ± M±N ± M±B ± ± ±
Colour Brown Brown ± Green Brown ± Black Brown ± White ±
Code N ± ± ± ± ± ± ± ±
Colour Black ± ± ± ±
Code R R±V ± R±N ± R±G ± ± ±
Colour Red Red ± Green Red ± Black Red ± Yellow ±
Code S S±N ± S±G ± ± ± ± ±
Colour Pink Pink ± Black Pink ± Yellow ± ±
Code V V±N ± ± ± ± ± ± ±
Colour Green Green ± Black ± ± ±
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 155 175
. Power train 6 7
. Pump 22.5 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) 4 4
Hydraulic tank (without hydraulic oil) 40 40
Control valve 33 33
Rear counterweight 322 450
Lateral counterweight
. L.H. 32 46.2
. R.H. 32 32
Swing motor 30.5 30.5
Swivel joint 20 20
Track frame assembly 1200 1700
Track roller 4.5 6.6
Idler assy. 52 55
Final drive 40 61
Sprocket 6 13
Swing circle 35 55
Shoe
. Steel shoe 180 294
. Rubber shoe 160 240
Swing bracket 70 93
Boom 132 180
Arm
. Standard 69 95
. Long arm 88 119
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
CAPACITY ( < )
KIND OF AMBIENT TEMPERATURE
RESERVOIR Specified Refill
FLUID ±20 ±10 0 10 20 30ëC
PC35R PC45R PC35R PC45R
FKI 907 10W
FKI 907 20W-20

OIL
Crankcase sump 6.9 8 6.9 8
. API CD FKI 907 SAE 30
FKI 907 SAE 40
OIL FKI 907 10W

Hydraulic circuit 63 63 33 33
. API CD
Final drive OIL FKI 907 10W 1 1.3 1 1.3

(each) . API CD
Fuel ]
FUEL 51.5 51.5 Ð Ð
tank ASTM D975 N. 2
WATER+
6.8 7.5 Ð Ð
ANTI-FREEZE
Engine coolant
WATER 6.8 7.5 Ð Ð
system
PERMANENT
FKI 931 6.8 7.5 Ð Ð
LIQUID
] 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%, (2) When starting the engine is weathers temperature
change oil in the oil pan ebery periodic maintenan- below 0ëC, be sure to use engine oil SAE 10W,
ce hours described in operation and maintenance SAE 20W-20, even if weather temperature goes
manual. up to 10ëC day time.
Change oil according to the following table if fuel (3) Use classification CD as engine oil, if use classifi-
sulphur content is above 0.5%. cation CC, reduce the engine oil change interval to
half.
Oil change interval in engine oil
Fuel sulphur content (4) Use original products, which have characteristics
pan
specifically formulated and approved for the engi-
0.5 to 1.0% 1/2 of regular interval ne, the hydraulic circuit of equipment and for re-
ductions.
Above 1.0% 1/4 of regular interval
00-12 PC35R-8 PC45R-8

GROUP 10
STRUCTURE AND FUNCTION
P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2 Control valve. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 22

Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3 CLSS . . . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 30
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 Swivel joint. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 52
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5 Swing motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 54
Final drive . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6 Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Track frame. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7 Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 61
Recoil spring . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8 Accumulator . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 65
Carrier roller . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 PPC Valves (Work equipment) . .. . . . . .. . . . . .. . . . .. . . . 66
Track roller. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 PPC Valve (Hammer) .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 70
Steel shoe . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10 Solenoid valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 73
Hydraulic circuit diagram PC35R . .. . . . .. . . . . .. . . . .. . 11 Electrical diagram (1/3) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 75
Hydraulic circuit diagram PC45R . .. . . . .. . . . . .. . . . .. . 13 Electrical diagram (2/3) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 77
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14 Electrical diagram (3/3) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 79
PC35R-8 PC45R-8 10-1

P.T.O.
5 3
4
RKP02590
1. Joint
2. Spring pin
3. Dumper
4. Flywheel cover
5. Body
10-2 PC35R-8 PC45R-8

POWER TRAIN
1. Swing motor
2. Swing circle
3. Idler
4. Control valve
1
5. Swivel joint
6. Travel motor
7. Engine
8. Hydraulic pump
2 9. Servocontrol - travel speed
increment solenoid valve
3 1 4 6
5 9 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
1 2 3
5 3 2
SectionAA-±AA
Sezione Section
SezioneBB±-BB
RKP02640
1. Outer race
2. Ball bearing
3. Inner race
4. Seal
5. Seal
10-4 PC35R-8 PC45R-8

SWING MACHINERY
M The figure represent PC35R
7
5
8
4
9
3
10
2
1 11
12
13
14
RKP02540
1. Seal ring 10. No. 2 planetary gear

2. Oil drainage plug 11. Hub
3. No. 2 sun gear (Z=19) 12. Bearing
4. Crown (Z=62) 13. Bearing
5. Spacer 14. Pinion
6. No. 1 sun gear (PC35R Z=11 - PC45R Z=10)
(PC35R Z=28 - PC45R Z=25)
7. No. 1 reduction gear SPECIFICATIONS
8. No. 1 planetary gear Reduction ratio: PC35R: 1 ± 13.69
PC45R: 1 ± 14.83
9. No. 2 reduction gear
PC35R-8 PC45R-8 10-5

FINAL DRIVE
1 2 3
9 8 7 RKP02560
1. Crankcase SPECIFICATIONS
2. No. 2 reduction gear Reduction ratio: PC35R: 1 ± 37
3. No. 1 reduction gear PC45R: 1 ± 53
4. Cover
5. No. 1 sun gear
(PC35R Z=15 - PC45R Z=10)
6. Oil drainage plug
7. No. 1 planetary gear
8. No. 2 sun gear (Z=16)
9. Housing (Z=80)
10-6 PC35R-8 PC45R-8

TRACK FRAME
1 2 3 4 5
7 8 6
RKP02610
1. Idler 5. Sprocket
2. Track frame 6. Track roller
3. Carrier roller 7. Recoil spring
4. Travel motor 8. Track shoe
PC35R-8 PC45R-8 10-7

RECOIL SPRING
1 2 3 4 5 6
A A
7
4 3
Section
SezioneAA±- A
A
RKP02630
1. Idler
2. Support
3. Rod
4. Cylinder
5. Recoil spring
6. Nut
7. Nipple
10-8 PC35R-8 PC45R-8

CARRIER ROLLER
6 1 2
4 3 RKP02470
1. Bearing 4. Seal ring

2. Gasket 5. Cover
3. Shaft 6. Roller
TRACK ROLLER
1 2 3 4
6 5
RKP02520
1. Roller 4. Shoulder
2. Shaft 5. Seal ring
3. Bushing 6. Gasket
PC35R-8 PC45R-8 10-9

STEEL SHOE
5 6
1 2
RKP02460
1. Bushing SPECIFICATIONS
2. Pin Width: 400 mm
3. Master pin Pitch: 135 mm
4. Master bushing
5. Shoe
6. Screw
7. Nut
8. Link
10-10 PC35R-8 PC45R-8

HYDRAULIC CIRCUIT DIAGRAM
PC35R
Swing motor
R.H. travel motor
PS
DB
Boom swing
cylinder
Hammer
T1-T2
cylinder
cylinder
Bucket
Boom
E P2
cylinder
G R/G
Arm
P1
T D
C
P
P1 P2 H
B M A L.H. travel motor
B
A
F
P1
R/G
Swivel joint P2
T1-T2
A10
B10 PB10 B8 A8 PB8 B7 A7 B6 A6 B5 A5 PB5 B4 A4 PB4 B3 A3 B2 A2 B1 A1 PB1 LS PS
TS
280 kg/cm2
Blade cylinder
250 kg/cm2
30 kg/cm2
Additional equipment
Raise
Reverse
Reverse
Set 1.5ⴞ0.2
Close
Raise
Open
Right
Right
L.H. side
L.H. travel motor

R.H. travel motor
C
swing Left
Forwards
Forwards
Blade
Open
Oil cooler
R.H. side
Swing
Left
Curled
Lower
Boom
Boom
Open
Bucket
Exhaust filter 10 ␮m
Arm
Suction filter 104 ␮m
PP
PA10 PA8 P2 A9 PA9 S2 PA5 PA4 PA1 PC P1 S1
P2 P1
L.H. PPC valve R.H. PPC valve

Swing Arm Bucket Boom E/G
Right Left Open Close Open Curled Raise Lower S1
Min Max
T T
Cylinder block
P P
P4 P3 P2 P1 100 Mesh P4 P3 P2 P1 100 Mesh P1L PLS

Valve LS
Valve PC
V=0,20 艎
P S
T
Y1 Y2
A B RKP03141
PC35R-8 PC45R-8 10-11

10-12 PC35R-8 PC45R-8
PC45R
Swing motor
R.H. travel motor
PS
DB
Boom swing
cylinder
Hammer
cylinder
T1-T2
cylinder
Bucket
Boom
E P2
cylinder
R/G
Arm
G
P1
T D
C
P
P1 P2 H
B T A L.H. travel motor
B
A
F
P1
R/G
Swivel joint P2
T1-T2
B9 A9 PB9 B8 A8 PB8 B7 A7 B6 A6 B5 A5 PB5 B4 A4 PB4 B3 A3 B2 A2 B1 A1 PB1 LS PS
TS
280 kg/cm2
Blade cylinder
250 kg/cm2
30 kg/cm2
Additional equipment
Reverse
Reverse
Set 1.5ⴞ0.2
Close
Raise
Open
Right
Right
Right
L.H. side
L.H. travel motor

R.H. travel motor
C
Blade
swing Left
Forwards
Forwards
Oil cooler
R.H. side
Swing
Raise
Left
Bucket
Curled
Lower
Boom
Boom
Open
Exhaust filter 10 ␮m
Arm
Suction filter 104 ␮m
PP
PA10 PA8 P2 S2 PA5 PA4 PA1 PC P1 S1
P2 P1
L.H. PPC valve R.H. PPC valve

Swing Arm Bucket Boom E/G
Right Left Open Close Open Curled Raise Lower
S1
Min Max
T T
Cylinder block
P P
P4 P3 P2 P1 100 Mesh P4 P3 P2 P1 100 Mesh P1L PLS

Valve LS
Valve PC
V=0,20 艎
P S
T
EV... EV...
A B RKP03131
PC35R-8 PC45R-8 10-13

HYDRAULIC PUMP
A A
View X
Vista X
1 X 2 b
C
c d
C
e
B
B
ViewZZ
Vista
f RKP02080
a. PS Port - From hydraulic tank 1. Main pump

b. P2 Port - To control valve (P2 Port) 2. Gear pump
c. PDA Port - Air bleeding
d. P1 Port - To control valve (P Port)
e. PLS Port - From control valve (LS Port)
f. P1L Port - From control valve (PP Port)
10-14 PC35R-8 PC45R-8

1. MAIN PUMP
1 2 3 4 5 6 7 8
10
Section
Sezione A
A ±- A
A
Section
Sezione C
C± C
-C
Section BB -±BB
Sezione
RKP02090
1. Shaft
2. Oil seal
3. Case
4. Swash plate
5. Shoe
6. Piston
7. Cylinder lock
8. Valve plate
9. Spring
10. Servo piston
PC35R-8 PC45R-8 10-15

FUNCTION
. The rotation and torque transmitted to the pump
shaft is converted to hydraulic energy and pressur-
ized oil is discharged according to the load.
. It is possible to change the discharge amount by
changing the swash plate angle.
1 2 3 4 5 6 7 8
B A a
RKP02110
STRUCTURE
. Cylinder block (7) is supported to shaft (1) by a . Piston (6) carries out motion relative to the axial di-
spline, and shaft (1) is supported by the front and rection inside each cylinder chamber of cylinder
rear bearings. block (7).
. The end of piston (6) has a concave ball shape and . The cylinder block (7) carries out rotation relative to
shoe (5) is caulked to it to form one unit. valve plate (8) while sealing the pressurized oil, and
Piston (6) and shoe (5) form a spherical bearing. this surface ensures that the hydraulic balance is
. Rocker cam (4) has plane A, and shoe (5) is always maintained correctly.
pressed against this surface as it slides in a circle. The oil inside each cylinder chamber of cylinder
Rocker cam (4) forms a static bearing sending high block (7) is sucked in and discharged through valve
pressure oil at cylindrical surface B with to the plate (8).
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 sur- 1 4 5 A 6 7 F
face A.
At this time, the rocker cam (4) moves along
the cylindrical surface B, so the angle a be-
tween 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),
X
the flat surface A acts as a cam for the shoe
(5). B E
By this, the piston (6) slides on the inside of RKP02120
the cylinder block (7), creates a difference be-
tween capacities E and F, then suction and
discharge of oil for the amount of this differ-
ence (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 F
E increases, and the oil is sucked at this pro-
cess.
(The figure shows the state of the pump when
suction of the chamber F and discharge of the
chamber E have completed). X
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 dis- 4 7 E
charge action of oil.
RKP02130
(In actual fact, the swash plate angle never be-
comes 0).
4 - In other words, discharge amount of the pump
is directly proportional to the swash plate an-
gle a.
PC35R-8 PC45R-8 10-17

2. Control of discharge amount
. As the swash plate angle a becomes larger, dif-
ference between the capacities E and F be- 3 4 F
comes larger, so the discharge amount Q in-
creases.
The swash plate angle a is changed by the ser-
vo 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 direc-
tion ( ).
. The upper and lower pressure receiving area of E RKP02140
the servo piston are different from each other,
and to the pressure chamber of the smaller pis-
ton side (upper), discharge pressure (self pres-
sure) 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 PC35R-8 PC45R-8

PC35R-8 PC45R-8 10-19
2. TCC VALVE, LS VALVE, SERVO PISTON
4 1 a
3 5
c
RKP02150
SERVO PISTON a - P1 Port - Main pump pressure inlet port

1. Spring b - GH Port - Gear pump pressure inlet port
2. Spacer c - PLS Port - From control valve (LS port)
3. Piston
4. Servo piston
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 be-
tween main pump discharge pressure PP and con-
trol 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 dis-
charge amount is supplied in accordance with the
demands of the control valve by controlling pump
discharge amount Q.
. However, when carrying out fine control or in other
cases where the range does not exceed the maxi-
mum 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.
. 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 re-
ceiving 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 dif-
ferential 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 in-
creased and the metering differential pressure be-
Pump discharge amount Q (ᐍ / min)
Engine at Engine at
comes higher. low idling full throttle
. 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 pres-
sures on both sides of gear pump metering throttle
(GH and GL) are brought to the LS valve. ⌬p (bar)
8 16
The relationship between pump discharge amount (8.4) (16) (kg /cm2)
Q and LS differential pressure DPLS changes as LS differential pressure ⌬ PLS
shown in the diagram on the right. RKP02341
PC35R-8 PC45R-8 10-21

CONTROL VALVE
c
O O
a r
N N
q s
M M
p t
L L
o u
K K
n v
d A J J
m w
H H
e l x
G G
k y
G G
f j z
F F
i aa
g E E
D D
h cc bb
C
B
A
mm
ll nn
hh
gg
ff
ee
dd A
B
C
View
Vista A
A RKP02350
10-22 PC35R-8 PC45R-8

a. S2 Port - From swing motor (T Port)
b. PA10 Port - From work equipment PPC valve (P2 Port)
c. PA8 Port - From L.H. PPC valve (P3 Port)
d. PA5 Port - From R.H. PPC valve (P4 Port)
e. PA4 Port - From R.H. PPC valve (P1 Port)
f. PA1 Port - From L.H. PPC valve (P1 Port)
g. LS Port - From hydraulic pump (PLS Port)
h. C Port - To exchange oil cooler
i. B1 Port - To arm cylinder (Head side)
j. B2 Port - To swivel joint (B Port)
k. B3 Port - To swivel joint (D Port)
l. B4 Port - To boom cylinder (Bottom side)
m. B5 Port - To bucket cylinder (Bottom side)
n. B6 Port - To boom swing cylinder (Bottom side)
o. B7 Port - To swivel joint (G Port)
p. P2 Port - From hydraulic pump (P2 Port)
q. B10 Port - To attachment (R.H. side)
r. TS Port - To hydraulic tank
s. A10 Port - To attachment (L.H. side)
t. A8 Port - To swing motor (A Port)
u. A7 Port - To swivel joint (F Port)
v. A6 Port - To boom swing cylinder (Head side)
w. A5 Port - To bucket cylinder (Head side)
x. A4 Port - To boom cylinder (Head side)
y. A3 Port - To swivel joint (C Port)
z. A2 Port - To swivel joint (A Port)
aa. A1 Port - To arm cylinder (Bottom side)
bb. P1 Port - From hydraulic pump (P1 Port)
cc. T Port - To hydraulic tank
dd. PC Port - To ST1 solenoid valve (P Port)
ee. PB1 Port - From L.H. PPC valve (P2 Port)
ff. PB4 Port - From R.H. PPC valve (P2 Port)
gg. PB5 Port - From R.H. PPC valve (P3 Port)
hh. PB8 Port - From L.H. PPC valve (P4 Port)
ll. PB10 Port - From work equipment PPC valve (P1 Port)
mm. PP Port - To hydraulic pump (P1L Port)
nn. B8 Port - To swing motor (B Port)
PC35R-8 PC45R-8 10-23

7
5 8
3 9
Section
SezioneAA±- A
A RKP02360
1. Safety valve
2. Suction valve (Close arm)
3. Suction valve (Raise boom)
4. Suction valve (Close bucket)
5. Suction valve (L.H. Boom swing)
6. Suction valve (Lower blade)
7. Suction valve (Work equipment R.H. side)
8. Suction valve (R.H. boom swing)
9. Suction valve (Lower boom)
10-24 PC35R-8 PC45R-8

1
10
Section BB-±BB
Sezione RKP02370
1. Spool (Attachment)
2. Spool (Swing)
3. Spool (Blade)
4. Spool (Boom swing)
5. Spool (Bucket)
6. Spool (Boom)
7. Spool (R.H. travel)
8. Spool (L.H. travel)
9. Spool (Arm)
10. Main relief valve
PC35R-8 PC45R-8 10-25

1 2
21
20 6
19 7
18 8
17 9
16 10
15
14
11
13
Section
SezioneCC±-C
C
12
RKP02390
1. Plug 12. Cooler check valve

2. Plug 13. Unload valve
14. Reducing valve
FLOW COMPENSATION VALVE
3. Attachment REDUCING PRESSURE COMPENSATION VALVE
4. Blade - boom swing 15. Arm
5. Blade - boom swing 16. L.H. Travel
6. Bucket 17. R.H. Travel
7. Boom 18. Boom
8. R.H. Travel 19. Bucket
9. L.H. Travel 20. Blade - boom swing
10. Arm 21. Attachment
11. LS bypass plug
10-26 PC35R-8 PC45R-8

2
4
8
5
Section D
Sezione D -±DD
7 SectionEE- ±EE
6
Sezione
11
10
14
SectionF F- F
Sezione ±F
16 Section G
Sezione G -±GG 15
13 12
RKP02380
1. Cooler check valve 11. Check valve

2. Safety valve 12. Reducing pressure compensation valve
3. Main relief valve 13 - Flow compensation valve
5 - LS bypass plug
TRAVEL VALVE
5. Unload valve
14. Spool
6. Main relief valve (servocontrol)
15. Reducing pressure compensation valve
7. Main relief valve spool
16 - Flow compensation valve
8. Reducing valve
ARM VALVE
9. Spool
10. Suction valve
PC35R-8 PC45R-8 10-27

2
1
3
10
9
8
13
4
7
12 11
6 Section
Sezione H
H± H
-H 5 Section JJ-±JJ
Sezione
22
15 21
14
16
23
20
17
19
Section K±
Sezione K K
-K 18
Section
Sezione L
L ±- L
L
RKP02400
BOOM VALVE BOOM SWING VALVE

1. Safety valve 14. Suction valve
2. Check valve 15. Check valve
3. Check valve 16. Suction valve
4. Suction valve 17. Reducing pressure compensation valve
5. Reducing pressure compensation valve 18. Reducing pressure compensation valve
6. Flow compensation valve 19. Flow compensation valve
7. Spool 20. Spool
8. Suction valve
BLADE VALVE
BUCKET VALVE 21. Suction valve
9. Suction valve 22. Check valve
10. Check valve 23. Spool
12. Flow compensation valve
13. Spool
10-28 PC35R-8 PC45R-8

2
1
Section NN-±NN
Sezione
Section M -±MM
Sezione M
4
3
6 5
Section
Sezione O
O± O
-O
RKP02530
SWING VALVE
1. Spool
2. Plug
ATTACHMENT VALVE
3. Suction valve
4. Check valve
6. Flow compensation 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
Pump passage PLS
Main pump
LS passage
Min. Max.
Servo piston
∆ PLS
LS valve
Differential pressure
large (high) Differential
pressure
TCC valve small (low)
Pump pressure high

Pump
pressure low RKP00651
PC35R-8 PC45R-8 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
∆P ∆P
S1 S2
Pressure Pressure
compensation compensation
valve valve
PIMP
RKP02311
10-32 PC35R-8 PC45R-8

3. Functions and operation of each valve
NAMES OF HYDRAULIC CIRCUITS AND VALVES
PP TS
1. Unload valve: LS+34.3 bar
(35 kg/cm2)
B9
2. Safety valve:
Hammer 279 bar (285 kg/cm2)
PA10
11 A9
3. Main relief valve:
PB9
245 bar (250 kg/cm2)
7 Left 4. Self-pressure reducing valve
B
B8
Swing 5. Pilot relief valve:
A8 motor 29 bar (30 kg/cm2)
PA8 A
PB8 Right 6. Self-pressure sequence valve:
P2 30 bar (29 kg/cm2)
7. Pressure compensation valve
13 8. Suction valve
8 B7
9. Lock valve
10. Cooler check valve:
A7
0.4 bar (4 kg/cm2)
Blade
S2
8 11. Check valve
B6
12. Check valve
A6 Boom (Boom raise):
8 11 swing 20 bar (20 kg/cm2)
7 8 13. Check valve
B5
(Bucket raise):
A5 25 bar (25 kg/cm2)
11 Bucket
PA5
8 13 PB5
B4
8
7
9
A4
Boom
PA4 PB4
7 11 8 Revers
P2
B3
R.H. travel
A3
P1
Forwards
7 Revers
P1
B2
L.H. travel
A2
P2
Forwards
7
B1
A1
PA1 PB1
Arm
7
PC
5 6
P1 4 1 3 LS
2
2
S1
C T
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 A 1 PLS S2
T 2
PP
RKP02270
OPERATION . In this way, pump discharge PP is set to 34.3 bar

When control valve is at HOLD (35 kg/cm2).
. At the left end of spool (1), pump pressure PP is act- PP =Pump discharge
ing on area S1 and LS pressure PLS is acting on PLS=Load Sensing circuit
area S3.
T =Tank circuit
. When the control valve is at HOLD, LS pressure A =To control valve spool
PLS is not generated, so only pump discharge PP
has any effect, and PP is set by the load of spring
(2).
. 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 cir-
cuit 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).
PLS
PP 2
T
RKP02280
OPERATION
During fine control of control valve
. When fine control is carried out on the control . In other words, pump discharge pressure PP is set
valve, LS pressure PLS is generated and acts on to a pressure equal to the force of spring (2) (34.3
area S3 at the right and of spool (1). bar (35 kg/cm2))+LS pressure PLS, and LS differ-
When this happens, the area of the opening of the ential pressure DPLS becomes 34.3 bar (35 kg/
control valve spool is small, so there is a big differ- cm2).
ence between LS pressure PLS and pump dis-
charge pressure PP.
. 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.
3
1
PLS
PP 2
T
RKP02220
OPERATION
Control valve operated
. When the control valve is operated to a larger . As a result, pump circuit PP and tank circuit T are
stroke, LS pressure PLS is generated and acts on shut off, and all the pump discharge amount Q
area S3 at the right end of spool (1). flows to the actuator circuit.
When this happens, the area of the opening of the
control valve spool is large, so the difference be-
tween LS pressure PLS and pump discharge pres-
sure PP is small.
. 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 pres-
sure 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.
A b
T
PLS1
2 a c 3
PP
4 PLS
RKP02100
OPERATION
1) Boom, arm, bucket, swing valve
. When spool (1) is operated, pump pressure PP . Actuator circuit pressure PA (=A) acts on the left
flows from control valve (2) and notch a in spool end of reducing valve (3); the reduced pump pres-
(1) through bridge passage b to actuator circuit A. sure PP acts on the other end.
. At the same time, reducing valve (3) also moves to . As a result, reducing valve (3) is balanced at a po-
the right, so pump pressure PP has its pressure re- sition where actuator circuit pressure PA and the
duced by the pressure loss at notch C. It is intro- pressure of spring chamber PLS1 are the same.
duced to LS circuit PLS, and then goes to spring Pump pressure PP reduced at notch C becomes ac-
chamber PLS1. tuator circuit pressure A and is taken to LS circuit
. When this happens, LS circuit PLS is connected to PLS.
tank circuit T from LS by-pass plug (4) (see the sec-
tion on the LS by-pass plug).
PC35R-8 PC45R-8 10-37

1 T A b 5
T
a
6
b e
f
2
7 d
PP 3 PLS
4
RKP02170
2) Boom swing, blade valve

. When boom swing spool (1) is operated, pump . As a result, pump pressure PP is reduced at notch
pressure PP is reduced by reducing valve (3) (in d, becomes the actuator circuit pressure, and is
the same way as in item 1), and is sent to the LS sent to LS circuit PLS.
circuit PLS.
H The boom swing and blade valves are different
. When the blade spool (5) is operated, pump pres- from the boom, arm, bucket, and travel valves: they
sure PP flows from flow control valve (2), passage share one pressure compensation valve and bring
e, and notch a in blade spool (5) through bridge in the LS pressure.
passage b to actuator circuit A.
. 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 sta-
bility by lowering the effective LS differential pressure.
1 PLS
PP a T
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 or-
ifice 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 Side receiving

W W
A A
T
a a
PPA
PLS1 PPA PA
1
2 PA
PP
PLS
RKP02181
OPERATION
. If the load pressure of the other actuator (right side) . Flow control valve (2) and reducing valve (1) are ba-
becomes higher during compound operations, the lanced in position where the difference in pressure
oil flow in actuator circuit A on this side (left side) between PLS and PA acting on both ends of redu-
tries to increase. cing valve (1) and the pressure loss between PP
and PPA on both sides of flow control valve (2) are
. If this happens, the LS pressure PLS of the other ac-
the same.
tuator acts on spring chamber PLS1, and reducing
valve (1) and flow control valve (2) are pushed to . In this way, the pressure difference between up-
the left ( ). stream pressure PPA and downstream pressure
PA of both spools used during compound opera-
. Flow control valve (2) throttles the area of opening
tions is the same, so the pump flow is divided in
between pump circuit PP and spool upstream
proportion to the area of opening of notch a of each
PPA, and pressure loss is generated between PP
spool.
and PPA.
10-40 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).
A b
T
S1
S2
PPA 1
2 PA 3
PP 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) di-
vides the flow and sends more oil to the side receiving compensation.
Side receiving Side receiving

W
A A
T
a a
PPA
PLS1 PPA PA
1
2 PA
PP
4 PLS
RKP02201
OPERATION
. If the other actuator (right side) is relieved during . PLS2 passes through LS introduction throttle b of
compound operations, each circuit pressure (PPA, reducing valve (1) and becomes PLS. PLS is con-
PA) of the other actuator becomes the same as nected to the tank circuit from LS by-pass plug
the pump circuit pressure (PP=relief pressure). (4), so pressure loss is generated at LS introduction
. In this case, spring chamber PLS2 of the other ac- throttle b (the condition becomes PLS<PLS2).
tuator (right side) becomes the same as pump cir- . As a result, even if the other actuator is relieved, a
cuit pressure PP because of the balance of redu- pressure differential is created between PP and
cing valve (1). PLS, so more oil flows to actuator circuit A on this
side (left side).
10-42 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

AL PAL AR PAR
1L T 1R T
PLS
2 3 2
3 a a
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
AL PAL AR PAR
1L T 1R T
PLS
2 3 2
3 a a
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 gen-
erated 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
2
4
1 TS
RKP02160
1. Poppet
2. Poppet spring
3. Pilot spool
4. Pilot spring
5. Check valve
6. 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.
1
RKP02290
2. Boom lever at HOLD

When the boom is raised and the control lever is
returned to HOLD, the circuit for the holding pres-
sure at the bottom end of the boom cylinder is b
closed by poppet (1). At the same time, the circuit 3
for the oil flowing into poppet (1) through orifices a
and b of poppet (1) is closed by pilot spool (3). 1
As a result, the boom id held in position.
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).
a TS
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 dis-
charge pressure PP to ensure the pilot basic pressure
T PP
LS
TS
PC 2 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 de-
tails, 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
RKP02320
OPERATION
. Unload spool (1) moves to the left ( ) in the direc-
tion of the arrow, and pump discharge pressure PP
becomes higher than the pressure of actuator cir-
cuit (5) by the amount of the LS differential pres-
sure. (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 re-
duced to 29 bar (30 kg/cm2) by self-pressure redu-
cing 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 se-
quence valve (4) remains open.
PC35R-8 PC45R-8 10-49

5 T PP
4 LS
TS
PC 2 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 redu-
cing 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.
To swing
P2 motor A8
B8
To swing
motor
PB8
PA8
From swing
PPC valve
From swing
PPC valve
Load check Load check

valve 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
d e
3
f
c
g
2
4 b h
Section A
A-±AA i l m n
1 Sezione
RKP02510
r o
q p
1. Cover
2. Body
3. Shaft
4. Gasket
a. H Port - From travel motors (T1 - T2 Ports) i. a Port - From control valve (A2 Port)
b. A Port - To R.H. travel motor (P2 Port) l. f Port - From control valve (A7 Port)
c. B Port - To L.H. travel motor (P1 Port) m. b Port - From control valve (B2 Port)
d. F Port - To blade cylinder (Head side) n. g Port - From control valve (B7 Port)
e. G Port - To blade cylinder (Bottom side) o. c Port - From control valve (A3 Port)
f. D Port - To R.H. travel motor (P2 Port) p. e Port - From ST1 solenoid valve (B Port)
g. E Port - To travel motors (PS Port) q. d Port - From control valve (B3 Port)
h. C Port - To R.H. travel motor (P1 Port) r. h Port - To hydraulic tank
10-52 PC35R-8 PC45R-8

PC35R-8 PC45R-8 10-53
SWING MOTOR
A A
6 2
5 a
3
4
RKP02550
10-54 PC35R-8 PC45R-8

8
7
9
d
13
10
12
11
Section AA-±AA
Sezione RKP01510
1. Plate a. DB Port - To hydraulic tank

2. Cylinder b. A Port - From control valve (A8 Port)
3. Piston c. M Port - To control valve (S2 Port)
4. Disc d. B Port - From control valve (B8 Port)
5. Shoe
6. Center spring SPECIFICATIONS
7. Safety valve spring Max. pressure: PC35R: 165 5 bar
PC45R: 200 5 bar
8. Plug
Displacement: PC35R: 20.7 rev.
PC45R: 26.1 rev.
10. Check valve
11. Plug
12. Recoil cylinder
13. Safety valve
PC35R-8 PC45R-8 10-55

TRAVEL MOTOR
PC35R
1 2 3 4
B
A
8 7 6 5
a b c d
10
9 11
16
12
15
14
Section
SezioneAA±-AA 13
RKP02600
10-56 PC35R-8 PC45R-8

e
17
19 18
Section B -±BB
Sezione B
RKP02620
1. Valve plate R.H. motor

2. Piston a. T1 Port - Not used
3. Shoe b. P1 Port - From swivel joint (C Port)
4. Swash plate c. P2 Port - From swivel joint (D Port)
5. Piston spring
d. T2 Port - From swivel joint (H Port)
6. Piston
e. PS Port - From swivel joint (E Port)
7. Cylinder
8. Center spring L.H. motor
9. Plug a. T1 Port - From swivel joint (H Port)
10. Orifice b. P1 Port - From swivel joint (B Port)
11. Check valve c. P2 Port - From swivel joint (A Port)
d. T2 Port - Not used
13. Orifice
14. Orifice
15. Counterbalance valve spring SPECIFICATIONS
16. Spool return spring Nominal pressure: 245 bar (250 kg/cm2)
17. Plug Displacement:
18. Spool return spring (travel increment) . High speed: 16.00 cm3/rev.
19. Counterbalance valve spring (travel increment) . Low speed: 26.30 cm3/rev.
Swing speed:
. High speed: 2250 rpm
. Low speed: 1369 rpm
PC35R-8 PC45R-8 10-57

PC45R
2 3 4 5 6
1
A
B
A
10 9 8 7
a b c d
13
12 14
19
15
18
17
Section
Sezione A
A ±- A
A
16
RKP06690
10-58 PC35R-8 PC45R-8

e
20
22 21
Section B -±BB
Sezione B
RKP02621
1. Valve plate R.H. motor

2. Brake piston a. T1 Port - Not used
3. Piston b. P1 Port - From swivel joint (C Port)
4. Brake disc c. P2 Port - From swivel joint (D Port)
5. Shoe
d. T2 Port - From swivel joint (H Port)
6. Swash plate
7. Piston spring
8. Piston L.H. motor
9. Cylinder a. T1 Port - From swivel joint (H Port)
10. Center spring b. P1 Port - From swivel joint (B Port)
11. Brake spring c. P2 Port - From swivel joint (A Port)
12. Plug
d. T2 Port - Not used
13. Orifice
14. Check valve
15. Check valve spring SPECIFICATIONS
16. Orifice Nominal pressure: 245 bar (250 kg/cm2)
17. Orifice Displacement:
18. Counterbalance valve spring . High speed: 16.00 cm3/rev.
19. Spool return spring . Low speed: 26.30 cm3/rev.
20. Plug Swing speed:
21. Spool return spring (travel increment) . High speed: 2910 rpm
22. Counterbalance valve spring (travel increment) . Low speed: 1770 rpm
PC35R-8 PC45R-8 10-59

10-60 PC35R-8 PC45R-8
CYLINDERS
BOOM
1 2
3 4 5 6 7 8 9 10 11
RKP02420
1. Bushing (Head side) 5. Gasket 9. Ring

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

2. Bushing (Bottom side) 6. Cylinder 10. Nut
3. Rod 7. Piston gasket
4. Head 8. Ring
PC35R-8 PC45R-8 10-61

BUCKET
1 2
3 4 5 6 7 8 9 10
RKP02430

4. Head 8. Ring
BOOM SWING
1 2
3 4 5 6 7 8 9 10
RKP02440

4. Head 8. Ring
10-62 PC35R-8 PC45R-8

BLADE
1 2
3 4 5 6 7 8 9 10
RKP02450

4. Head 8. Ring
PC35R
Boom
Cylinder Arm Bucket Boom swing Blade
Canopy Cabin
Piston rod diameter 45 45 45 40 45 45
Cylinder inside diameter 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

46 46 46 41 46 46
across flat
PC45R
Boom
Cylinder Arm Bucket Boom swing Blade
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
Piston nut width

55 55 55 50 55 55
across flat
PC35R-8 PC45R-8 10-63

10-64 PC35R-8 PC45R-8
ACCUMULATOR
B
RKP00700
TECHNICAL DATA FUNCTION

Servocontrol feed unit . An elastic rubber bag (1) containing nitrogen is
Nominal volume: 0.35 , fitted inside the accumulator to maintain oil pres-
sure in the circuit to which the accumulator is con-
Pre-loading: 12 bar nected.
Working pressure: 35 ± 45 bar
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
a b
d c
E E
D D
e
B f
A C
C A RKP01070
L.H. PPC VALVE R.H. PPC VALVE

a. P2 Port - To control valve (PB1 port) a. P2 Port - To control valve (PB4 port)
b. P4 Port - To control valve (PB8 port) b. P4 Port - To control valve (PA5 port)
c. P1 Port - To control valve (PA1 port) c. P1 Port - To control valve (PA4 port)
d. P3 Port - To control valve (PA8 port) d. P3 Port - To control valve (PB5 port)
e. T Port - To ST1 solenoid valve (T port) e. T Port - To control valve (TS port)
f. P Port - From ST1 solenoid valve (A port) f. P Port - From ST1 solenoid valve (A port)
10-66 PC35R-8 PC45R-8

6
5 7
4
8
3
9
2 10
Section
Sezione A
A ±- A
A Section
Sezione B
B±- B
B
Section
SezioneDD±- D
D
Section
Sezione C
C ±- C
C
Section E±
Sezione E - EE
RKP01080
1. Spool 7. Joint
2. Adjusting spring (internal) 8. Cover
3. Return spring (external) 9. Pin
4. Plunger 10. Body
5. Disc
6. Nut
PC35R-8 PC45R-8 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 cham-
ber D through fine control hole f in spool (1). (Fig. 1)
D
f T
P
1
P3 (P1) P4 (P2)
A Control valve
B
FIG. 1 RKP01091
2. During fine control (NEUTRAL fine control)

When piston (4) starts to be pushed by disc (5), re-
tainer (7) is pushed; spool (1) is also pushed by me-
tering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber 5
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes from 4
port P1 to port A.
When the pressure at port P1 becomes higher, 3
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP. 2
At almost the same time, it is connected to drain D
chamber D to release the pressure at port P1. f T
When this happens, spool (1) moves up or down so
that the force of metering spring (2) is balanced with P
the pressure at port P1. The relationship in the po-
sition of spool (1) and body (8) (fine control hole f is
at a point midway between drain hole D and pump 1 PP
pressure chamber PP) does not change until retai-
P1 P2 10
ner (7) contacts spool (1).
Therefore, metering spring (2) is compressed pro-
portionally to the amount of movement of the con-
trol lever, so the pressure at port P1 also rises in
proportion to the travel of the control lever. In this A B
Control valve
way, the control valve spool moves to a position
where the pressure in chamber A (the same as
FIG. 2 RKP01101
pressure at port P1) and the force of the control
valve spool return spring are balanced. (Fig. 2)
10-68 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 5
to drain chamber D and the pressure oil at port P1
is released. 4
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con-
3
trol hole f is shut off from drain chamber D. At al-
most the same time, it is connected to pump pres-
2
D
sure chamber PP, and the pump pressure is sup- f
plied until the pressure at port P1 recovers to a T
pressure that corresponds to the lever position. P
When the spool of the control valve returns, oil in f
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working. 1 PP
The oil passes through port P2 and enters chamber
B to fill the chamber with oil. (Fig. 3) P1 P2
A B
Control valve
FIG. 3 RKP01111
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 5
control hole f and flows to chamber A from port P1,
and pushes the control valve spool. 4
The oil returning from chamber B passes from port
P2 through fine control hole f' and flows to drain 9
chamber D. (Fig. 4)
D
f T
P
f
1 PP
P1 P2
A Control valve
B
FIG. 4 RKP01121
PC35R-8 PC45R-8 10-69

PPC VALVE
HAMMER
5
4
c d 6
3 7
2
8
1
9
SectionAA-±AA
Sezione
RKP00960
a. T Port - To ST1 solenoid valve (T port) 1. Spring

b. P Port - From ST1 solenoid valve (A port) 2. Adjusting spring (internal)
c. P1 Port - To control valve (PB10 port) 3. Return spring (external)
d. P2 Port - To control valve (PA10 port) 4. Plunger
5. Lever
6. Cover
7. Stopper
8. Body
9. Filter (100 mesh)
10-70 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 cham-
ber D through fine control hole f in spool (1). (Fig. 1)
D
T
f P
1
P1 P2
A Control valve B
RKP00971
FIG. 1
2. During fine control (NEUTRAL fine control)

When piston (4) starts to be pushed by lever (5), re-
tainer (7) is pushed; spool (1) is also pushed by me-
tering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same 5
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
4
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. 7 D
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1. T
When this happens, spool (1) moves up or down so 2
that the force of metering spring (2) is balanced with 8
the pressure at port P1. The relationship in the po-
sition of spool (1) and body (8) (fine control hole f is f P
at a point midway between drain hole D and pump
pressure chamber PP) does not change until retai-
ner (7) contacts spool (1). 1 P1 P2
Therefore, metering spring (2) is compressed pro-
portionally to the amount of movement of the con- PP
trol 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
A Control valve B
where the pressure in chamber A (the same as
pressure at port P1) and the force of the control FIG. 2 RKP00981
valve spool return spring are balanced. (Fig. 2)
PC35R-8 PC45R-8 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. 5
When this happens, fine control hole f is connected
to drain chamber D and the pressure oil at port P1
is released. 4
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con-
trol hole f is shut off from drain chamber D. At al-
most the same time, it is connected to pump pres- 7 D
sure chamber PP, and the pump pressure is sup-
plied until the pressure at port P1 recovers to a T
pressure that corresponds to the lever position. 2
When the spool of the control valve returns, oil in P
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working. f
The oil passes through port P2 and enters chamber f'
B to fill the chamber with oil. (Fig. 3)
1 P1 P2 PP
A Control valve B
FIG. 3 RKP00991
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 5
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 4
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4)
7 D
T
2
8
P
f
f'
1 P1 P2 PP
A Control valve B
FIG. 4 RKP01001
10-72 PC35R-8 PC45R-8

SOLENOID VALVE
ST1 SERVOCONTROL (TRAVEL INCREMENT)
a b c d
1 2
RKP00810
a. S Port - To accumulator 1. Y2 Servocontrol

b. A Port - To PPC valve (P port) 2. Y1 Travel increment
c. B Port - To swivel joint (e port)
d. P Port - From control valve (PC port)
e. T Port - To hydraulic tank
PC35R-8 PC45R-8 10-73

10-74 PC35R-8 PC45R-8
ELECTRICAL DIAGRAM (1/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A2.5
2.1
A2.5 2 A2.5
2.1
X10 B - N1
3.9
G1
M - V1 2.12
H1 H2 H3 H4
FU2 FU9
3A 7.5A
R1 ACC BR R2 C
OFF ACC
R1
ST
HA1 S1 X6 1
S1 B X6 2
R1 10 X5 R1 X6 3
X6 4
X6 5
X5 H5 H6 H7 H8 H9
11 M1 X6 6
R - N2.5
B - G1 X6 7
R6
3 X10 12
X5 X6 9
X10
R1.5 X6 10
2.15
N1 X6 11
M1
M4
M - N1
A - R1
A - V1
X2
R - N2.5
X6
R - V1
R1
G1 12
B - N1 X6 13 P1 P2 P3
X11 2 X11 3
X-K1 2 4 13 X5 C/N1 X6 14
K1 KT1
3
t° q h
X5 X6
X5
R6
7 C - N1 15
X-K1 6
1 X10 X7 1 X5 X6 16
4
4
X-K1 X11 1 X11
A - R1
3
M4
FUG X-K1
S1
R - V1
B - G1
C - N1
60A
C/N1
N1
R6
1 2 3 9 2 4 5 4 8
X1 X1 X4 X4 X4 X4 X4 X4
X1 S2
R - N2.5
R35
S - N1
R6
L - R1
S1
00000 00 h
G1
A - R1
12 Vcc
M4
C - N1
C/N1
1
X3 X3
X28
1
M1 G2
30 50 X8
M V1 Y1
30
G S3 S4 R2
3
p t
U
31 31
R1 t
X8
N35
2
P4
N1
N1
31
2.1
RKP06570
COMPONENTS: CONNECTORS: FUSES:

G1 BATTERY H8 DIRECTION INDICATOR WARNING LIGHT S1 DASHBOARD X1 4-WAYS CONNECTOR FU2 FUSE 3A
G2 ALTERNATOR (NOT USED) S2 PUSH-BUTTON X2 2-WAYS CONNECTOR (BUZZER - STARTER RELAY - INSTRUMENT)
H1 AIR FILTER CLOGGING WARNING LIGHT H9 DASHBOARD LIGHT S3 LOW PRESSURE ENGINE OIL PRESSURE SWITCH X3 2-WAYS CONNECTOR FU9 FUSE 7.5 A
(NOT USED) HA1 BUZZER S4 HIGH WATER TEMPERATURE TERMOSTAT X4 9-WAYS CONNECTOR MARK (ALTERNATOR - TRAVEL INCREMENT
H2 PRESSURE OIL WARNING LIGHT K1 STARTER RELAY V1 TRAVEL INCREMENT SOLENOID VALVE DIODE X5 13-WAYS CONNECTOR MARK SOLENOID VALVE)
H3 BATTERY WARNING LIGHT KT1 PRE-HEATER TIMER Y2 TRAVEL INCREMENT SOLENOID VALVE DIODE X6 16-WAYS CONNECTOR FKI INSTRUMENT FUG GENERAL FUSE 60A
H4 PRE-HEATER WARNING LIGHT M1 STARTER MOTOR X7 5-WAYS CONNECTOR
H5 BRAKE PRESSURE WARNING LIGHT P1 TERMOMETER X8 2-WAYS CONNECTOR DEUTSCH
(NOT USED) P2 LEVEL INDICATOR X10 4-WAYS CONNECTOR
H6 OIL LEVEL WARNING LIGHT P3 COUNTER-HOUR X11 4-WAYS CONNECTOR
(NOT USED) P4 INSTRUMENT PANEL X28 1-WAY CONNECTOR
H7 POSITION LIGHT WARNING LIGHT R1 PRE-HEATER X-K1 4-WAYS CONNECTOR
(NOT USED) R2 WATER TEMPERATURE WATER
PC35R-8 PC45R-8 10-75

10-76 PC35R-8 PC45R-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A2.5 A2.5
1.19 3.1
A2.5 A2.5
1.19 3.1
R1.5
1.3
G1
XS5 2 1 XS5 XS6 XS6 2 1 XS6
FU10 FU1 FU6 1 1 3 FU11 FU7 FU8 FU4
7.5 A 30 A 10 A 0 0 2
7.5A 7.5A 7.5A 10A
R - N1
G - N1.5
2
S5 A E
S6
X5 XS5 6 5 XS5 XS6 6
XS6 5
G - N1.5
A - N1.5
G/R1
C - L1
S7
R - V1
H - G1.5
R - N1.5
B - R1
V4
V - N1
R1.5
S8
G1
N1
1.12
3 1 2
K3 X5 X25 X25
1
X6
L - N1.5
L - R1.5
X5
7
B - R1.5
3.0
K2 X4
M - B1
S - G1
X6
R - N1.5
B - R1.5
C - L1
1 6
H - N1
H -R1
H -L1
X4 X4
V - N1
X16 X16 X16
4 3 2
N1.5
L - N1.5
L - R1.5
L - N1
1 2 3 4 1 2
X7 X7 A C B
KT2 X17 X19 X19 X19
X16 1 X23 X23 X23
M - B1
R1.5
V - N1
S - G1
S9
R - V1
2 1
1
X14 X13 X13 1

X21
M2 X20
Y4
M S10 Y3 XP
V3
p H10 V5
X13 HA2
X14 3
X17 X20
2
X21
N1.5
2
N1
N1
N1
N1
N1
N1
N1.5
N1
31 31
1.19 3.1
RKP06580

H10 WORKING BEAM V3 STOP MOTOR DIODE X4 9-WAYS CONNECTOR MARK X25 2-WAYS CONNECTOR FU1 FUSE 30A (STOP MOTOR)
HA2 HORN V4 WARNING LIGHT DIODE X5 13-WAYS CONNECTOR MARK XS5 CONNECTOR FOR SWITCH MERIT FU4 FUSE 10A (CAR RADIO)
K2 STOP MOTOR RELAY V5 HAMMER SOLENOID VALVE DIODE X6 16-WAYS CONNECTOR FKI INSTRUMENT XS6 CONNECTOR FOR SWITCH MERIT FU6 FUSE 10A (FUEL PUMP - HORN - TBG)
K3 HORN RELAY XP ELECTRICAL SOCKET X7 5-WAYS CONNECTOR MARK FU7 FUSE 7.5 A (HAMMER SOLENOID VALVE OPTIONAL)
M2 FUEL PUMP Y3 HAMMER SOLENOID VALVE X13 3-WAYS CONNECTOR FU8 FUSE 7.5A (ELECTRICAL SOCKET - 30 + CABIN)
S5 OPTIONAL SWITCH (TBG) Y4 STOP MOTOR X14 2-WAYS CONNECTOR FU10 FUSE 7.5A (STOP MOTOR COIL)
S6 LIGHT SWITCH X16 4-WAYS CONNECTOR FU11 FUSE 7.5A (WORKING BEAM)
S7 PUSH-BUTTON X17 2-WAYS CONNECTOR
S8 HAMMER SOLENOID VALVE X19 5-WAYS CONNECTOR MARK
PUSH-BUTTON X20 2-WAYS CONNECTOR DEUTSCH
S9 N.A. PUSH-BUTTON X21 2-WAYS CONNECTOR DEUTSCH
S10 PRESSOSTAT X23 3-WAYS CONNECTOR DEUTSCH
PC35R-8 PC45R-8 10-77

10-78 PC35R-8 PC45R-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A2.5
2.19
A2.5
2.19
XS11 2 1 XS11 XS14 3 2 1 XS14

FU5 FU3
1 1
0 7.5A 0 2 15A
R - G1
S11 S14
S - N1.5
6 5 6 5
XS11 XS11 XS14 XS14
S12
B1.5
B1.5
S - N1.5
4
X5
B - R1.5 N1
2.19
R - G1
5
X5
R - G1
B - N1
1.12
B - N1
S13
5
X19
A/R1
C1.5
L1.5
B - N1
X19
A/R1
1 2 3 1
X24 X26 X26 X27
Y2 M R3
M3
V7
X27
X24 X26 3
2 1
N1.5
N1
N1
31
2.19
RKP06590

M3 VENTILATOR X5 13-WAYS CONNECTOR MARK FU3 FUSE 15A (VENTILATOR)
R3 FUEL LEVEL INDICATOR X19 5-WAYS CONNECTOR MARK FU4 FUSE 10 (CAR RADIO)
S11 ROTATING BEAM SWITCH X24 2-WAYS CONNECTOR DEUTSCH
S12 ARM REST MICRO X26 4-WAYS CONNECTOR
S13 SERVOCONTROL MICRO X27 3-WAYS CONNECTOR
S14 SWITCH A VENTILATOR XS11 CONNECTOR FOR SWITCH MERIT
V7 SERVOCONTROL SOLENOID VALVE DIODE XS14 CONNECTOR FOR SWITCH MERIT
Y2 SERVOCONTROL SOLENOID VALVE
PC35R-8 PC45R-8 10-79

10-80 PC35R-8 PC45R-8
GROUP 20
TESTING AND ADJUSTMENTS
Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2 Control and adjustment of the track-shoe tension. . 38
Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24 Control and regulation of the pressures in the
Checking the engine speed . .. . . . . .. . . . .. . . . . .. . . . .. . 25 hydraulic circuits .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
Adjustment of valve clearance . . . . .. . . . .. . . . . .. . . . .. . 26 Control and regulation of the LS differential
Measurement of the compression pressure .. . . . .. . 27 pressure and adjustment of the ls valve . . .. . . . .. . . . 42
Control and adjustment of the tension of Regulation of the PC valve .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
the fan belt . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 28 Control and regulation of the servo-control
Control and adjustment of the injection timing . . .. . 29 power supply . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Control and adjustment of the accelerator stroke . . 31 Elimination of residual pressures - pressurisation
of the tank . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Adjustment of the stroke of the blade
command lever . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32 Bleeding air from the hydraulic circuits . . . .. . . . .. . . . 47
Adjusting the flexible cables .. . . . . .. . . . .. . . . . .. . . . .. . 33 Control of hydraulic drifts - analysis of the causes
of a drift . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 49
Control and adjustment of the stroke of the
travel lever . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 34 Checking for any leakages inside the working
equipment cylinders. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Adjustment of the stroke of
the boom swing command pedal . .. . . . .. . . . . .. . . . .. . 35 Checking for any leakages inside the
swing motor .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Adjustment of the PPC valve clearances . . . .. . . . .. . 36
Methods for testing for leakages inside the
Adjustment of the rubber pad and safety swivel joint . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 57
microswitch for servo-control engagement . .. . . . .. . 37
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 Permissible

value value
High idling rpm 2700 2675 ± 2725

Engine speed Low idling rpm 1150 1125 ± 1175
Rated speed rpm 2500 Ð
Exhaust gas At sudden acceleration Bosch Max. 3.5 Max. 6.0

colour At high idling speed Index Max. 1.5 Max. 3.0
Intake valve (20ëC) mm 0.20 0.20

Valve clearance
Exhaust valve (20ëC) mm 0.20 0.20
Compression Oil temperature 40-60ëC kg/cm2 33w1 26w1

pressure
(SAE30 oil) (Engine speed) rpm (250) (250)
Blow-by Water temperature in operating range

pressure Ð Ð
(SAE30 oil) At high idling speed mm H2O
(Water temperature in operating range)

Engine oil At high idling speed (SAE30) kg/cm2 3.0 ± 3.5 Min. 2.0
pressure At low idling speed (SAE30) kg/cm2 1.5 Min. 1.0
At low idling speed (SAE10W) kg/cm2 1.5 Min. 1.0
Engine oil Whole speed range ëC Max. 120 Max. 120

temperature
Fuel injection Before top dead center (BTDC) Degree 14w1 14w1
timing
Fan-belt tension Deflection when pressed with finger mm 10 ± 15 Ð

force of approx. 6 Kg
20-2 PC35R-8 PC45R-8

. FOR THE ENGINE
PC45R-8
4D84E-3FA
Standard Permissible
value value
2700 2675 ± 2725

1150 1125 ± 1175
2500 Ð
Max. 3.5 Max. 6.0

Max. 1.5 Max. 3.0
0.20 0.20
0.20 0.20
33w1 26w1
(250) (250)
Ð Ð
3.0 ± 3.5 Min. 2.0

1.5 Min. 1.5
1.5 Min. 1.5
Max. 120 Max. 120
14w1 14w1
10 ± 15 Ð
PC35R-8 PC45R-8 20-3

. FOR THE MACHINE
Classifi- Check item Test condition Unit Standard Permissible

cation value value
. Boom circuit: max. pressure
. Hydraulic oil temperature: 45 ± 55ëC
. Cooling circuit: in correct range 2600 2550 ± 2650
. Engine oil pressure: in correct range
H Measure when pressure has stabilised
Engine
Engine speed with

one pump at max. . Boom and swing circuit:
rpm
pressure
max. pressure
2580 2530 ± 2630
. Cooling circuit: in correct range
. Engine oil pressure: in correct range
H Measure when pressure has stabilised
Boom control < a b < a b

ᐉ
a b
Arm control
Bucket control
30 6 6 30 6 6
Swing control
Control valve
RKP01970
mm
Work equipment control
ᐉ
Blade control a b
Boom swing control 20 6 6 20 6 6
Travel control RKP01980
Boom control . At centre of Neutral Raise 60 50 ± 70

lever Lower
lever knob
. Reading at
Arm control end of travel Neutral
Open 60 50 ± 70
lever Curled
. Equipment
on the ground
Bucket control lever Neutral Open 60 50 ± 70
. Engine Curled
stopped
Stroke of levers and pedals
. Tip of pedal Swing RH

Swing control lever Neutral Swing LH 60 50 ± 70
Blade control lever Neutral Raise 75 60 ± 90

Lower
mm
Boom swing Neutral Swing RH 20 15 ± 25
pedal Swing LH
Travel control Neutral Forward 90 80 ± 100

lever Backward
Accelerator lever Min. Ð Max. 130 110 ± 150
Work equipment, 5 Max. 15

swing
Play of control lever
Travel 10 Max. 25
20-4 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value value
2550 2500 ± 2600
2540 2490 ± 2590
< a b < a b
30 6 6 30 6 6
20 6 6 20 6 6
60 50 ± 70
60 50 ± 70
60 50 ± 70
60 50 ± 70
80 65 ± 95
20 15 ± 25
90 80 ± 100
130 110 ± 150
5 Max. 15
10 Max. 25
PC35R-8 PC45R-8 20-5

. FOR THE MACHINE

cation value value
Boom lever 2.1 1.7 ± 2.5

Operating force for control of levers and pedals
Arm lever . Engine speed: high idling 2.1 1.7 ± 2.5

Bucket lever . Instrument coupling at centre 1.9 1.5 ± 2.3
of control lever knob
. Instrument coupling on outside
Swing lever edge (for pedal control) 1.9 1.5 ± 2.3
. Reading at end of travel
Boom swing pedal kg 5.0 4.0 ± 6.0
Blade lever 3.0 2.2 ± 3.8
Travel control lever 1.8 1.4 ± 2.3
Min. Max. 2.0 1.5 ± 2.5

Travel accelerator
lever
Max. Min. 1.8 1.3 ± 2.3
. Engine speed: high idling

Unload pressure kg/cm2 35 30 ± 40
. All levers at HOLD
. Relieve pump outlet pressure
Boom 250 10 250 10
Arm 250 10 250 10
Bucket 250 10 250 10

Servocontrol 30 30
Circuit pressure
. Hydraulic oil temperature: 45 ± 55ëC 5 5

. Check one circuit at a time
Boom swing . Relieve pump outlet pressure 250 10 250 10
Blade kg/cm2 250 10 250 10
Travel 250 10 250 10
Swing 168 5 168 5
. Hydraulic oil temperature:

45 ± 55ëC All levers at HOLD 35 30 ± 40
LS differential . Engine speed: max.
pressure . Differential pressure=
pump delivery Travel rotating freely,
pressure ± LS pressure travel lever at half-way 16 16w1
position
20-6 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value 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 5 30 5
250 10 250 10
250 10 250 10
250 10 250 10
200 5 200 5
35 30 ± 40
16 16w1
PC35R-8 PC45R-8 20-7

. FOR THE MACHINE

cation value value
Work equipment at max. reach
mm 430 540
Braking angle RKP01840
(40) (50)
. No load in bucket (Degree)
. Make centering marks on the outer swing
circle rings. Rotate the revolving frame
360ë and lock in position. Measure the dif-
ference between the marks after stopping.
90ë 2.3w0.3 Max. 2.9
Time taken to start swing sec

RKP01840
. No load in bucket
. Hydraulic oil temperature: 45 ± 55ëC 180ë 3.8w0.5 Max. 4.5
. Measure the time taken for swings
to start from positions at 90ë and
180ë.

Swing
Time taken for to swing sec 33w3 Max. 38

RKP01840
. No load in bucket
. Make one turn to settle machine
. Measure the time taken to make 5 full
swings.
15°
135° RKP01990
mm 160 270
Hydraulic drift of swing (15ë) (25ë)
. Load in bucket: PC35R: 176 kg (Degree)
PC45R: 270 kg
. Engine switched off
. Park the machine on a 15ë slope and po-
sition the boom at 135ë with respect to
the ground surface.
. On the outer swing circle, mark the posi-
tion between revolving frame and track fra-
me. After 15 minutes measure the drift.
20-8 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value value
475 595
(40ë) (50ë)
2.5w0.3 Max. 3.0
4.3w0.5 Max. 5.0
33.0w3 Max. 40
240 360
(20ë) (30ë)
PC35R-8 PC45R-8 20-9

. FOR THE MACHINE

cation value value

Swing
Internal leakage from . Swing lock: engaged ,/min Ð Ð

swing motor
. Measure the leakage
. Pressurize circuit.
Measuring posture
Low speed
30 25 ± 35
Travel motor swing

speed (1) sec
(no-load) RKP01950
High speed
Engine speed: high idling
. Hydraulic oil temperature: 45 ± 55ëC 19 16 ± 22
. Rest the bucket on the ground, rai-
se one track-shoe, rotate one turn,
then measure time taken for next.
Measuring posture
Low speed
45°
25.5 21 ± 30
(26.3) (22 ± 31)
Travel speed (2) RKP01850

sec
High speed
.
Travel
Engine speed: high idling

. Hydraulic oil temperature: 45 ± 55ëC 15.5 12 ± 19
. On flat ground (16.0) (12.5 ± 19.5)
. Travel for at least 10 metres and
then check on the time needed to
cover 20 metres
45°
Low speed
Max. 500 Max. 550

RKP01850

45 ± 55ëC
Travel deviation . Travel 20 metres on flat ground mm
and measure the deviation.
H The surface must be firm and hori-
zontal.
High speed
20m
Max. 300 Max. 330
X
10m
RKP01830
H Measure dimension «X»
20-10 PC35R-8 PC45R-8

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

. FOR THE MACHINE

cation value value
Measuring posture
30°
Hydraulic drift of mm Max. 300 Max. 350
travel motors
Travel
RKP02000
. Engine stopped.
. Hydraulic oil temperature: 45 ± 55ëC.
. Machine parked on sloping ground.
. Measure the drift after 5 minutes
Leakage of travel motor . Hydraulic oil temperature: 45 ± 55ëC ,/min Ð Ð
. Lock shoe
Measuring posture
Short arm Max. 300 Max. 300
Total work equipment
(Downward movement
of tips of bucket teeth)
Long arm Max. 300 Max. 350
RKP01860
. Bucket: rated load: Short arm 14 Max. 25

PC35R: 176 kg
Boom cylinder PC45R: 270 kg
(Retraction) . In this position, measure ex-
tension or retraction of each mm
Long arm 18 Max. 25
cylinder, and any leakages oc-
curring when a load is applied
to the tips of the bucket teeth.
Hydraulic drift of working equipment
. Horizontal and level ground Short arm 20 Max. 25

. Levers: neutral
Arm cylinder . Engine: switched off
(Extension) . Oil temperature: 45 ± 55ëC.
. Take measurements as soon Long arm 22 Max. 25
as the engine stops.
. Measure the variations every 5
Bucket cylinder minutes and check the total 15 Max. 25
(Retraction) variation after 15 mins.
Short arm Max. 15 Max. 25
15°
135° RKP01990
Boom swing . Bucket: rated load: mm

PC35R: 176 kg
PC45R: 270 kg
. Engine stopped.
. Hydraulic oil temp.: 45 ± 55ëC
. In the same position as above, Long arm Max. 20 Max. 30
stop the machine on a 15ë slo-
pe and position the revolving
frame at 90ë. Measure the ex-
tension and retraction of the
cylinder after 15 minutes.
20-12 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value value
Max. 330 Max. 400
Ð Ð
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

cation value value
Hydraulic drift of working equipment
Blade
(measure the downward RKP01870
mm Max. 30 Max. 45
movement of the edge
of the blade)
. 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.
Boom Max. 2.0 Max. 5.0

Internal cylinder

leakage
Arm . Hydraulic oil temperature: 45 ± 55ëC cm3/ Max. 2.0 Max. 5.0
. Check leakages: on the cylinder on the si- min
de opposite to the one under pressure.
Bucket Max. 2.0 Max. 5.0
20-14 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value 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

cation value value
. Measuring posture
Boom
Raise
3.0 2.6 ± 3.4
Bucket teeth on the ground
RKP01820
Lower
. Engine speed: high idling 3.0 2.6 ± 3.4
Cylinder fully extended
45 ± 55ëC
. Measuring posture
Closed
Arm
3.3 2.9 ± 3.7
Cylinder fully retracted
RKP01880
Inout
2.7 2.4 ± 3.0
Cylinder fully extended . Engine speed: high idling
45 ± 55ëC
. Measuring posture
Bucket
Dump
Work equipment
3.3 2.9 ± 3.7

Speed

sec.
Curled
RKP01890

45 ± 55ëC
. Measuring posture
Boom swing
L.H.
7.5 6.5 ± 8.5

RKP01960
R.H.

45 ± 55ëC
. Measuring posture
Blade
Raise
1.2 1.0 ± 1.4

Blade on the ground
RKP01900
Lower
Blade raised to . Engine speed: high idling 1.2 1.0 ± 1.4

max. height . Hydraulic oil temperature:
45 ± 55ëC
20-16 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value 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

cation value value
Measuring posture
Boom Max. 2.0 Max. 2.5

RKP01910
. Engine speed: low idling

. With the work equipment fully extended,
lower the boom and measure the time ta-
ken to raise the machine from when the
bucket reaches the ground.
Measuring posture
Arm RKP01920
0 0
. Bring the boom into a horizontal position.
Retract the arm cylinder completely and
Work equipment
then extend it. Measure the time elapsing

Time lags
from when the arm stops at dead centre

until it starts to move again.
sec.
Measuring posture
Bucket RKP01930
0 0
. 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 Max. 1.0 Max. 1.2

. Raise the blade to its max. height, then lo-
wer it. Measure the time that it takes to rai-
se the machine after the blade touches the
ground.
20-18 PC35R-8 PC45R-8

. FOR THE MACHINE
PC45R-8
value value
Max. 2.0 Max. 2.5
0 0
0 0
Max. 1.0 Max. 1.2
PC35R-8 PC45R-8 20-19

. FOR THE MACHINE

cation value value
Theoretical flow cm3 8.4
Motor speed rpm 2500

Gear pump P2 Test pressure 165
kg/cm2
Nominal capacity
,/min 19.5
. Hydraulic oil temperature: 45 ± 55 ëC
. Delivery piston pump P1

. Pump speed: 2500 rpm
. Gear pump P2: without load
Q (ᐍ/min)
0 bar
100 92.5 ᐉ/min
113.7 bar
91 ᐉ/min
Pump characteristics
90
109.8 bar
79 ᐉ/min
80
0 bar 13.2 bar

70 82.5 ᐉ/min 66.3 ᐉ/min
60
245 bar
50 32.4 ᐉ/min
137.2 bar
58.4 ᐉ/min
40
30
245 bar
24.3 ᐉ/min
20
10
0 49 98 147 196 245 P(bar)

(50) (100) (150) (200) (250) (kg/cm2)
RKP06711
20-20 PC35R-8 PC45R-8

Classifi- . Delivery piston pump P1

cation . Pump speed: 2500 rpm
. Gear pump P2: at max. pressure
Q (ᐍ/min)
0 bar
100 92.5 ᐉ/min
51 bar
92 ᐉ/min
90
39.2 bar
81 ᐉ/min
80
76.4 bar
0 bar 67.5 ᐉ/min
70 82.5 ᐉ/min
60
60,7 bar
50 62.5 ᐉ/min
40
245 bar
16 ᐉ/min
30
20
10 245 bar
6 ᐉ/min
0 49 98 147 196 245 P(bar)

(50) (100) (150) (200) (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

cation value value
Theoretical flow cm3 10.5
Motor speed rpm 2500

Gear pump P2 Test pressure 200
kg/cm2
Nominal capacity
,/min 24.5
. Hydraulic oil temperature: 45 ± 55 ëC
. Delivery piston pump P1

. Pump speed: 2500 rpm
. Gear pump P2: without load
Q (ᐍ/min)
130
0 bar
118 ᐉ/min 122.5 bar
120 116.6 ᐉ/min
110
100
0 bar
107.8 ᐉ/min
117.6 bar
90
104 ᐉ/min 162.7 bar
81.2 ᐉ/min
80
245 bar
70 49 ᐉ/min
162.7 bar
72.3 ᐉ/min
60
50
245 bar
40.2 ᐉ/min
40
30
20
10
0 49 98 147 196 245 P(bar)

(50) (100) (150) (200) (250) (kg/cm2)
RKP06731
20-22 PC35R-8 PC45R-8

Classifi- . Delivery piston pump P1

cation . Pump speed: 2500 rpm
. Gear pump P2: at max. pressure
Q (ᐍ/min)
130
0 bar
118 ᐉ/min 53.9 bar
117 ᐉ/min
120
33.3 bar
110 107 ᐉ/min
100
0 bar
107.8 ᐉ/min
90 84.2 bar
82.5 ᐉ/min
80
70
71.5 bar
72.9 ᐉ/min
60
50
245 bar
23 ᐉ/min
40
30
20
245 bar
12 ᐉ/min
10
0 49 98 147 196 245 P(bar)

(50) (100) (150) (200) (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 Code Name Q.ty Remarks
Valve clearance A 1 Commercially Feeler gauge 1 Ð

available
1 ATR800090 Compression gauge 1 0-70 kg/cm2

Compression pressure B
2 ATR800130 Adapter 1 Ð
1 ATR800070 Multi-scale tachometer 1 20 - 4000 rpm

Engine speed C
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm
1 ATR800170 Compression gauge 1 Scale 60 bar

Hydraulic pressure E
4 ATR800200 Servocontrol kit 1 Ð

(Differential pressure)
Track shoe tension G 1 823001135 Grease nipple 1 Included in the

machine tool kit
20-24 PC35R-8 PC45R-8

TESTING AND ADJUSTMENTS CHECKING THE ENGINE SPEED
CHECKING THE ENGINE SPEED
When checking the engine rpm , always be very

careful not to touch parts that reach high tempera-
tures and not to get entangled in rotating elements.
H Check the engine speed after the following conditions
have been reached:
C1
. Temperature of engine cooling water: 68 ± 80 ëC.
. Temperature of hydraulic oil: 45 ± 55 ëC.
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 "mini-
mum" position).
. High idling without load (accelerator lever in MAX
"maximum" position).
H Low idling: 1150w25 rpm
H High idling: 2700w25 rpm MIN
H If the minimum and maximum speeds do not fall

within permissible limits when the engine is with-
out load, check the position locks of the accelera-
tor lever, and the sheathing of the accelerator
well, before carrying out any tests under load.
(See «ADJUSTMENT OF THE ACCELERATOR
LEVER»). RKPA3890
. Engine rpm with the pumps under load.

H Boom at max. pressure: PC35R: 2600w50 rpm
PC45R: 2550w50 rpm
H Boom and swing at max. pressure:

PC35R: 2580w50 rpm
PC45R: 2540w50 rpm
H If engine efficiency does not fall within permissi-

ble limits, have the engine checked by an
authorised workshop.
PC35R-8 PC45R-8 20-25

TESTING AND ADJUSTMENTS ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE
. Adjust the clearance between valve and rockers to the

following values:
Unit: mm
With Suction valves Exhaust valves 2

engine
cold 0.20 0.20
1
1 - Remove the intake filter and the valve cover.
2 - Turn the drive shaft in the normal direction of rotation 1
until the line (1) marked as no. 1 on the flywheel is in
alignment with the reference notch (2) on the flywheel
housing.
RKP06440
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 4
turn and realign the reference marks (1) and (2).
3 - Loosen the lock nut (3) and unscrew the adjustment 3
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. 5
1 - If the valve caps (5) are damaged, replace
them with new ones. YES
SI NO
NO
2 - Make sure that the valve caps fit perfectly and
are lying flat on the valve stem.
4 - Insert the feeler gauge A1 between the rocker (6) and RKP06450
5
the valve cap (5).
Rotate the adjusting screw (4) until it rubs against the
feeler gauge A1.
4 3
Secure this position with the nut (3).
Lock nut: 25.5w2.5 Nm 6
H After locking the nut (3), check the valve clear-
ance again.
5 - PC35R
After adjusting the No. 1 cylinder, rotate the drive
shaft 240ë each time and adjust the valve clearance
of the other cylinders according to the ignition se- A1
quence.
H Ignition sequence: 1 - 3 - 2.
RKP06530
After adjusting the No. 1 cylinder, rotate the drive
shaft 180ë each time and adjust the valve clearance
of the other cylinders according to the ignition se-
quence.
10 8
H Ignition sequence: 1 - 3 - 4 - 2.
9
. Assembly of the valve cover
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
7
(9) and the lock nuts (10).
Lock nuts for cover: 25w3 Nm
RKP06560
20-26 PC35R-8 PC45R-8

TESTING AND ADJUSTMENTS 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.
2
H Test conditions: 3
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55 ëC.
. Battery: fully charged.
. Valve clearance: adjusted
(See «ADJUSTMENT OF VALVE CLEARANCE»).
1
. Air filter functioning properly.
RKPA3900
1 - Remove the clamp (1) and disconnect the high-pres-
sure tube (2).
2 - Remove the nozzle holder (3) of the cylinder to be
checked. 5
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.
RKPA3910
5 - Mount the adapter B2 and connect the test pressure

gauge B1. C1
H Check that the seal is mounted in the adapter,
and that it is undamaged.
B2
6 - Turn the engine using the starting motor and read the
compression value. B1
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. RKP06370
H Compression value:
Normal: 33w1 kg/cm2 a 250 rpm
Minimum permissible: 26w1 kg/cm2 a 250 rpm
H Maximum difference between the cylinders: 40
2 ± 3 kg/cm2
Compression pressure (kg/cm2)
35
7 - After the reading, re-assemble the nozzle holder (3),
and reconnect the high- pressure tube (2) and the 30
connector (4).
Nut that secures the nozzle: 7.84w0.98 Nm 25
High-pressure coupling: 31.85w2.45 Nm 20
200 250 300 350 400

Engine speed (rpm)
RKP06751
PC35R-8 PC45R-8 20-27

CONTROL AND ADJUSTMENT OF THE
TESTING AND ADJUSTMENTS 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 be-
tween the alternator (2) and the pulley (3) that 5 1 4
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.
2
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-tighten- 3
ing stop.
10 ± 15 mm
10⫼15 mm
2 - Rotate the alternator (2) to give the belt (1) the cor-
rect tension and tighten the screws (4) and (5).
3 - Check the belt (1) tension. 2
H If the belt has been replaced with a new one,
check the tension again after about 20 hours of 1
operation. Crankshaft
Puleggia
Screws fastening the alternator to the timing pulley
albero motore
system cover: 45 ± 54 Nm RKP04800
Screws locking the support: 25 ± 32 Nm
20-28 PC35R-8 PC45R-8

TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
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 1
The cylinders are numbered 1-2-3-4 counting from the
flywheel side.
H The spark advance notches of 0ë-10ë-15ë-20ë; are
also marked on the flywheel. In order to read the inter-
mediate 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 cas-
ing.
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. 2
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 de-
livery tubes (4) from the injection pump.
4 - Rotate the flywheel slowly in a counter-clockwise di- 4
rection (seen from the flywheel side), checking care-
fully the level of the fuel in the No. 1 union of the in-
jection pump. Stop the rotation when the fuel level
starts to rise.
3
RKPA3901
5 - Check the position of the notches at 15ë and 10ë that

appear in the hole in the casing and, in function of the
position, establish the true fuel injection timing. 15°
H In order to determine the degrees of intermediate 20°
fuel injection timing, sub-divide the space be- 10°
tween 10ë and 15ë. 15°
H Normal fuel injection timing: 14w1ë 10°
1/3
Notch
2
RKPA0011
PC35R-8 PC45R-8 20-29

TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
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 6
pump (5) towards the outside.
. To DELAY the injection rotate the pump (5) to-
wards the cylinder block.
H Check the extent of the movement on the scale 7
(7).
7 - Lock the nuts (6) that fasten the pump to its block. 5
Pump fastening nuts: 25 ± 35 Nm
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
TESTING AND ADJUSTMENTS OF THE ACCELERATOR STROKE
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE
H Test conditions:
. Engine: switched off.
. Working equipment: resting on the ground.
1
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 7
stroke, in the minimum position, until the lever (5)
rests against the minimum-adjustment screw (6). MIN
H If the lever (4) touches the housing (7), loosen the 3 2
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).
4 9
3 - Tighten the screw (2) until it is 0.1 mm from the lever
(4) and tighten the lock-nut. 8
RKPA4731
1
4 - Push the accelerator control lever (4) to the end of its

stroke in the maximum position, until the lever (5) 10 5
6
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. 1
RKPA3951
PC35R-8 PC45R-8 20-31

ADJUSTMENT OF THE STROKE OF THE
TESTING AND ADJUSTMENTS 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 1
1 - Move the operator's cab forwards complete.
2
2 - Loosen the nuts (1) and unscrew the screws (2) by a 2
few turns.
RKPA3960
3 - Adjust the centering of the lever (3) with respect to the

housing (4) by loosening the outside nut (5) of one of 3
the sheathings and tightening the inside nut (6) of the
other by the same amount. 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
7
full stroke.
6
6 - Tighten the lock-screw (2) until it rests on the lever
and then turn it for another half turn. Secure the posi- 5 8
tion with the nut (1). RKPA3961
7 - Repeat this lever adjustment (3) for the other direc-

tion.
Before starting the engine to check the adjust-
ment, make sure that the valve block spool re-
turns to its neutral position each time the lever
(3) is released.
20-32 PC35R-8 PC45R-8

TESTING AND ADJUSTMENTS 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. 1
RKPA2220
2 - Loosen the nut (2) in the sheath of the drive (3) to be

adjusted. Travel Boom swing
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 4 4
is absolutely correct, the locknuts of the sheath 2
should be behind the bracket (4).
4 - Firmly tighten the nuts (2).
2 3
3
RKPA4930
[ ALIGNAMENT ERROR
A BETWEEN LEVER
IN NEUTRAL POSITION
0 ± 3 mm
TRAVEL
LEVERS
= =
BOOM SWING
CONTROL PEDAL
2 4
RKP06630
[ A= for canopy: 200 mm
for cabin 220 mm
PC35R-8 PC45R-8 20-33

CONTROL AND ADJUSTMENT OF THE STROKE
TESTING AND ADJUSTMENTS 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
6
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. 2
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 4 5
(2).
6 - Repeat the same operations for the other direction RKPA4940
and for the other lever.
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
TESTING AND ADJUSTMENTS 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 direc- 2
tion. Keep this position and tighten the screw (4) until 5
it touches the support. Tighten the screw (4) by a final 4
half-turn.
4 - Hold the pedal (5) in position and lock the nut (3).
5 - Repeat the same operations for the other working di-
rection of the pedal.
Before starting the engine, check that the pedal
and control valve spools return to their neutral
positions. RKPA3970
6
4
4
3
3
RKP06640
PC35R-8 PC45R-8 20-35

TESTING AND ADJUSTMENTS 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. 2
Turn the ignition key to the «I» position and move the
command levers in all directions in order to release
1 3
all pressure in the hydraulic circuits.
Return the ignition key to the «O» (OFF) position and 4
remove it.
Push the lever of the safety device into the
«LOCKED» position.
Slowly loosen the oil-tank refuelling cap to eliminate
residual pressure.
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 acti-
vate 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
TESTING AND ADJUSTMENTS 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).
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
3
starting point of the cut-off slot.
4 - Keep this position and bring the rubber pad into con-
tact with the console (6).
6
4
2
RKPA3230
5 - Release the servo-control engagement lever and se-

cure the rubber pad (3) with the nut (2).
3
3 mm
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.
7
3 - Lower the console (6) into its working position.
4 - Tighten the microswitch (9) until it depresses the
push-button by 3w0.5 mm. 9
5 - Put the console (6) into its 'safe' position and lock the
nut (8). 8
6 - Connect the connectors (7) and replace the cover (1). RKPA3240
PC35R-8 PC45R-8 20-37

TESTING AND ADJUSTMENTS 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 ÷ 150
100100 ± 150
mmmm
halfway between the sprocket wheel and the

track-shoe stretcher wheel.
2 - Rotate the revolving frame 90ë 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 sprock-
et 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 en-

gaging 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. "A"
H If difficulties are found when injecting the
grease, move the machine slowly backwards
and forwards over a short distance.
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 op-
erator. 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.
RKPA4000
20-38 PC35R-8 PC45R-8

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

HYDRAULIC CIRCUITS
H Test conditions: PRESSURES IN THE CIRCUITS AND IN THE
. Engine: at working temperature. TANK») and place the safety engagement levers
into their locked positions.
. MIN and MAX. engine speeds: within permissi-
ble limits. After having connected the pressure gauges, pres-
surise the tank. For details, see «PRESSURISA-
TION OF THE TANK».
Before removing the plugs in order to measure the
pressures, release the residual pressures in the
circuits (see «ELIMINATION OF THE RESIDUAL
OIL COOLER
TANK
P2
DIESEL P1
RKP06761
. The control valve consists of the spools that command:

Command Ports
Arm (Close - Open) A1 - B1
Travel motor L.H. A2 - B2 B
(Backwards - Forwards)
1 2 3 4 5 6 7 8 10
Travel motor R.H. A3 - B3 A
(Backwards - Forwards)
Boom (Raise - Lower) A4 - B4
Bucket (Dump - Curl) A5 - B5
Boom swing (R.H. - L.H.) A6 - B6 RKP06770
Blade (Lower - Raise) A7 - B7

Swing (R.H. - L.H.) A8 - B8
Hammer (Suction - Delivery) A9 - B9
PC35R-8 PC45R-8 20-39

1. Control of operating pressure (unloading valve)

1 - Remove the plug (1) of pump P1 and mount a E1
pressure adapter.
2 - Connect a pressure gauge E1 (60 bar). 1
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 RKPA4010
valve must be substituted.
2. Control the operating pressures of the working

equipment and machine travel
1 - Remove the plug (1) of pump P1 and mount a E3
pressure adapter.
2 - Connect a pressure gauge E2 (400 bar) or E3 1
(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 equip-
RKPA4020
ment, push the piston to the end of its stroke.

To check the pressure of machine travel, in-
sert a block "A" between the chassis and
the sprocket wheel.
H Normal pressures: A
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 RKPA4030
bar).
Insert the turret swing locking-pin.
3 - Start the engine and bring it up to high idling.
4 - Check the pressure for a swing to the right and a E3
swing to the left, bringing the lever of the left-hand
PPC valve to the end of its stroke and with the 1
pressure stabilized.
H Normal pressure:
PC35R: 168 5 kg/cm2 (165 5 bar)
PC45R: 200 5 kg/cm2 (196 5 bar)
RKPA4040
20-40 PC35R-8 PC45R-8

Valve adjustment
H The unloading valve cannot be re-adjusted, only sub-
stituted.
1. Adjustment of the main relief valve 1

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 CLOCK-
WISE direction. RKPA4050
. To DECREASE pressure, turn in a COUN-

TER-CLOCKWISE direction.
H Each turn of the adjusting screw (3) varies the
pressure by about 125 bar (128 kg/cm2).
3 - Lock the nut (2). 2
Nut: 69w10 Nm
H After adjustment, check the adjustment of the
main relief valve with the same procedures as
used for the measurements.
RKP06360
2. Adjustment of the safety valve of the swing mo-

tor
Do not calibrate the valves when the circuits are
1
under pressure.
H To perform these adjustments, follow the proce-
dures 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 fol-
lows:
1 - Loosen the lock nut (2) and turn the adjusting
screw (3). RKPA4060
. To INCREASE pressure, turn in a CLOCK-

WISE direction.
. To DECREASE pressure, turn in a COUN-
TER-CLOCKWISE direction. 3
H Each turn of the adjusting screw (3) varies the 2
2 - Lock the nut (2).
Nut: 8.8w1 Nm
RKP06430
PC35R-8 PC45R-8 20-41

CONTROL AND REGULATION OF THE LS DIFFERENTIAL
TESTING AND ADJUSTMENTS PRESSURE AND ADJUSTMENT OF THE LS VALVE

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 pres-
sure adapters. 1
2 E4
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).
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 RKPA4070
LS differential pressure according to the test con-

ditions in Table 1.
Table 1
Position of LS differential2 pressu-
the travel re in kg/cm (bar) NOTES
lever
The LS differential pressure
Neutral 35w5 (34.3w4.9) is equal to the pressure gi-
ven 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 1 E3
pressure adapters.
2 - Connect pressure gauge E2 or E3 to the pres-
sure 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 condi- RKPA4080
tions 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 cor-
rect.
5 - Disconnect the pressure gauge E2 or E3 from the 2 E3
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 pres-
sure of the pump (PP) in order to obtain the differ-
ential pressure value DPLS (PP ± LS=DPLS)
H DPLS normal= 34.3 bar (35 kg/cm2) RKPA4090
20-42 PC35R-8 PC45R-8

TESTING AND ADJUSTMENTS PRESSURE AND ADJUSTMENT OF THE LS VALVE
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
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 COUNTER-
CLOCKWISE direction.
H Each turn of the adjusting screw (4) varies the
RKP06780

Nut: 31w3.5 Nm
3
H After the adjustment, check the setting of the LS 4
valve (1) following the procedure used for the test.
RKP06510
PC35R-8 PC45R-8 20-43

TESTING AND ADJUSTMENTS 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 en-
gine speed, the delivery pressure and the LS differen- 1
tial 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). 2
. 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
RKPA4100
the screw (3) in a COUNTER-CLOCKWISE direc-

tion to DECREASE the torque absorption.
3 - After adjustment, tighten the check-nut (2).
2
3
RKP06500
20-44 PC35R-8 PC45R-8

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

POWER SUPPLY
H Test conditions:
. Engine: at working temperature. E1
. Hydraulic oil temperature: 45 ± 55 ëC.
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
1
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
2
all leers in neutral position.
4 - Check the pressure.
H Normal pressure: 29 5 bar (30 5 kg/cm2)
2. Regulating the servo-control valve

If the pressure value does not fall within the toler- RKPA4120
ances, regulate the valve (2) as follows:

1 - Loosen the lock nut (3) and turn the adjusting
screw (4).
. To INCREASE pressure, rotate in a CLOCK-
WISE direction. 3
. To DECREASE pressure, rotate in a COUN-
TER-CLOCKWISE direction.
H Each turn of the screw (4) varies the pressure 4
by 56 kg/cm2 (55 bar).
Nut: 22w2.5 Nm
RKP07150
PC35R-8 PC45R-8 20-45

ELIMINATION OF RESIDUAL PRESSURES -
TESTING AND ADJUSTMENTS PRESSURISATION OF THE TANK
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION

OF THE TANK
1. Elimination of pressures from the hydraulic cir-
cuits.
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» po-
sition.
2. Elimination of pressure in the tank

The hydraulic oil tank is of the sealed and pres-
surised type.
1
When tubes are to be removed or disconnected
for controls or repairs, or when caps are re-
moved, 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 re-
lease 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

TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS

Sequence of operations or procedures for bleeding the air
Procedures for bleeding air
1 2 3 4 5 6 7
Bleeding air Starting Bleeding Bleeding air Bleeding air Pressuris- Starting
from pumps engine air from from swing from travel ing tank tasks
cylinders motor motor
. Substitution of hydraulic oil p p p p p p p
. Cleaning tank filter ,1 ,1
. Substitution filter p p p
. Repair - substitution
pump p p p p p
. Removal of suction tube
. Substitution - repair
control valve p p p p
. Repair-Substitution
cylinders p p p p
. Removal of cylinders tube
swing motor p p p
p
. Removal of tubes
from swing motor
travel motor - joint
. Removal of tubes p p p p
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). 1
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 al-
low it to run at low idling for about 10 minutes 2
before proceding to bleed the air from the cir-
cuits. RKPA4101
PC35R-8 PC45R-8 20-47

TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
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 pressuris-
ing 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 RKP04940
stroke until it reaches max. pressure in both direc-
tions.
4 - Repeat the operation (starting from point 2) for the
arm, bucket, arm swing, and blade cylinders.
33 Giri
Turns
3. Bleeding air from the swing motor
Make sure that the swing-locking pin is not en-
gaged.
1 - With the engine at low idling, rotate the revolving

frame three turns towards the left.
2 - Repeat the same manoeuvre, rotating the revol-
ving frame to the right. 33Giri
Turns
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 track-
shoe.
H Engage the travel increment for about 10 sec-
onds.
100÷±150
100 150 mm
mm
5. Bleeding air from any optional equipment

H This method must be used for all the optional
working equipment, unless otherwise indi-
cated. 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 -
TESTING AND ADJUSTMENTS 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 NOR-
MAL 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 proce-
dures indicated in the «NORMAL TECHNICAL
DATA».
2. Analysis of the causes of hydraulic drifts

Before disconnecting the tubes, release hydrau-
lic pressures in the circuits (see «ELIMINATION
OF THE RESIDUAL PRESSURES»). 2
1. Boom test
1 - Position the machine with the arm vertical and 3
with the back of the bucket resting on the ground. 1
2 - Stop the engine and release the residual hydrau-
lic pressures.
3 - Disconnect the hoses (1) and (2) that supply the 4
cylinder on the head side and on the base side. RKPA4950
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. RKP04990
PC35R-8 PC45R-8 20-49

2. Arm test
1 - Position the machine with the arm completely ex-
tended and with the bucket teeth on the ground.
lic pressures.
RKP05000
3 - Disconnect the hose (1) from the arm cylinder

and plug them to prevent the entry of impurities. 2
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.
lic pressures.
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
side to catch any oil leakages. RKP05020
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 135ë to the left.
lic pressures.
RKP05040
3 - Disconnect from control valve the pipe (1) and

plug it.
H Plug the control valve union to prevent entry
of impurities 1
RKPA4140
4 - Disconnect the boom swing cylinder hose (2) and

plug it.
5 - Attach a provisional tube on the head side to
2
catch any oil leakages.
RKPA4150
6 - Start the engine and move the machine to a 15ë

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 15°
to the control valve.
135°
RKP05050
20-52 PC35R-8 PC45R-8

5. Blade test
1 - Position the machine with the arm resting verti-
cally on the ground and with the bucket resting
on its back.
2 - Raise the blade completely and support it on a
centrally-positioned block.
lic pressures.
RKP04930
4 - Disconnect the hoses (1) and (2) of the blade cy-

linder (3) and plug them.
3 1
5 - Plug the hole of the blade cylinder on the head
side and attach a provisional tube on the base 2
side to catch any oil leakages.
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. RKPA4160
. 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 IN-
SIDE THE SWIVEL JOINT».
6. Swing motor test

1 - Position the machine with boom, arm and bucket
raised as in the figure and with the revolving
frame turned 135ë to the left.
lic pressures.
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. At-
tach provisional tubes to the motor to catch any
oil leakages.
4 - Start the engine, move the machine to a 15ë
slope, and stop the engine. 1
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.
2
. If the revolving frame rotates the drift is due to
either the safety valve or the control valve. RKPA4170
H To establish the cause of the drift, install a

new safety valve.
15°
135°
RKP05050
20-54 PC35R-8 PC45R-8

CHECKING FOR ANY LEAKAGES INSIDE
TESTING AND ADJUSTMENTS 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 cylin-
der 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 RKP04720
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. POSITION FOR THE ARM AND BUCKET TEST
RKP04710
TUBE HEAD DELIVERY

SIDE BOTTOM SIDE
MAXIMUM
PRESSURE
RKP04751
PC35R-8 PC45R-8 20-55

CHECKING FOR ANY LEAKAGES INSIDE
TESTING AND ADJUSTMENTS THE SWING MOTOR
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR
H Test conditions:
. Engine: at working temperature. 2
. Hydraulic oil: 45 ± 55ëC.
. Turret: locked in place with the swing-locking pin.
1
1 - Disconnect the drainage tube (1) of the motor (2) and
plug it.
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 mea-

sure 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
TESTING AND ADJUSTMENTS INSIDE THE SWIVEL JOINT
METHODS FOR TESTING FOR LEAKAGES INSIDE THE

SWIVEL JOINT
H Test conditions:
. Hydraulic oil: 45 ± 55ëC.
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 F Blade cylinder, head side - Rise
tubes of the joint of the line to be checked.
G Blade cylinder, base side - Descent
If this corrects the defect, it is certainly due to the
swivel joint. B Travel motor to the left - Forward
If the defect persists, it can be ascribed to other
causes, but definitely not to the swivel joint.
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 C Travel motor to the right - Reverse
those lines subjected to working pressures.
The drainage line is therefore not included in
these tests.
The test method consists of pressurising the line to be
checked and measuring any leakages from the adja-
RKP06790
cent lines according to the following tables:
TABLE A
Symbol Line to be controlled (under pressure) Adjacent line (possible leakages) Sym.
External leak (visible) Ð
F Blade cylinder, head side - Rise
Blade cylinder base side - Descent G
Blade cylinder, head side - Rise F
G Blade cylinder base side - Descent
Travel motor to the left - Forward B
Blade cylinder base side - Descent G
B Travel motor to the left - Forward
Travel motor to the right - Forward D
Travel motor to the left - Forward B
D Travel motor to the right - Forward
Travel speed increment E
Travel motor to the right - Forward D
E Travel speed increment
Travel motor to the left - Reverse A
Travel speed increment E
A Travel motor to the left - Reverse
Travel motor to the right - Reverse C
Travel motor to the left - Reverse A
C Travel motor to the right - Reverse
External leak (visible) Ð
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
TESTING AND ADJUSTMENTS INSIDE THE SWIVEL JOINT
3. Preparation for the testing:

. Travel motor
. Travel increment
1 - Release all residual hydraulic pressures. 1
2
(See «ELIMINATION OF THE RESIDUAL PRES-
SURES 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 impuri-
ties.
3 - Disconnect from the relative actuators the tubes
that correspond to the lines adjacent to the one RKPA4180
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.
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 PRES-
SURES FROM THE CIRCUITS»).
3
2 - Disconnect from the blade cylinder (3) the tube (4) 4
corresponding to the line to be checked and seal 4
it. Also plug the holes in the actuators 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
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. Lines adjacent
3 - After 30 seconds, then for the next full minute
check to see if there are any leakages.
Line to be
H If oil leaks out of one of the two tubes of the tested
actuators (adjacent lines), it means that there
is a leakage of the intermediate gasket be-
tween the high pressure line and the adja-
cent line.
RKP04761
20-58 PC35R-8 PC45R-8

GROUP 30
REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3 FUEL TANK

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

RUBBER TRACK SHOES BOOM SWING CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 51 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 66
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 51 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 67
STEEL TRACK-SHOES BLADE CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 52 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 68
SPROCKET WHEEL WORK EQUIPMENT CYLINDERS
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 53 Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 69
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 53 Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 71
FINAL DRIVE UPPER WORK EQUIPMENT
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 54 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 75
IDLER AND RECOIL SPRING BUCKET
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 55 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 77
SPRING RECOIL AND THRUST ARM
CYLINDER GROUPS Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 78
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 56 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 79
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 57 ARM ASSEMBLY
IDLER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 80
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 59 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 80
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 60 BOOM
TRACK ROLLERS Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 81
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 61 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 82
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 61 BOOM SWING SUPPORT
BOOM CYLINDER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 83
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 63 BLADE
ARM CYLINDER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 84
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 64
BUCKET CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 65
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 65
30-2 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION 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 re-
moving 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 re-
covered.
INSTALLATION GROUP *** : . . . . . . . . . . . . . . . . . . . . . Title of operation.

. To install, reverse removal procedure.
: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving ~ ~ ~ (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 LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
PC35R-8 PC45R-8 30-3

REMOVAL AND INSTALLATION 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 in-
stallation 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 hoi-
sting 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.
. 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 en-
gine 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.
30-4 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Description Q.ty Notes

Removal - installation A 1 ATR200460 Equipment 1 For master pin
of steel track shoe
Disassembly - assembly B 1 ATR200720 Equipment 1 Removal - installation

recoil spring recoil spring
1 ATR200620 Equipment for disassembly 1 All cylinders

- assembly cylinders
Dynamometric wrench
2 ATR800190 with multiplier 1 Max. 400 kg (400 dNm)
3 ATR200730 Pliers for mounting gaskets 1 All cylinders
ATR200740 Plunger éi 30 2
4 Mounting bushings on
cylinders and piston rod
ATR200750 Plunger éi 35 2
Wrench for cylinder é 65 1

5 Removal - installation of
head
6-point socket wrench (30) 1

6 Removal - installation of
piston
Disassembly - assembly C ATR200870 6-point socket wrench (41) 1
cylinders
Plunger for piston rod é 30 1
7 Mounting ring on
the head
Plunger for piston rod é 35 1
Plunger for cylinder é 50 1

8 Mounting piston gasket
Gauge for cylinder é 50 1
Gauge for cylinder é 55 1

9 Gauging piston gasket
ATR200990 Gauge for cylinder é 60 1
ATR201000 Gauge for cylinder é 70 1
Bushing for piston rod 1

é 30
10 Mounting head
ATR201150 Bushing for piston rod 1
é 35
PC35R-8 PC45R-8 30-5

REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Description Q.ty Notes

Bushing for piston é 50 1
Bushing for piston é 55 1

Disassembly - assembly C 11 Assembling
cylinders piston - cylinder
ATR201190 Bushing for piston é 60 1
ATR201200 Bushing for piston é 70 1
1 Plunger 1
Assembly of idler D
2 Plunger 1
30-6 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION STARTER MOTOR
REMOVAL OF THE STARTER MOTOR

Disconnect the negative terminal cable (±) from the
battery.
1 - Remove cabin.
(For details, see «REMOVAL OF CABIN»).
2 1
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).
3
4
RKPA4200
INSTALLATION OF THE STARTER

MOTOR
. To install, reverse the removal procedure.
6
Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
RKPA4210
PC35R-8 PC45R-8 30-7

REMOVAL AND INSTALLATION ALTERNATOR
REMOVAL OF THE ALTERNATOR

battery.
1 - Remove cabin.
(For details, see «REMOVAL OF CABIN»).
2 1
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 alter- 3 4
nator to be rotate.
6 - Free the pulley (8) from the fan-belt and remove alter-
nator (9). 5
RKPA4220
INSTALLATION OF THE
ALTERNATOR 7
H Adjust the tension of the fan belt. (For details, see «20.
CONTROLS AND ADJUSTMENTS»). 9
8
RKPA3921
30-8 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION INJECTION PUMP
REMOVAL OF INJECTION PUMP

. Disconnect the negative terminal cable (±) from
the battery. 1
. Close the cock of separator to prevent fuel leaka-
ge.
1 - Remove oil-cooler - radiator group.
(For details, see «REMOVAL OF THE OIL-COOLER - 3
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
4 - Disconnect injection pump (3) lubricating pipe (6).
5 - Disconnect high pressure pipes (7) from injection 5
pump (3).
RKPA4240
9
6 - Remove the inlet cover (8) to ignition gear system.
7 - Loosen and remove nut (9) and lock washer (10) of 8
10
pump driving gear.
H Be careful not let nut (9) and lock washer drop in
the housing.
RKPA4250
8 - Remove pump (10) driving gear (3).

H Before removing pump driving gear, mark posi- X2
tion compared to idling gear. 13
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.
11 X1
10 X2
RKP06390
PC35R-8 PC45R-8 30-9

REMOVAL AND INSTALLATION INJECTION PUMP
9 - Loosen nuts (12) (No. 3) and remove injection pump

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

(For details, see «20. CONTROLS AND ADJUST-
MENTS»).
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.
MENTS»).
30-10 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION NOZZLE HOLDER
REMOVAL OF THE NOZZLE HOLDER
1 - Remove the suction filter (1) and the supporting brac-

ket (2).
1
RKPA4270
2 - Remove the high-pressure pipes (3) and the fuel re-

turn tubes (4).
3
4
RKPA3902
3 - Loosen nuts (5) and remove clips (6).

4 - Remove the complete injection nozzles.
6
5
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

REMOVAL AND INSTALLATION WATER COOLANT PUMP
REMOVAL OF WATER COOLANT PUMP

battery.
H Drain the engine coolant. 1
2
Coolant: Approx. 8 ,
1 - Remove the engine hood (1) and R.H. lateral counter-

weight (2).
R.H. lateral counterweight: 45 kg
RKPA4290
2 - Disconnect the air intake tube (3) and remove the

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

5 9
H Only for cabin version. Disconnect the heating
circuit tube (7). 10
4 - Disconnect the connectors (8).

8
5 - Remove from the radiator the fan cover (9) and di-
sconnect the fan-cooling conveyor (10).
6
7
RKPA4310
6 - Loosen the screws (11), remove the cooling fan (12)

and the spacer (13). Take out the fan-cooling con-
veyor (10). 12
13
Loosen the alternator drive belt and disengage the
pulley of the water pump.
11
RKP06800
30-12 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION WATER COOLANT PUMP
7 - Loosen the screws (14) and remove the complete 17

pump (15), gasket (16) and O-ring (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 cir-
cuits. Stop the engine and check the level.
H Only for cabin version. Make sure that the hea-
ting 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

REMOVAL AND INSTALLATION CYLINDER HEAD
REMOVAL OF THE CYLINDER HEAD

battery.
1
H Drain the engine coolant.
1 -Remove the water coolant pump. (For details, see

«REMOVAL OF WATER COOLANT PUMP»).
2
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 «REMO- 5
VAL OF THE NOZZLE HOLDER»). 4
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 tap- 7
pets by 2-3 turns.
8 - Take out the rocker-arm control rods (8). 7
RKP06820
9 - Loosen clips (9) and disconnect exhaust pipe from

muffler (10) .
9 10
10 - Loosen the screws (11) from support (12) and nuts
13
(13) from muffler.
Remove muffler (10). 12
11
RKPA4980
30-14 PC35R-8 PC45R-8

11 - Take out the screws (14) in the sequence indicated

and remove the complete cylinder head (15). 14
H The cylinder head gasket (16) must be substituted
every time it is dismantled.
15
16
RKP06830
PC35R
Exhaust side
Flywheel side
8 14 5
2 12 9 3
4 10 11 1
6 13 7
Intake side
RKP06841
PC45R
Exhaust side
Flywheel side
7 16 14 6
1 9 18 12 4
3 11 17 10 2
5 13 15 8
Intake side
RKP06851
PC35R-8 PC45R-8 30-15

INSTALLATION OF THE CYLINDER HEAD

PC35R
Exhaust side
1 - Fill up the cooling circuit.
Flywheel side
7 1 10
Coolant: approx. 8 , 13 3 6 12
2 - Start the engine to circulate the liquid through all cir- 11 5 4 14

cuits. Stop the engine and check the level. 9 2 8
H Only for cabin version. Make sure that the hea-

ting cock is open. Intake side
Nuts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
RKP07161
PC45R
Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
Exhaust side
H Adjust valve clearance. (For details, see «20. CON-
Flywheel side
TROLS AND ADJUSTMENTS - Adjusting valve clea- 12 3 5 13

rance»). 18 10 1 7 15
16 8 2 9 17
Screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm 14 6 4 11
Nuts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
Intake side
H Raise the cylinder head, keeping it horizontal, and RKP07171
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 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION OIL COOLER
REMOVAL OF THE OIL COOLER

Completely lower the working equipment until it is re-
sting on the ground and stop the engine.
Release all residual pressures from the circuits and
1 2
the tank. (For details, see «20. CONTROLS AND AD-
JUSTMENTS»).
H Drain the hydraulic oil.
Oil cooler: Approx. 33 ,
1 - Remove R.H. lateral counterweight (1) and R.H. late-
ral cover (2).
R.H. lateral counterweight PC35R: 32 kg
PC45R: 46 kg RKPA4291
2 - Remove the intake tube (3) and tube (4).
3 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). 8 7 9
INSTALLATION OF THE
OIL COOLER 6 RKPA4330
H Fill the hydraulic oil tank with oil up to its maximum le-
vel.
Hydraulic oil required: approx. 33 ,
Lateral counterweight screws:. . . . . . . . . . . . . Nm

1 - Start the engine at low idling to circulate the oil throu-
ghout the system.
2 - Pressurise the tank and bleed air from all circuits.
MENTS»).
PC35R-8 PC45R-8 30-17

REMOVAL AND INSTALLATION OIL COOLER - RADIATOR GROUP
REMOVAL OF THE OIL COOLER - RADIATOR GROUP

Release all residual pressures from the circuits and 2 3
the tank. (For details, see «20. CONTROLS AND AD- 1
JUSTMENTS»).
1 - Remove the engine hood (1), R.H. lateral counter-
weight (2) and R.H. lateral cover (3).
R.H. lateral counterweight 45 kg
RKPA4292
2 - Drain the coolant and hydraulic oil.

3
Hydraulic oil: Approx. 33 , 6
Coolant: Approx. 8 , 4
3 - Remove the suction pipe (3) and disconnect the coo-
lant delivery tubes (4) and return pipes (5). 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
6 - Remove the bracket (9). 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

REMOVAL AND INSTALLATION OIL COOLER - RADIATOR GROUP
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 le-
vel.

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 cen-
tered 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

REMOVAL AND INSTALLATION ENGINE HOOD
REMOVAL OF THE ENGINE HOOD

3
1 - Block the engine hood (1) in its raised position, take
out the screws (2) that fasten the hinge (3) to the fra-
me and remove the hood.
1
2
RKPA4360
INSTALLATION OF THE
ENGINE HOOD
H Check the alignment of the outside edges, the cente-

ring and the adjustment of the closing mechanism (4). 4
RKPA4370
30-20 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION CANOPY
REMOVAL OF CANOPY
sting 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 1
RKPA4380
INSTALLATION OF CANOPY
Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm 2
RKPA2760
RKPA2770
PC35R-8 PC45R-8 30-21

REMOVAL AND INSTALLATION CAB
REMOVAL OF CAB
the ignition key.
1 - Loosen the clamp (1) and disconnect the heating pipe 3

1
(2).
2 - Remove the cover (3).
2
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

REMOVAL AND INSTALLATION HEATING FAN
REMOVAL OF THE HEATING FAN

the ignition key. 1
2
H Drain the engine coolant. 5
1 - Remove the floor mat.
2 - Remove screws (1).
3
3 - Loosen screws (2) and take out the cover (3).
4 - Remove the travel increment pedal (4). 4
RKPA2800
5 - Remove the L.H. lower cover (for details, see «REMO-
VAL 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.
7
6
RKPA4311
7 - Loosen screws (8) (No. 2), remove cover (9) and remo-
8 10 9
ve the complete fan (10).
H Accompany the tubes (6) and (7) to avoid to dama-
ge them.
H Take care not to take out completely the tube (6)
and (7) from engine box.
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
12
RKPA2830
PC35R-8 PC45R-8 30-23

REMOVAL AND INSTALLATION 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

REMOVAL AND INSTALLATION COUNTERWEIGHT
REMOVAL OF THE COUNTERWEIGHT

1 - Remove the lateral counterweight (1) and (2). 2

1
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

4
tightening torque.
4 - Attach the counterweight (5) to some hoisting tackle, 5
remove the screws, and pull out the counterweight
(5).
INSTALLATION OF THE
COUNTERWEIGHT RKPA4400
Lateral counterweight screws:. . . . . . . . . . . . . Nm
Counterweight screws: . . . . . . . . . . . . . . . . . . . . . . .
Counterweight screws: . . . . . . . . . . . . . . . . . . . . Nm
PC35R-8 PC45R-8 30-25

REMOVAL AND INSTALLATION FUEL TANK
REMOVAL OF FUEL TANK

H Drain the fuel.
1 2
Fuel: max. 51.5 ,
1 - Remove R.H. lateral counterweight (1) and R.H. late-
ral cover (2).
R.H. counterweight: 45 kg
RKPA4291
2 - Remove the panel (3).

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

H Disconnect the fuel level connector (9). 8 9
RKPA4430
30-26 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION FUEL TANK
INSTALLATION OF THE FUEL TANK
Nut: 5.9w0.49 Nm 10 11
H Tighten before external nut (10) and then nut (11).
1 - Fill up the tank.
Tank: max. 51.5 ,

2 - Bleed the air from the fuel pipes and start the engine. RKPA4440
PC35R-8 PC45R-8 30-27

REMOVAL AND INSTALLATION HYDRAULIC TANK
REMOVAL OF THE HYDRAULIC TANK

the tank. (For details, see «20. CONTROLS AND AD- 2 1
JUSTMENTS»).
H Drain out the hydraulic oil. 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. RKPA4450
Remove the cab. (For details, see «REMOVAL OF

CAB»).
4 - Remove the exhaust tubes (4) and (5). 5
RKPA4460
5 - Remove the exhaust tube (6) and the intake tube (7).
6
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
8
RKPA4470
30-28 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION HYDRAULIC TANK
INSTALLATION OF THE HYDRAULIC TANK
1 - Fill the hydraulic oil tank to maximum level.
Hydraulic oil needed: approx. 33 ,
ghout the system.
MENTS»).
PC35R-8 PC45R-8 30-29

REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
REMOVAL OF THE ENGINE-PUMP GROUP

1
Release all residual pressures from the circuits and 2
the tank. (For details, see «20. CONTROLS AND AD- 3
JUSTMENTS»).
H Drain out the hydraulic oil.
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 de-
tail, see «REMOVAL OF COUNTERWEIGHT»).
3 - Remove the R.H. hood (5) and the panel (4). 4 5
RKPA4411
4 - Disconnect the tubes (6) and (7) from the fuel tank.
re-assembly.
5 - Disconnect the fuel level connector (8). 8
7
6
RKPA4480
6 - Remove the cab or the canopy.

(For details, see the single removal) 9
8 - Loosen the screws (10) and remove the fixed hood
support (11).
10
11
10
RKPA5000
30-30 PC35R-8 PC45R-8

9 - Remove the oil cooler - radiator group (12).

(Fro details, see «REMOVAL OF OIL COOLER - RA- 12
DIATOR GROUP»).
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 15
with fuel tank.
14
H Check that the fixed hood completely free while it
is being raised, and that no other parts are dama-
ged.
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 20
19
19
RKPA5020
PC35R-8 PC45R-8 30-31

15 - Disconnect the fuel delivery tube (22) and fuel return 23

tube (23).
16 - Disconnect the control accelerator cable.
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
26
20 - Disconnect the ground (29).
24
28 29
25
RKPA5040
21 - Disconnect the water temperature connectors (30).

22 - Disconnect the alternator connector (31) and starting 30
motor connector (32).
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 whi-
le it is being raised, and that no other parts are da- 33
maged.
Engine -pump group: PC35R: 210 kg
PC45R: 260 kg
RKPA4850
30-32 PC35R-8 PC45R-8

INSTALLATION OF THE ENGINE-PUMP GROUP
H Adjust the accelerator stroke. (For details, see «20.

CONTROLS AND ADJUSTMENTS»).
Vibration-damping nuts:. . . . . . . . . . . . . . . . . . . Nm
1 - Fill the tank with hydraulic oil up to the maximum le-
vel.
While filling the tank, bleed air from the pump.
MENTS»).

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
JUSTMENTS»).
PC35R-8 PC45R-8 30-33

REMOVAL AND INSTALLATION PUMP
REMOVAL OF THE PUMP

Lower the working equipment until it is resting on the
ground and stop the engine.
6
JUSTMENTS»).
1 - Remove the hydraulic oil tank. (For detail, see «RE- 3
MOVAL OF HYDRAULIC TANK»).
2 - Disconnect the delivery tubes (1) and (2) and the 4
Load Sensing tube (3) and (4) from the pump.
2
3 - Attach the pump to some hoisting tackle and apply a 1
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

6
Pump screws: Loctite . . . . . . . . . . . . . . . . . . . . . . . .
Pump screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm 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.
JUSTMENTS»).
30-34 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING
REMOVAL OF ENGINE-PUMP COUPLING

ground and stop the engine.
1
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
ENGINE-PUMP COUPLING 2
. To install, reverse the removal procedure. 3
Flywheel cover screws: Loctite . . . . . . . . . . . . . . .

Flywheel cover screws: . . . . . . . . . . . . . . . . . . . Nm
Coupling screws: Loctite . . . . . . . . . . . . . . . . . . . . . RKPA4500
Coupling screws: . . . . . . . . . . . . . . . . . . . . . . . . . Nm
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 pressuri-
se the tank. (For details, see «20. CONTROLS AND
ADJUSTMENTS»).
PC35R-8 PC45R-8 30-35

REMOVAL AND INSTALLATION CONTROL VALVE
REMOVAL OF THE CONTROL VALVE

1
JUSTMENTS»).
H Drain out the hydraulic oil. 2
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). 5 6
re-assembly.
3
3 - Disconnect the cylinder (6) from inner control valve 4
box cover (6). 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).
9 9
RKPA3962
30-36 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION CONTROL VALVE
6 - Disconnect the cables (10) and (11) from travel con-

trol 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.
3
8 - Take out the screws (12) and remove the control val-
ve 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

vel.

ghout the system.
MENTS»).
H Adjust the travel control lever, blade control lever

and boom swing control pedal stroke.
(For detail, see 20. CONTROLS AND ADJUST-
MENTS).
PC35R-8 PC45R-8 30-37

REMOVAL AND INSTALLATION LEFT-HAND PPC VALVE (ARM-BUCKET)
REMOVAL OF LEFT-HAND PPC VALVE (ARM-BUCKET)

Lower the working equipment until it is resting on the 1
ground, stop the engine and remove the ignition key.
2
Release all residual pressures from all circuits and 4
from the tank. (For details, see «20. CONTROLS
AND ADJUSTMENTS»).
1 - Take off the arm-rest (1).

2 - Disconnect cap (2).
3
H Take great care not to damage the frame (3).
5
RKPA3090
3 - Take out the screws (4) and remove the L.H. cover
(5). 8
4 - Remove the hose-clamp (6), remove the screws (7)
and remove the PPC valve (8).
7 6
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 exchan- 8
ging them during re-assembly.
9
INSTALLATION OF LEFT-HAND
PPC VALVE (ARM-BUCKET)
. To install, reverse the removal procedure. RKPA3110
H Check carefully the positions for re-connecting

the tubes.
T
Position
P T P1 P2 P3 P4
White White Green Green Blue Blue P2
S M A C L R P
P4
If the couplings are removed from the PPC valves,
make sure that the coupling with a filter is mounted
on input P. P3 P1
RKPA3120
30-38 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION RIGHT-HAND PPC VALVE (BOOM-BUCKET)
REMOVAL OF RIGHT-HAND PPC VALVE (BOOM-BUCKET)

ground, stop the engine and remove the ignition key. 1
Release all residual pressures from all circuits and
2
AND ADJUSTMENTS»). 4
2 - Disconnect cap (2).
H Take great care not to damage the frame (3).
3
3 - Take out the screws (4) e overturn the cover toward
engine hood. RKPA3130
4 - Disconnect the horn connector (5).
7
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 8
to prevent entry of impurities.
H Check that the tubes are marked to avoid exchan-
ging them during re-assembly.
7
INSTALLATION OF RIGHT-HAND
PPC VALVE (BOOM-BUCKET)
To install, reverse the removal procedure.
RKPA3150
.
H Check carefully the positions for re-connecting

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

REMOVAL AND INSTALLATION SERVOCONTROL SOLENOID GROUP
REMOVAL OF THE SERVOCONTROL SOLENOID GROUP

ground, and stop the engine.
AND ADJUSTMENTS»).
1 - Remove the L.H. side lower panels (1).

1
(For details, see «REMOVAL OF THE SIDE LOWER
PANELS»).
RKPA4451

H Mark the connectors to avoid exchanging them
during re-assembly. 4 5
3
2
3 - Disconnect in sequence: 6
- the travel increment control pipe (3);
- the union (4);
- the solenoid valve pipe (5);
- the union (6).
7
8
4 - Take out the screws (7) and remove the solenoid
group (8) complete with accumulator. RKPA4720
INSTALLATION OF THE
SERVOCONTROL SOLENOID GROUP
30-40 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION PLATFORM
REMOVAL OF THE PLATFORM

AND ADJUSTMENTS»).
1 - Remove the canopy or the cab.

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

covers (2).
3
3 - Disconnect the servo-controls tubes (3) (No. 10).
re-assembly.
H Plug the tubes and raccords to prevent entry of 3
impurities.
RKPA5070
4 - Disconnect (4) and (5) from EV solenoid valve (6).

4
5
RKPA4721
5 - Disconnect the delivery and exhaust tubes (8) from

attachment PPC valve (7).
6 - Disconnect the connectors (9) travel increment pedal
control.
7 8
RKPA5080
PC35R-8 PC45R-8 30-41

7 - Disconnect the cables (10) and (11) of travel com-

mand.
10 11
RKPA5090
8 - Disconnect the cables (12) and (13) of accelerator

and blade command.
13
12
RKPA4730

15
10 - Disconnect cup (15). 14
H Take great care not to damage the frame (16). 18
11 - Take out the screws (17) overturn the cover (18) to-
ward engine hood.
17
16
RKPA3132
12- Disconnect the connectors (19) and ground cables

(20). 19
20
RKPA4870
30-42 PC35R-8 PC45R-8

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 23
being raised and that no other parts are damaged. 22
Platform: 40 kg
RKPA4880
24
25
RKPA5100
PC35R-8 PC45R-8 30-43

INSTALLATION OF THE PLATFORM
H Fill the tank with hydraulic oil up to the maximum le-

vel.
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 pressuri-
se 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

REMOVAL AND INSTALLATION SWIVEL JOINT
REMOVAL OF THE SWIVEL JOINT

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

re-assembly. 3
3 - Remove the stopper (4).
RKPA4740
4 - Remove the protective cover (5) from the lower track-

frame.
RKPA4750
5 - Disconnect the tubes (6) from the swivel joint (7).

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

REMOVAL AND INSTALLATION 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

REMOVAL AND INSTALLATION 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.
H Drain out the hydraulic oil.
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). 6
H Mark the tubes to avoid exchanging them during 3
re-assembly.
H Plug the tubes to prevent entry of impurities. 4
4 - Take out the screws (6) (No. 8) and remove the swing
machinery (7). 7
Swing machinery: 37 kg
5
INSTALLATION OF SWING RKPA4770
MACHINERY
Swing machinery screws: 130 Nm

Swing machinery screws: Loctite 262
vel.

there are no leaks.
3 - Stop the engine, check the oil hydraulic level and, if
necessary, top it up.
JUSTMENTS»).
PC35R-8 PC45R-8 30-47

REMOVAL AND INSTALLATION REVOLVING FRAME
REMOVAL OF REVOLVING FRAME

Fully extend the arm and open completely the buc-
ket, lower the equipment until it rests on the ground;
stop the engine. 1
AND ADJUSTMENTS»).
H Drain the hydraulic oil and the fuel.
Hydraulic oil: approx. 33 , 2
Fuel: max. 51.5 ,
1 - Remove the work equipment.
(For details, see «REMOVAL OF THE WORK EQUIP- RKPA4741
MENT»).
2 - Removal the boom cylinder. (For details, see «REMO-
VAL OF BOOM CYLINDER»).
3 - Remove the cab or the canopy.
(For details, see the single removal) 5
4 - Remove the rear counterweight. (For details, see
«REMOVAL OF THE REAR COUNTERWEIGHT»).
4
5 - Remove the swing machinery. (For details, see «RE-
MOVAL OF SWING MACHINERY»).
6 - Disconnect the upper tubes (1) (No. 8) from the swivel
joint.
H Mark the tubes to avoid exchanging them during RKPA5110
re-assembly.
7 - Remove the bracket (2) of the joint.
8 - Disconnect the swing circle lubrication tube (3) and
remove the coupling (4). 5
9 - Loosen and remove the screws that secure the revol-
ving 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 posi- RKP07180
tion for safety.

12 - Remove the revolving frame (5).
Revolving frame: PC35R: 1500 kg
PC45R: 1550 kg
30-48 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION 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 tu-
bes 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

REMOVAL AND INSTALLATION SWING CIRCLE
REMOVAL OF THE SWING CIRCLE
1 - Remove the evolving frame (For details, see «REMO-

VAL OF THE REVOLVING FRAME»).
2 - Take out the screws (1) that secure the swing circle 1
S
(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

REMOVAL AND INSTALLATION RUBBER TRACK SHOES
REMOVAL OF RUBBER TRACK SHOES
1 - Rotate the turret by 90ë 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 grea- 1
se 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. 2
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 RKPA4001
machine slowly backwards and forwards.
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

REMOVAL AND INSTALLATION 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). 1 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 3
machine slowly backwards and forwards.
3 - Using the tool A1, remove the connecting pin (1). RKPA4900
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. 2
5 - Push down with the boom in order to raise the lower
track-frame and pull out the track-shoe (3). 3
Track-shoe: PC35R: 180 kg
PC45R: 294 kg RKP06650
INSTALLATION OF
STEEL TRACK-SHOES
H Adjust the track-shoe tension. (For details, see

1 - Rotate the turret 90ë 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

REMOVAL AND INSTALLATION SPROCKET WHEEL
REMOVAL OF THE SPROCKET WHEEL
1 - Remove the track-shoe. (For details, see «REMOVAL

OF TRACK-SHOES»).
2 - Rotate the turret 90ë 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
1
2
Screws: Loctite 262
Screws: PC35R: 120 Nm
PC45R: 190 Nm RKPA4780
PC35R-8 PC45R-8 30-53

REMOVAL AND INSTALLATION FINAL DRIVE
REMOVAL OF THE FINAL DRIVE
1 - Remove the sprocket wheel. (For details, see «RE-

MOVAL 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 im-
purities.
4 - Take out the screws (3). 1
5 - Remove the final drive (3).
Complete final drive: PC35R: 40 kg
INSTALLATION OF THE 3
FINAL DRIVE
2
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. RKPA4800
MENTS»).
30-54 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION 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
2
RKPA4910
3
RKPA4920
INSTALLATION OF IDLER AND

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

«20. CONTROLS AND ADJUSTMENTS).
PC35R-8 PC45R-8 30-55

REMOVAL AND INSTALLATION 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).
2 3
RKPA4810
2 - Using tool B1 press spring (4). Loosen screw (6) and

nut (5). F
B1
H Installed load of spring:
6
Model Rubber shoe Steel shoe 5
PC35R 3151 kg 2008 kg 4
PC45R 4326 kg 2748 kg
8
3 - Release the spring (4) slowly.
RKP06890
4 - Remove the stopper (7) and spring (4) from cylinder

(8).
7
H Free length of spring: PC35R: 275 mm
PC45R: 302 mm 4
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
13
11
9
12
10
RKP06910
2. Recoil spring
7
1 - Mount the spring (4) and stopper (7) on the cylinder.
4
RKP06900
2 - Using tool B1, set recoil spring (4) to press.

Put the tool B1 and the cylinder (8) correctly un-
der the press.
3 - Press the spring (4) slowly until reaching the size "A". F
H Size "A": B1
Model Rubber shoe Steel shoe
PC35R 188.1 mm 213.1 mm a
b
PC45R 202.2 mm 238.2 mm
5 6
H Installed load of spring:
Model Rubber shoe Steel shoe
PC35R 3151 kg 2008 kg
4
PC45R 4326 kg 2748 kg
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 out-

of-parallel between surface "c" of the cylinder (8) and 8 7
surface "d" of stopper (7) is less than 0.5 mm.
c d
RKP06940
3. Piston
1 - Tighten valve (2) completely and then turn back it ap-
prox. 2 turns. e
3 2
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. RKP06930
30-58 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION IDLER
DISASSEMBLY OF THE IDLER
1 - Remove cover (1) and bracket (2).

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

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

REMOVAL AND INSTALLATION 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).
D2
H Wash and remove all grease and oil from the floa- 9
ting seals and their contact surface, then dry the
parts. 8
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.
RKP07010
3 - Using tool D2, insert the floating seals (7) in supports

(4).
H Wash and remove all grease and oil from the floa- D2
ting seals and their contact surface, then dry the
parts. 7 4 5
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.
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).
4
7 - Fill inside idler (89 with engine oil.
1
3
Idler: approx. 70 cc 2
8 - Mount 2nd support (4) e tighten screw (3).
Screw: Loctite 242 5 4
9 - Mount bracket (2).
Screw: 110.5w12.5 Nm
Screw: Loctite 242
3
10 - Mount cover (1). RKP06950
30-60 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION TRACK ROLLERS
REMOVAL OF THE TRACK ROLLERS
1 - Slowly loosen the grease nipple (1) to let out the grea- 1
se and release tension in the track-shoe.
The grease contained in the cylinder is under

pressure and could seriously injure the Opera-
tor. For this reason, the valve should not be loo-
sened 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 90ë towards the removal side and
force the boom down to raise the lower track-frame RKPA4820
(2).
3 - Loosen the screws (3) and remove the rollers (4).
INSTALLATION OF THE
4
TRACK ROLLERS
. To install, reverse the removal procedure. 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 rol-
lers (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

REMOVAL AND INSTALLATION BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

Fully extend the arm and open the bucket complete-
ly. Lower the equipment until it rests on the ground.
1 - Remove the pin (1).

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 re-
tracted position. 4
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
A
holes in the cylinder to prevent entry of impurities. 3

RKPA4621
7 - Remove the cylinder (2).

Boom cylinder: PC35R: 30 kg
PC45R: 40.5 kg
2
RKPA4840
30-62 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION BOOM CYLINDER
INSTALLATION OF THE BOOM CYLINDER

3
H Adjust the shim thickness so that the clearance bet- 6
ween 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 bet- 3

ween cylinder (3) and boom (7) is below 1 mm.
7
Internal bushings: ASL800050
1 - Start the engine and bleed the air from the cylinder.
MENTS»).
H After bleeding the air, check the level of oil in the
tank. MAX. 1 mm
RKP07030
PC35R-8 PC45R-8 30-63

REMOVAL AND INSTALLATION 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 2
on the ground with the arm in a vertical position.
1
1 - Stop the engine and release the pressures from the
cylinder by moving the left-hand PPC valve lever se-
veral 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 re- RKPA4510
tracted position of the piston.

5 - Stop the engine and release any residual hydraulic
ADJUSTMENTS»).
6 - Disconnect the tubes (4) and plug them. Also plug the 5 4 A 1 3
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 bet- MAX. 1 mm
ween cylinder and arm is below 1 mm.

RKP07040
. Start the engine and bleed the air from the cylinder.
MENTS»).
H After bleeding the air, check the oil level in the
tank.
MAX. 1 mm
RKP07050
30-64 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION BUCKET CYLINDER
REMOVAL OF THE BUCKET CYLINDER

Completely open the front equipment. Make the ne-
cessary movements to rest the bucket teeth on the
ground with the arm supported on a block «A».
1
1 - Stop the engine and release the pressures from the
cylinder (1) by moving the right-hand PPC valve lever 2
several times.
RKPA4530
2 - Place a block «B» beneath the cylinder (1) and remo-

ve the pin (2).
B
3 - Start the engine and retract the piston rod (3).
5 3
tracted position.
4
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 impu- A
rities. 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
When aligning the positions between the hole and RKP07060
the pin, do not insert fingers in the holes to check

alignment.
H Adjust the shim thickness so that the clearance bet-

ween cylinder and bucket link and between arm and
bucket link is below 1 mm.

MENTS»).
H After bleeding the air, check the oil level in the MAX. 1 mm
tank. RKP07070
PC35R-8 PC45R-8 30-65

REMOVAL AND INSTALLATION BOOM SWING CYLINDER
REMOVAL OF THE BOOM SWING CYLINDER

Swing the work equipment approx. 45ë to the left
and extend completely the boom swing cylinder. Lo-
wer the working equipment to the ground with all sa-
fety 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 pres-
sures.
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) comple- RKPA4550
tely.
tracted position.
4 - Stop the engine and move the command pedal boom
swing cylinder several times to release residual pres- 1
sures. (For details, see «20. CONTROLS AND AD-
JUSTMENTS»).
3
2
RKPA4560
5 - Remove the fuel tank (4).

(For details, see «REMOVAL OF FUEL TANK»).
4
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 impu-
rities.
6 7
RKPA4580
30-66 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION BOOM SWING CYLINDER
8 - Disconnect the tube (8).

9 - Loosen the screws (9) and remove the plate (10). 8
10 - Put a sling round the cylinder (11) and apply a slight 9
tension to the cables.
11 - Take out the pin (12) and remove the cylinder (11).
10 12
Boom swing cylinder: PC35R: 28 kg

PC45R: 40 kg 11
RKPA4121
INSTALLATION OF THE
BOOM SWING CYLINDER

ween cylinder and swing bracket is below 1 mm.
MAX. 1 mm
RKP07080

1 - Start the engine and bleed the air from the cylinder.
MENTS»).
H Adjust the shim thickness so that the clearance

MAX. 1 mm
between cylinder and revolving frame is below 1

mm.
RKP07090
PC35R-8 PC45R-8 30-67

REMOVAL AND INSTALLATION 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
1 - Remove the protection (1).
H Place a supporting block «A» beneath the cylin-
der.
2 - Stop the engine, release the pressures in the cylinder
(2) by moving the command lever several times in
both directions.
RKPA4590

H Bind the piston rod with wire to secure the fully re- 5
2
tracted position.
4
ADJUSTMENTS»).
6 - Disconnect the tubes (5) and plug them. Also plug the 4
holes in the cylinder to prevent entry of impurities. A

8 - Remove the cylinder (2). 3 RKPA4600
Blade cylinder: PC35R 20 kg

PC45R 24 kg
INSTALLATION OF THE
BLADE CYLINDER


MENTS»).
H After bleeding the air, check the oil level in the
tank.
30-68 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
DISASSEMBLY OF THE WORK EQUIPMENT CYLINDERS
1 - Take off the guard rings (1) from both sides of the cy-
linder and from the piston rod. 1
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 cylin-

der) to the head (3) and apply the dynamometric tool
C2. C2
C5
RKPA1400
4 - Unscrew the head (3) and extract it completely from

the cylinder (2).
3
2
RKPA1410
PC35R-8 PC45R-8 30-69

5 - Raise the cylinder and hook the piston rod to the mo-
bile group of the tool C1.
6 - Extract the piston rod group (4) from the cylinder.
4
7 - Remove the cylinder (2) and the piston rod group.
C1
2
RKPA1420
8 - Lock the complete piston rod (4) onto the apparatus

C1. 4 6
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:
UnitaÁ di misura: mm
Cylinder 5 C6 C2
Boom
Boom Arm Bucket Blade
Model swing
PC35R 46 50 46 46 50
PC45R 55 55 50 55 55 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 sli-
ding surfaces.
H Prepare each individual component before commen-
cing the final assembly. 7
1. Assembly of the cylinder head
1 - Position the guard ring (7) and, using a press and the C7
push rod C7, press it home in the head (3).
H Check the orientation carefully. 3 3
RKPA1440
2 - Mount the snap ring (8).

8
3 - Using the tool C3, mount the lip-seal (9).
H Check that the lips face into the cylinder.
C3
RKPA1450
4 - Mount the O-ring (10), the anti-extrusion ring (11) and

the O-ring (12) onto the cylinder head (3). 10 3 11 12 17 18 17
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).
7 9
RKZ05260
PC35R-8 PC45R-8 30-71

2. Piston assembly
1 - Using the tool C8, mount the piston seal. Mount in se-
quence 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).

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

1 - Using a press and the tool C4 adapted to the diame-
ter, insert the bushing (17) into the piston rod (4). 4
17
2 - Insert the support «A» beneath the piston rod.
C4
RKPA1480
3 - Mount the pilot boss C10 adapted to the diameter on-

to the extremity of the piston rod.
4 C10 4 3
4 - Slide the head (3) onto the piston rod (4).
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). 19 6
H Carefully check the orientation of the chamfer on
the brake bushing.
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:
UnitaÁ di misura: mm
Cylinder Boom
Boom Arm Bucket Blade
Model swing 5 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. C4
2 - Position the bushing (20) and mount it onto the cylin- 2
der (2). C1
H Leave the cylinder in position, ready for the next
assembly operation.
20
RKPA1393
PC35R-8 PC45R-8 30-73

3 - Lubricate the threading and the first part of the cylin-

der (2). C11
6
Cylinder: ASL800050
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 4
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
2
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:
C2
UnitaÁ di misura: mm C5
Cylinder Boom
Boom Arm Bucket Blade 3
Model swing 2
PC35R 588w59 677w68 490w49 637w64 677w68
PC45R 677w68 863w86 677w68 735w74 942w94
12 - Mount the guard rings (1) on both sides of the cylin-

der and the piston rod. RKPA1401
30-74 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION UPPER WORK EQUIPMENT
REMOVAL OF THE UPPER WORK EQUIPMENT

Fully extend the arm and open the bucket complete-
ly. Lower the equipment until it rests on the ground.
battery.
1
1 - Stop the engine, release the pressures in the cylinder
by moving the PPC valve lever several times.
2 - Remove the pin (1). 2
3 - Lower the cylinder (2) until it rests on a stand «A».
RKPA4610

tracted position.
pressures. (For details, see «20. CONTROLS AND 3
ADJUSTMENTS»).
RKPA4620
6 - Disconnect the hoses (4) (No. 10); plug the tubes to

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

a slight tension to the cables.
7
load.
RKPA4640
PC35R-8 PC45R-8 30-75

REMOVAL AND INSTALLATION UPPER WORK EQUIPMENT
8 - Take away the pin (8). Remove the working equip-

ment (7).
H Check and make a note of the position of the
shim. 8
Working equipment: PC35R: 320 kg
PC45R: 450 kg
RKPA4650
INSTALLATION OF THE UPPER

WORK EQUIPMENT

ween cylinder and boom is below 1 mm.
When aligning the positions between the hole and MAX. 1 mm

Do not insert fingers in the holes to check alignment. RKP07100

ween 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

REMOVAL AND INSTALLATION BUCKET
REMOVAL OF THE BUCKET

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

7
8

3
H Insert O-ring (8) on both sides between the bucket (3) RKPA4670
and the arm (7).

H Check size "A".
If the size is below of limit size, replace O-rings.
Standard size Limit size
Size A
85 mm 83.5 mm
A
RKP07120
PC35R-8 PC45R-8 30-77

REMOVAL AND INSTALLATION ARM
REMOVAL OF THE ARM
1 - Remove the bucket. (For details, see «REMOVAL OF

THE BUCKET»).
2 1
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 4
(5).
H Plug the tubes and the holes on the cylinder to
prevent entry of impurities. 3
6 - Put a sling round the cylinder (5). 5
7 - Remove the cylinder (5) completely of levels.
(For details, see «REMOVAL OF THE BUCKET CY-
LINDER»).
Complete cylinder: PC35R: 55 kg RKPA4690
PC45R: 65 kg
8 - Position a block «A» beneath the arm cylinder com-

mand (6). 7
9 - Remove the pin (7) completely retract the piston rod
(8).
6 8
A
RKPA4700
10 - Put a sling round the arm (9) and apply a slight ten-
sion to the cables. 10
11 - Remove the pin (10) and take out the arm (9).
Arm: PC35R: 69 kg
PC45R: 95 kg
9
Long arm: PC35R: 88 kg
PC45R: 119 kg
RKPA4710
30-78 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION 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.


ween arm and boom is below 1 mm.
alignment.
from the cylinder.
RKP07130

PC35R-8 PC45R-8 30-79

REMOVAL AND INSTALLATION ARM ASSEMBLY
REMOVAL OF THE ARM ASSEMBLY

safety devices engaged with the arm in a vertical po-
sition and the bucket curled.
1 - Stop the engine and release the pressures from buc-

ket cylinder and from optional working equipment cir-
cuit.
2 - Attach a block «a» beneath the cylinder (1) and remo-
ve the pin (2).
3 - Start the engine and retract the piston (3).
4 - Stop the engine and release the residual hydraulic RKPA3750

ADJUSTMENTS»).
5 - Disconnect the tubes (4) of bucket cylinder command. 1
3
H Plug the tube and the holes on the cylinder to pre- 2
vent entry of impurities.
6 - Disconnect the delivery and exhaust equipment tu-
bes (5).
7 - Remove the pin (6) and take out the arm complete (7). A
5
Arm complete: PC35R: 185 kg 4

INSTALLATION OF THE
ARM ASSEMBLY
H Insert the shims on both sides of the piston rod. 6

Do not insert fingers in the holes to check alignment. RKPA3760
H Insert the shims on both sides of the arm.

alignment.
from the cylinder.
30-80 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION BOOM
REMOVAL OF THE BOOM

battery. 1
1 - Remove the arm assembly. (For details, see «REMO-
VAL OF THE ARM ASSEMBLY»). 2
2 - Remove the arm cylinder. (For details, see «REMO-
VAL 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 ti-
mes to release pressures in the cylinder.
6 - Place a stand «B» beneath the cylinder (3).
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
10 - Put a sling round the boom (2) and apply a slight ten- A
RKPA3770
sion to the cables.
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 6
7
RKPA3780
PC35R-8 PC45R-8 30-81

REMOVAL AND INSTALLATION BOOM
INSTALLATION OF THE BOOM
H Insert the shims on both sides of the piston rod.

H Insert the shims on both sides of the arm.

alignment.
from the cylinder.
30-82 PC35R-8 PC45R-8

REMOVAL AND INSTALLATION 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 EQUIP-
MENT»). 1 4
2 - Remove the boom cylinder. (For details, see «REMO-
VAL OF THE BOOM CYLINDER»).
3 - Disconnect the boom swing cylinder from swing sup-
port (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 sup-
port.
6 - Attach the boom swing support (4) to some hoisting 3
tackle and apply a slight tension to the cable.
7 - Take out the bracket (5), remove the pin (6) and remo-
ve the boom swing support (4).
H Make a note of the position and the quantity of
shims (7).
Boom swing support: PC35R: 70 kg 2
PC45R: 93 kg
RKPA3830
INSTALLATION OF THE BOOM

SWING SUPPORT 5

alignment.
Pins: ASL800050
H Adjust the shim thickness so that the clearance bet- RKPA3820
ween swing bracket (4) and frame (8) is below 0.5 mm.
Supporting surfaces and shims: ASL800050
4 6
8
7
MAX.0,5mm
RKP06351
PC35R-8 PC45R-8 30-83

REMOVAL AND INSTALLATION BLADE
REMOVAL OF THE BLADE
1 - Rotate the turret 90ë and rest the working equipment

on the ground.
2 - Disconnect the cylinder from the blade. (For details,
see «REMOVAL OF THE BLADE CYLINDER»).
2
3 - Attach the blade to some hoisting tackle, using the la-
teral holes provided (1) and the cylinder attachment 4
(2).
group.
4 - Take out the pin (3). 1
RKPA3800
5 - Remove the blade (4).

Blade: PC35R: 154 kg 3
PC45R: 235 kg
INSTALLATION OF THE BLADE

4
Internal bushings: ASL800050 RKPA3810

30-84 PC35R-8 PC45R-8

GROUP 40
STANDARD MAINTENANCE
Swing circle . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2 Hydraulic pump . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 14

Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3 Control valve. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 15
Final drive . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 Swivel joint. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 21
Sprocket . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5 Swing motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 22
Idler .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6 Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 24
Steel shoe . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7 PPC Valve . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 28
Carrier roller. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 PPC Valve (hammer). .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
Track roller . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10 Cylinder . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 30
Rubber shoe . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 Work equipment . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 32
Track frame . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
PC35R-8 PC45R-8 40-1

SWING CIRCLE
1 130 Nm
with Loctite 262
130 Nm
with Loctite 262
RKP02730
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

1 Axial bearing clearance Replace
0.2 ± 0.3 1.5
40-2 PC35R-8 PC45R-8

SWING MACHINERY
25 Nm 42 Nm
750 ± 850 Nm 4
6
20 ± 30 Nm
130 Nm
with Loctite 262
ASL800050
RKP02650
Unit: mm
Backlash between Standard clearance Clearance limit

1 No. 1 sun gear and
No. 1 planetary gear 0.10 0.30
Backlash between
2 No. 1 planetary gear and 0.15 0.35
No. 1 gear ring
Replace
Backlash between
3 No. 2 sun gear and 0.10 0.30
No. 2 planetary gear
Backlash between
4 No. 2 planetary gear and 0.15 0.35
No. 2 gear ring
Standard size Repair limit

Size of pinion in the zone
5
of contact with the sealing ring Repair or
50 0.020 49.750
replace
6 Preload bearings ± 0.05 Ð Ð0.10 +0.010
PC35R-8 PC45R-8 40-3

FINAL DRIVE
1 2
PC35R: 120 Nm
PC45R: 190 Nm
with Loctite 262
25 Nm
RKP02660
Unit: mm
Standard clearance Clearance limit

Backlash between No. 2 PC35R
1 0.15 0.35
planetary gear and housing
PC45R 0.18 0.40
PC35R 0.15 0.35

Backlash between No. 1
2
planetary gear and housing
PC45R 0.18 0.40
Backlash between PC35R 0.10 0.30 Replace

No. 2 planetary gear PC45R 0.12 0.35
Backlash between PC35R 0.10 0.30

No. 1 planetary gear PC45R 0.12 0.35
PC35R 0.5 ± 1.5 2.5

Backlash between
5
No. 1 sun gear and disc
PC45R 0.5 ± 1.5 2.5
40-4 PC35R-8 PC45R-8

SPROCKET
4
3
PC35R: 120 Nm
PC45R: 190 Nm
with Loctite 262
2 1
RKP02670
Unit: mm
Standard size Tolerance Repair limit
+1
Wear at roots of PC35R 344.3 332
1 ±2
sprocket teeth
+1
PC45R 380.37 368
±2
PC35R 386.2 w1.5 374

Wear at tips of
2 Build up by
sprocket teeth +0
PC45R 423.99 412 solder or
±3
replace
PC35R 20 ± 18
Face width at tips of
3
sprocket teeth
PC45R 26 ± 24
+0.5
PC35R 27 24
±1
Face width at base
4
of sprocket teeth
+0.5
PC45R 33 30
±1
PC35R-8 PC45R-8 40-5

IDLER
4
3 5
7 8
6 2 1
RKP02480
Unit: mm

Outer diameter of PC35R
1 338w1 330
track shoe guide
PC45R 373w1 365
Outer diameter PC35R 300w1 292

2
of tread PC45R 335w1 327
Build up by
Width of track PC35R 28 20 welding or
3 replace
shoe guide PC45R 37 29
PC35R 64 59
4 Total width
PC45R 75 70
PC35R 18 22
5 Width of tread
PC45R 19 23
Clearance between PC35R 0.25 1.0

6
shaft and support PC45R 0.25 1.0
Thickness of metal on PC35R 8.6 4.6
7 idler tread
(centre of tread width) PC45R 10.3 6.3
Tolerance Standard Clearance Replace
Standard size
Shaft Hole clearance limit
Clearance between
8 idler shaft and ± 0.025 +0.142 0.105 ±
PC35R 35 1.5
bushing ± 0.064 +0.080 0.206
± 0.025 +0.142 0.105 ±
PC45R 35 1.5
± 0.064 +0.080 0.206
40-6 PC35R-8 PC45R-8

STEEL SHOE
PC35R
8 2
5
7
RKP03800
Unit: mm
Standard size Repair limit Rotate pin

1 Link pitch Ð or replace
101.6
104 Replace
Rotate
Outer diameter 30 bushing or
2 32 replace
of bushing
28 Replace
3 Grouser height 16.5 8.5 Build up by

welding or
4 Link height 61 5 replace
Standard Tolerance Standard Interference

Interference between size Shaft Hole interference limit
5
regular pin and link
+0.22 0
32 0.07 0.22
+0.12 +0.05
Interference between +0.15 0

6 19 0.07 0.15 Replace
pin and link +0.12 +0.05
Interference between ±0.02 0

7 19 0.02 0.12
master pin and link ±0.07 +0.05
Clearance between Standard size Clearance limit

8
link joint faces 0.6 1.2
PC35R-8 PC45R-8 40-7

PC45R
3
116w1 Nm 6 5
RKP02461
Unit: mm

Standard size Repair limit Rotate pin
1 Link pitch 137.3 or replace
135
139.3 Replace
Rotate
Outer diameter 33.05 bushing or
2 35.05 replace
of bushing
31.05 Replace
3 Grouser height 18 6 Build up by
welding or
4 Link height 65 60 replace
Standard Tolerance Standard Interference

Interference between size Shaft Hole interference limit
5
regular pin and link
35.05 (Shaft) ± 0.09
0.1 0.09 0.16
35.00 (Hole) ± 0.15
Interference between 22.53 (Shaft) +0.04 +0.352
6 0.13 0.27 Replace
pin and link 22.00 (Hole) ± 0.04 +0.3
Interference between 22.53 (Shaft) ± 0.03 +0.352
7 0.078 0.17
master pin and link 22.00 (Hole) ± 0.07 +0.3
Clearance between Standard size Clearance limit

8
link joint faces 0.6 1.2
40-8 PC35R-8 PC45R-8

CARRIER ROLLER
2
270 Nm
3 RKP02471
Unit: mm

1 Outer diameter of tread
70 60 Replace
2 Width of tread 100 ±
Standard tolerance Clearance limit

3 Axial play of roller Replace
0 ± 0.5 1.0
PC35R-8 PC45R-8 40-9

TRACK ROLLER
4 3
6
2 1
PC35R: 190 Nm
PC45R: 270 Nm
with Loctite 262
7
8
RKP02521
Unit: mm

Outer diameter PC35R
1 112 106
of thread
PC45R 123 117
Outer diameter PC35R 85 77

2 Build up by
of protusion PC45R 95 87 welding or
replace
PC35R 34 37
3 Width of thread
PC45R 34.5 37.5
PC35R 26 20
4 Width of protusion
PC45R 41 35
Tolerance Standard Clearance
Standard size
Shaft Hole clearance limit
Clearance between ±0 +0.183 0.144 ±
5 PC35R 25 1.5
shaft and bushing ± 0.013 +0.144 0.196
± 0.025 +0.142 0.105 ± Replace
PC45R 35 1.5
± 0.054 +0.080 0.192
± 0.073 +0.030 0.018 ±
Interference PC35R 32 ±
± 0.048 +0 0.073
6 between
roller and bushing ± 0.079 +0.030 0.024 ±
PC45R 42 ±
± 0.054 +0 0.079
Standard size Clearance limit
Replace
PC35R 0.20 0.74
7 Axial play of roller
Replace
PC45R 0.25 0.81
bushing
Thickness of metal on Standard size Repair limit Build up or

8
idler tread 26.5 22.5 replace
40-10 PC35R-8 PC45R-8

RUBBER SHOE
Section A
Sezione A-±AA
RKP02500
Unit: mm
1 Wear of lug height PC35R 25 5
PC45R 25 5
Wear of roller guard PC35R 71 63

2 Replace
portion PC45R 85 67
Standard size Tolerance Repair limit

Wear of meshing
3 PC35R 25 w0.5 29
portion of sprocket
PC45R 25 w0.5 29
PC35R-8 PC45R-8 40-11

TRACK FRAME
Rubber shoe
1
RKP06670
Unit: mm

Item Repair limit
Curvature 5 (for length of 1000 mm)
1 Deformation of frame Correct
Twisting 5 (for length of 300 mm)
Opening of idler 5
Item Standard size Repair limit
Build up by
Track welding
96 100
Vertical width of frame
2
idler guide
Build up by
Idler
94 90 welding or
support
replace
Track Build up by
161 165
frame welding
Horizontal width of
3 Build up by
idler guide Idler
159 155 welding or
support
replace
Free Preloaded Installed Free Installed
4 Recoil spring length length load length load Replace
PC35R 257 188.1 3151 kg 251.5 2899 kg
PC45R 302 202.2 4326 kg 294.0 3980 kg
40-12 PC35R-8 PC45R-8

Steel shoe
RKP02740
Unit: mm

Item Repair limit
Curvature 5 (for length of 1000 mm)
1 Deformation of frame Correct
Twisting 5 (for length of 300 mm)
Opening of idler 5
Item Standard size Repair limit
Build up by
Track welding
96 100
Vertical width of frame
2
idler guide
Build up by
Idler
94 90 welding or
support
replace
Track Build up by
161 165
frame welding
Horizontal width of
3 Build up by
idler guide Idler
159 155 welding or
support
replace
Free Preloaded Installed Free Installed
4 Recoil spring length length load length load Replace
PC35R 257 213.1 2008 kg 252.2 1787 kg
PC45R 238.2 238.2 3748 kg 295.0 2446 kg
PC35R-8 PC45R-8 40-13

HYDRAULIC PUMP
30.9w3.43 Nm
(3.15w0.35 kgm)
17.2w2.45 Nm
(1.75w0.25 kgm)
23.5w3.92 Nm
24.5w4.9 Nm 68.6w9.81 Nm (2.4w0.4 kgm)
(2.5w0.5 kgm) (7.0w1.0 kgm)
View
Vista ZZ
RKP02081
40-14 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
B
29.4 ± 34.3 Nm View
Vista ZZ 9.8 ± 12.7 Nm A
(3 ± 3.5 kgm) (1 ± 1.3 kgm)
N N
L L
K K
J J Z
H H
F F
E E
A
9.8 ± 12.7 Nm B
(1 ± 1.3 kgm) C
RKP02351
PC35R-8 PC45R-8 40-15

39.2 ± 49 Nm
(4 ± 5 kgm)
39.2 ± 49 Nm
(4 ± 5 kgm)
Section
SezioneAA±-AA RKP02700
40-16 PC35R-8 PC45R-8

1
2
6.9 ± 9.8 Nm
(0.7 ± 1.0 kgm)
39.2 ± 49 Nm
(4 ± 5 kgm)
Section B ±BB- B
Sezione RKP02690
Unit: mm

Spool return spring Free length Installed Installed Free Installed
1 (boom, arm, bucket, x é.D. length load length load When
swing, hammer) damage or
22.6N 18.1 N
29x17.5 28.5 Ð deformation
(2.3 kg) (1.8 kg)
is found,
Spool return spring 98 N 78.4 N replace the
2 46.2x20 25.4 Ð spring
(blade, travel) (10 kg) (8.0 kg)
Spool return spring 74.5 N 59.6 N
3 42x20 25.4 Ð
(boom swing) (7.6 kg) (6.1 kg)
PC35R-8 PC45R-8 40-17

5
1.3 ± 1.7 Nm 1
(0.13 ± 0.17 kgm)
47 ± 58.8 Nm
(4.8 ± 60 kgm) 2
117.6 ± 161.8 Nm
117.6 ± 161.8 Nm (12 ± 16.5 kgm)
(12 ± 16.5 kgm)
117.6 ± 161.8 Nm
(12 ± 16.5 kgm) 3
Section
Sezione C
C ±- C
C RKP02710
Unit: mm

Free length Installed Installed Free Installed
Pressure compensation
1 x é.D. length load length load
valve spring
6.86N 5.49 N
20x8.4 12 Ð
(0.7 kg) (0.56 kg)
When
193.2 N 154.6 N damage or
2 Unload valve spring 28.57x19.2 15 Ð
(19.7 kg) (15.8 kg) deformation
is found,
78.8 N 63 N replace the
3 Cooler check valve spring 27.2x13.2 21 Ð
(8.04 kg) (6.43 kg) spring
Self-pressure reducing
88.2 N 70.6 N
4 valve sequence 40.5x41.3 35.5 Ð
(9.0 kg) (7.2 kg)
valve spring
Spool return spring 22.6 N 18.1 N
5 29x17.5 28.5 Ð
(hammer) (2.3 kg) (1.8 kg)
40-18 PC35R-8 PC45R-8

137 ± 157 Nm 117.6 ± 161.8 Nm
(14 ± 16 kgm) (12 ± 16.5 kgm)
49 ± 58.8 Nm
(5 ± 6 kgm)
Section
SezioneEE±-EE
2 1
19.6 ± 24.5 Nm
1 (2 ± 2.5 kgm)
Section
SezioneFF±-FF Section
Sezione H
H ±- H
H
RKP02680
Unit: mm

Free length Installed Installed Free Installed When
1 Check valve spring x é.D. length load length load damage or
deformation
1.96N 1.57 N is found,
21.9x5 15.8 Ð
(0.2 kg) (0.16 kg) replace the
spring
13.83 N 11.1 N
2 Check valve spring 13.7x7.6 9.8 Ð
(1.41 kg) (1.13 kg)
PC35R-8 PC45R-8 40-19

19.6 ± 24.5 Nm 19.6 ± 24.5 Nm
1 (2 ± 2.5 kgm)
1 (2 ± 2.5 kgm)
Section
Sezione JJ -±JJ Section
Sezione K
K ±- K
K
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
39.2 ± 49 Nm
(4 ± 5 kgm) Section LL-±LL
Sezione RKP02720
Unit: mm

Check valve spring Free length Installed Installed Free Installed When
1 (Bucket, boom, x é.D. length load length load damage or
swing, hammer) deformation
1.96N 1.57 N is found,
21.9x5 15.8 Ð
(0.2 kg) (0.16 kg) replace the
spring
Check valve spring 19.7 N 15.8 N
2 13.97x6.5 11.8 Ð
(Blade) (2.01 kg) (1.61 kg)
40-20 PC35R-8 PC45R-8

SWIVEL JOINT
RKP02490
Unit: mm
Standard size Standard clearance Clearance limit

Clearance between
1 Replace
rotor and stator
60
PC35R-8 PC45R-8 40-21

SWING MOTOR
177w10 Nm 39w2 Nm
A A
157w10 Nm
8.8w1 Nm
Section A -±AA
Sezione A RKP06700
Unit: mm
N-
Check item Criteria Remedy
o.
Standard size Repair limit When
damage or
1 Check valve spring deformation
x é.D. length load length load
is found,
30.1 15.7 2.3 N 25.5 1.6 N replace
Clearance between shoe Standard clearance Clearance limit

2
and piston 0.03 ± 0.15 0.4
Replace
Clearance between piston
3 0.01 ± 0.02 0.4
and cylinder
40-22 PC35R-8 PC45R-8

PC35R-8 PC45R-8 40-23
TRAVEL MOTOR
PC35R
63.7w4.9 Nm
2
3
B
B
34.5w5 Nm
A
240w5 Nm 31.9w2.5 Nm
2.5w0.5 Nm
10w1 Nm 2.5w0.5 Nm
Section A -±AA
Sezione A RKP02601
40-24 PC35R-8 PC45R-8

53.7w5 Nm 53.7w5 Nm
5
SectionBB- ±BB
Sezione
RKP02622
Unit: mm
Clearance between Standard clearance Clearance limit

1
piston and cylinder 0.01 ± 0.02 0.4
Replace
Clearance between
2 0.03 ± 0.15 0.4
shoe and piston
Travel increment Free Installed Installed Free Installed When

3
piston spring length length load length load damage or
deformation
23 15.6 7.8 N 21.5 6.2 N
is found,
4 Braking valve return spring 32.8 24.7 113 N 31.2 90 N replace the
spring
Travel increment
5 36 29.5 68 N 34.7 54 N
spool return spring
PC35R-8 PC45R-8 40-25

PC45R
3
B
34.5w5 Nm
B
A
63.7w4.9 Nm 5
240w5 Nm 31.9w2.5 Nm
2.5w0.5 Nm
10w1 Nm 2.5w0.5 Nm
RKP06691
Section A ± A
40-26 PC35R-8 PC45R-8

53.7w5 Nm 53.7w5 Nm
6
Section
Sezione B
B ±- B
B
RKP02623
Unit: mm
Clearance between Standard clearance Clearance limit

1
piston and cylinder 0.01 ± 0.02 0.4
Replace
Clearance between
2 0.03 ± 0.15 0.4
shoe and piston
Travel increment Free Installed Installed Free Installed

3
piston spring length length load length load When
damage or
23 15.6 7.8 N 21.5 6.2 N deformation
4 Braking valve return spring 32.8 24.7 113 N 31.2 90 N is found,
replace the
5 Brake spring 23 20 205 N 22.4 164 N spring
Travel increment
6 36 29.5 68 N 34.7 54 N
spool return spring
PC35R-8 PC45R-8 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)
3
Section
Sezione A
A± A
-A Section B -±BB
Sezione B
8.33w2.45 Nm
(0.85w0.25 kgm)
2
Section
SezioneDD±- D
D
3 6.37w2.45 Nm
(0.65w0.25 kgm)
Section
Sezione C
C ±- C
C
Section
Sezione EE±- E
E RKP01330
Unit: mm

Centering spring
1 x é.D. length load length load When
(P3 and P4 port)
damage or
9.8 N 7.8 N
38.7x15.5 34 Ð deformation
(1.0 kg) (0.8 kg)
is found,
Centering spring 17.7 N 14.1 N replace the
2 42.5x15.5 34 Ð spring
(P1 and P2 port) (1.8 kg) (1.44 kg)
16.7 N 13.7 N
3 Metering spring 26.5x9.2 24.9 Ð
(1.7 kg) (1.4 kg)
40-28 PC35R-8 PC45R-8

PPC VALVE
FOR HAMMER
13.23w1.47 Nm
(1.35w0.15 kgm)
RKP01710
Unit: mm

1 Centering spring x é.D. length load length load
308.7 N 277.5 N Replace
54.4x21.2 40.5 53.1
(31.5 kg) (28.3 kg)
24.5 N 21.6 N
2 Metering spring 25.9x11.0 25.0 25.8
(2.5 kg) (2.2 kg)
PC35R-8 PC45R-8 40-29

CYLINDERS
PC35R
Boom: 588w59 Nm Boom: 1520w152 Nm (Wrench size: 46 mm)
Arm: 677w68 Nm Arm: 2060w206 Nm (Wrench size: 50 mm)
Bucket: 490w49 Nm Bucket: 1520w152 Nm (Wrench size: 46 mm)
Boom swing: 637w64 Nm Boom swing: 1520w152 Nm (Wrench size: 46 mm)
Blade: 677w68 Nm Blade: 2060w206 Nm (Wrench size: 50 mm)
2 1 3
RKP03830
Unit: mm
Standard Tolerance Standard Limit

Cylinder
size Shaft Hole clearance clearance
± 0.025 + 0.152 0.032 ±

Boom 45 0.551
± 0.087 + 0.007 0.239
Clearance ± 0.025 + 0.152 0.032 ±
Arm 45 0.539
between ± 0.087 + 0.007 0.239 Replace
1
piston rod and cylinder head
cylinder head ± 0.025 + 0.132 0.031 ±
Bucket 40 0.551
± 0.087 + 0.006 0.219
± 0.025 + 0.152 0.032 ±
Boom swing 45 0.551
± 0.087 + 0.007 0.239
± 0.025 + 0.152 0.032 ±
Blade 45 0.551
± 0.087 + 0.007 0.239
± 0.025 + 0.142 0.105 ±
Boom 40 1.0
± 0.087 + 0.080 0.229
± 0.025 + 0.142 0.105 ±
Arm 40 1.0
± 0.064 + 0.080 0.206
Clearance
between ± 0.170 + 0.142 0.250 ±
2 Bucket 35 1.0
cylinder head ± 0.232 + 0.080 0.374
bushing and pin
± 0.025 + 0.128 0.100 ±
Boom swing 45 1.0
± 0.064 + 0.075 0.192
± 0.025 + 0.142 0.105 ±
Blade 50 1.0
± 0.064 + 0.080 0.206 Replace
± 0.025 + 0.128 0.100 ± bushing
Boom 45 1.0
± 0.064 + 0.075 0.192
± 0.025 + 0.142 0.105 ±
Arm 40 1.0
± 0.087 + 0.080 0.229
Clearance
between ± 0.025 + 0.142 0.105 ±
3 Bucket 35 1.0
cylinder bottom ± 0.087 + 0.080 0.229
bushing and pin
± 0.025 + 0.142 0.105 ±
Boom swing 45 1.0
± 0.064 + 0.080 0.206
± 0.025 + 0.142 0.105 ±
Blade 50 1.0
± 0.064 + 0.080 0.206
40-30 PC35R-8 PC45R-8

PC45R
Boom: 677w68 Nm Boom: 2845w285 Nm (Wrench size: 55 mm)
Arm: 863w86 Nm Arm: 2845w285 Nm (Wrench size: 55 mm)
Bucket: 677w68 Nm Bucket: 2060w206 Nm (Wrench size: 50 mm)
Boom swing: 735w74 Nm Boom swing: 2845w285 Nm (Wrench size: 55 mm)
Blade: 942w94 Nm Blade: 2845w285 Nm (Wrench size: 55 mm)
2 1 3
RKP03830
Unit: mm
Standard Tolerance Standard Limit

Cylinder
size Shaft Hole clearance clearance
± 0.025 + 0.164 0.032 ±

Boom 50 0.551
± 0.087 + 0.007 0.239
Clearance ± 0.025 + 0.152 0.032 ±
Arm 45 0.539
between ± 0.087 + 0.007 0.239 Replace
1
piston rod and cylinder head
cylinder head ± 0.025 + 0.164 0.032 ±
Bucket 50 0.551
± 0.087 + 0.007 0.251
± 0.025 + 0.164 0.032 ±
Boom swing 50 0.551
± 0.087 + 0.007 0.251
± 0.025 + 0.164 0.032 ±
Blade 50 0.551
± 0.087 + 0.007 0.251
± 0.025 + 0.142 0.105 ±
Boom 50 1.0
± 0.087 + 0.080 0.229
± 0.025 + 0.128 0.100 ±
Arm 45 1.0
± 0.064 + 0.075 0.192
Clearance
between ± 0.180 + 0.142 0.260 ±
2 Bucket 45 1.0
cylinder head ± 0.242 + 0.080 0.384
bushing and pin
± 0.025 + 0.142 0.105 ±
Boom swing 50 1.0
± 0.064 + 0.080 0.206
± 0.030 + 0.124 0.130 ±
Blade 55 1.0
± 0.104 + 0.100 0.228 Replace
± 0.025 + 0.142 0.100 ± bushing
Boom 50 1.0
± 0.087 + 0.080 0.215
± 0.025 + 0.142 0.105 ±
Arm 45 1.0
± 0.064 + 0.080 0.206
Clearance
between ± 0.025 + 0.128 0.100 ±
3 Bucket 45 1.0
cylinder bottom ± 0.064 + 0.075 0.192
bushing and pin
± 0.025 + 0.142 0.105 ±
Boom swing 50 1.0
± 0.064 + 0.080 0.192
± 0.030 + 0.174 0.130 ±
Blade 55 1.0
± 0.104 + 0.100 0.278
PC35R-8 PC45R-8 40-31

WORK EQUIPMENT
PC35R
H
C
I
D A
B
J F E P
G
Q O
K
N RKP03840
M
1
2
Section
Sezione B
B ±- B
B Section
SezioneCC±- C
C
Section AA-±AA
Sezione
SectionDD-±DD
Sezione Section
Sezione EE±- E
E Section
Sezione FF ±- F
F
Sezione Section HH-±HH

Sezione Section II-±I I
Sezione
SectionGG- ±
GG RKP03810
40-32 PC35R-8 PC45R-8

6
4
Section J -±JJ
Sezione J Section LL-±LL
Sezione
Section K -±KK
Sezione K
7 5
Section N -±NN
Sezione N
Section
SezioneM
M±- M
M
Section
Sezione O
O ±- O
O Section
Sezione P
P ±- P
P Section Q -±Q
Sezione Q Q RKP03820
Unit: mm
Standard Tolerance Standard Clearance

Clearance between bushing
and mounting pin of boom size Shaft Hole clearance limit
1
swing bracket and revolving
frame ± 0.036 + 0.207 0.156 ±
100 1.0
± 0.090 + 0.120 0.297
± 0.025 + 0.128 0.100 ±
2 and mounting pin of boom 45 1.0
± 0.064 + 0.075 0.192
swing bracket and boom
± 0.025 + 0.142 0.105 ±
3 and mounting pin of arm 40 1.0
± 0.064 + 0.080 0.206
and boom
± 0.170 ± 0.003 0.118 ±
4 and mounting pin of link and 35 1.0
± 0.230 ± 0.052 0.227 Replace
arm
± 0.170 ± 0.003 0.118 ±
5 and mounting pin of bucket 35 1.0
± 0.230 ± 0.052 0.227
and arm
± 0.170 ± 0.003 0.118 ±
± 0.230 ± 0.052 0.227
link
± 0.170 ± 0.003 0.118 ±
± 0.230 ± 0.052 0.227
and link
± 0.025 + 0.142 0.105 ±
8 and mounting pin of track 35 1.0
± 0.087 + 0.080 0.229
frame and blade
PC35R-8 PC45R-8 40-33

PC45R
H
C
I
D A
B
J F E P
G
Q O
K
N RKP03840
M
1
2
Section
Sezione B
B ±- B
B Section
SezioneCC±- C
C
Section AA-±AA
Sezione
SectionDD-±DD
Sezione Section
Sezione EE±- E
E Section
Sezione FF ±- F
F
Sezione Section HH-±HH

Sezione Section II-±I I
Sezione
SectionGG- ±
GG RKP03810
40-34 PC35R-8 PC45R-8

6
4
Section
SezioneJJ±-JJ Section
SezioneLL±- L
L
Section
SezioneKK±-KK
7 5
Section
SezioneNN±-NN
Section
SezioneMM
±M-M
Section
SezioneOO± -OO Section
SezionePP± -PP Section
SezioneQQ±-Q
Q RKP03820
Unit: mm
Standard Tolerance Standard Clearance

and mounting pin of boom size Shaft Hole clearance limit
1
swing bracket and revolving
frame ± 0.036 + 0.204 0.164 ±
110 1.0
± 0.090 + 0.128 0.294
± 0.025 + 0.142 0.105 ±
2 and mounting pin of boom 50 1.0
± 0.064 + 0.080 0.206
swing bracket and boom
± 0.025 + 0.142 0.105 ±
3 and mounting pin of arm 50 1.0
± 0.064 + 0.080 0.206
and boom
± 0.170 ± 0.012 0.105 ±
± 0.230 ± 0.065 0.218 Replace
arm
± 0.170 ± 0.012 0.105 ±
± 0.230 ± 0.065 0.218
and arm
± 0.170 ± 0.012 0.105 ±
± 0.230 ± 0.065 0.218
link
± 0.170 ± 0.012 0.105 ±
± 0.230 ± 0.065 0.218
and link
± 0.025 + 0.142 0.105 ±
8 and mounting pin of track 35 1.0
± 0.087 + 0.080 0.229
frame and blade
PC35R-8 PC45R-8 40-35

40-36 PC35R-8 PC45R-8

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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

c Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

00-1 10-27 10-68 20-29 30-11

PC35R-8 PC45R-8 00-2-1

00-2-2 PC35R-8 PC45R-8

PC35R-8 PC45R-8 00-3

00-4 PC35R-8 PC45R-8

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

PC35R-8 PC45R-8 00-5

HOW TO READ THE SHOP MANUAL

Symbol Item Remarks

Example Weight of parts or systems.

REVISED EDITION MARK

00-6 PC35R-8 PC45R-8

ing, and a serious accident can result.

1. If a part cannot be smoothly removed from the

The allowable load value is estimated to be

2) Sling wire ropes from the middle portion of the

PC35R-8 PC45R-8 00-7

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

6 1 10 5 0.96w0.1 9.5w1 1.3w0.15 13.5w1.5

8 1.25 13 6 2.3w0.2 23w2 3.2w0.3 32.2w3.5

10 1.5 17 8 4.6w0.5 45w4.9 6.5w0.6 63w6.5

12 1.75 19 10 7.8w0.8 77w8 11w1 108w11

14 2 22 12 12.5w1 122w13 17.5w2 172w18

16 2 24 14 19.5w2 191w21 27w3 268w29

18 2.5 27 14 27w3 262w28 37w4 366w36

20 2.5 30 17 38w4 372w40 53w6 524w57

22 2.5 32 17 52w6 511w57 73w8 719w80

24 3 36 19 66w7 644w70 92w10 905w98

27 3 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 4 55 27 230w25 2250w250 320w35 3150w350

39 4 60 Ð 295w33 2900w330 410w45 4050w450

00-8 PC35R-8 PC45R-8

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Thread diameter Width across flats TIGHTENING TORQUE

1/2" - 20 17 2.6w0.5 25.5w4.9

Nomenclature Code Applications

PC35R-8 PC45R-8 00-9

CABLE ELECTRIC WIRE CODE

CLASSIFICATION BY COLOUR AND CODE