2002 Komatsu PC35R-8 PC45R-8 Deluxe Hydraulic Excavator Shop Manual (P/N WEBM003900)

Komatsu Utility Division shop manual WEBM003900 covers 2002 PC35R-8 and PC45R-8 Deluxe hydraulic excavators: PC35R-8 serial F20932 and up, and PC45R-8 serial F21251 and up.

Search, navigation and wiring detail: The main chapters contain searchable text, but font encoding can affect searches in some PDF readers. Embedded bookmarks cover the service chapters. Cover lettering is only partly searchable; small wiring labels require zooming.

• Hydraulic diagnosis: Circuit-pressure testing, LS differential-pressure checks, PC valve adjustment, hydraulic drift analysis, and cylinder, swing-motor and swivel-joint leakage tests.

• Engine and cooling: Valve-clearance adjustment, compression testing, injection timing, and cylinder-head, injection-pump, water-pump and radiator/oil-cooler removal and installation.

• Cylinder repair: Work equipment cylinder disassembly and assembly, with seal replacement, piston assembly, bushing installation and component-specific tightening data.

• Undercarriage service: Rubber and steel track replacement, tension adjustment, idler and recoil-spring disassembly, and final-drive removal and installation.

• Electrical systems: Three wiring schematics with component, connector and fuse legends, plus starter, alternator and servocontrol safety-microswitch service.

• Inspection standards: Model-specific clearances, wear limits, gear backlash and spring criteria for swing, travel, control-valve and work-equipment components.

This manual is suited to mechanics experienced with excavator repair and equipped for hydraulic pressure testing, heavy-component lifting and press work.

CLSS and Hydraulic Fault Isolation

The Closed Center Load Sensing System (CLSS) section explains the variable-displacement main pump, TCC and LS valves, and control-valve pressure compensation. Proportional Pressure Control (PPC) coverage includes work-equipment and hammer valves, the accumulator, main relief valve, and servocontrol/travel-speed solenoid valves.

Hydraulic drift tests distinguish cylinder-seal leakage from control-valve faults, helping narrow the cause before a cylinder is removed for repair. Separate procedures cover hydraulic air bleeding and tank pressurization.

Engine, Fuel and Cooling Service

The engine tables distinguish the 3D84E-3FAE in the PC35R-8 from the 4D84E-3FAE in the PC45R-8. Model-specific valve-adjustment sequences and cylinder-head tightening diagrams accompany engine-pump group and P.T.O./engine-pump coupling removal.

Fuel-system coverage includes nozzle holders and injection-pump installation checks. Cooling procedures distinguish cab-heater connections from the canopy configuration.

Swing, Travel and Undercarriage Repair

Exploded and sectional component views explain the power train, swing circle, swing machinery and final-drive reduction ratios. Maintenance standards cover track frames, carrier rollers, track rollers and steel shoes, with separate travel-motor and final-drive data for each model.

Recoil-spring assembly data differ for rubber and steel tracks. Tool listings identify recoil-spring fixture ATR200720 and track master-pin tool ATR200460. Revolving-frame installation notes flag possible damage to locating pins and the swivel joint during refitting.

Work Equipment and Cylinder Repair

Boom, arm, bucket, boom-swing and blade procedures cover pin-and-bushing inspection and shim placement. Standard and long-arm configurations have separate drift criteria.

Cylinder assembly instructions address seal orientation, sizing and protective installation tools; careless installation can damage seals and sliding surfaces. The cylinder tooling list includes disassembly/assembly fixture ATR200620 and seal-installation pliers ATR200730.

Hydraulic and Electrical Diagrams

Separate Hydraulic Circuit Diagram PC35R and Hydraulic Circuit Diagram PC45R drawings show the model-specific circuits. Electrical Diagram (1/3) covers starting, charging and instruments; (2/3) covers lighting, fuel-pump and hammer circuits; (3/3) covers the heater fan and servocontrol interlock.

Electric wire codes explain conductor sizes and color markings. Main-pump section views show the internal piston and swash-plate arrangement.

Service Data and Scope Limits

Reference pages supply standard torque specifications, coating materials, fluid-capacity charts, temperature-based oil and coolant guidance, component weight tables and wire-rope lifting charts. Oil-change notes address fuel sulfur content; routine maintenance intervals are referenced to the operation and maintenance manual.

Some component-specific torque fields in the removal/installation chapter are blank. Full internal engine, hydraulic-pump, final-drive and swing-motor overhaul procedures are not included.

Safety notes address high-pressure hydraulics, component support and lifting precautions.

English PDF and Included Pages

One printable English PDF contains 286 pages total: 16 preliminary pages, 80 pages of Structure and Function, 58 of Testing and Adjustments, 84 of Removal and Installation, and 38 of Maintenance Standard, plus the main cover, four section dividers and five reverse pages. The two revision-list pages and all blank pages are already included in that total.