Komatsu PC35R-8, PC45R-8 Hydraulic Excavator Operation and Maintenance Manual (WEAM000302)

These PC35R-8 and PC45R-8 minis usually live in tight jobsites—utility trenches, residential foundations, landscaping—where they’re constantly tracking, swinging, and cycling the hydraulics all day. This operation and maintenance manual is what I’d keep handy to set a solid service rhythm, so the machine starts every morning and doesn’t quit mid-dig. If, for example, you notice the swing getting jerky or the boom slowing down, this book walks you through the basic checks and routine care to trace whether it’s an operator issue, a simple maintenance item, or something that needs a shop visit.

Applications & Use Cases

• Plan daily and weekly checks so you can spot leaks, loose hardware, or track issues before they shut the job down.
• Set up a realistic service schedule for filters, lubrication, and inspections that fits your actual workload.
• Verify correct operating procedures to avoid bad habits that wear out the swing, boom, and travel components early.
• Trace early hydraulic or control problems by following the recommended inspection order instead of guessing.
• Train new operators on how to warm up, shut down, and park the excavator without abusing the machine.

FAQ

Q: Can I use this manual on a tablet in the field?

A: Yes, it’s well-suited for digital use; you can zoom diagrams and quickly search terms while you’re next to the machine.

Q: Is it worth printing parts of it?

A: Many techs print the inspection and service pages to keep in a binder or toolbox for quick reference on muddy or wet sites.

Safety Note

Always follow the manual’s safety and lockout instructions before you inspect, adjust, or service any part of the excavator.

Komatsu PC35R-8, PC45R-8 Hydraulic Excavator Index:

• 1.1 FOREWORD
• 1.2 INFORMATION ON SAFETY
• 1.3 INTRODUCTION
  • 1.3.1 INTENDED USES
  • 1.3.2 IMPROPER OR UNAUTHORIZED USES
  • 1.3.3 MAIN CHARACTERISTICS
  • 1.3.4 RUNNING-IN
• 1.4 PRODUCT IDENTIFICATION
  • 1.4.1 MACHINE SERIAL NUMBER
  • 1.4.2 MACHINE IDENTIFICATION PLATE
  • 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
  • 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
  • 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
  • 1.4.6 CAB SERIAL NUMBER
  • 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS
• PAGE INTENTIONALLY LEFT BLANK
• TABLE OF CONTENTS
• PAGE INTENTIONALLY LEFT BLANK
• 2.1 SAFETY, NOISE AND VIBRATION PLATES
  • 2.1.1 POSITION OF THE SAFETY PLATES
  • 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
  • DANGER IN THE WORK AREA
  • DO NOT OPEN THE HOOD
  • CONSULT THE MANUAL
  • SAFETY DISTANCE
  • FILLING THE HYDRAULIC SYSTEM WITH OIL
  • HYDRAULIC OIL TOPPING UP
  • REFUELLING
  • ENGINE LUBRICATING OIL FILTER
  • FUEL FILTER
  • ENGINE AIR SUCTION FILTER
  • ENGINE COOLANT
  • ENGINE COOLANT PRESSURE
  • HYDRAULIC OIL LEVEL
  • HYDRAULIC OIL FILTER
  • ELECTRIC OUTLET
  • ANCHORAGE POINT
  • EMERGENCY EXIT
  • LIFTING POINT
  • DO NOT LIFT MORE THAN 1000 kg
  • 2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB
  • NOISE OUTSIDE THE CAB (PC35R)
  • NOISE OUTSIDE THE CAB (PC45R)
  • NOISE INSIDE THE CAB (PC35R)
  • NOISE INSIDE THE CAB (PC45R)
  • 2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY
  • EXTERNAL NOISE (PC35R)
  • EXTERNAL NOISE (PC45R)
  • NOISE PERCEIVED BY THE OPERATOR (PC35R)
  • NOISE PERCEIVED BY THE OPERATOR (PC45R)
  • 2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• 2.2 GENERAL PRECAUTIONS
  • 2.2.1 GENERAL SAFETY RULES
  • 2.2.2 SAFETY DEVICES AND GUARDS
  • 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
  • 2.2.4 UNAUTHORIZED MODIFICATIONS
  • 2.2.5 LEAVING THE OPERATOR’S SEAT
  • 2.2.6 GETTING ON AND OFF THE MACHINE
  • 2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
  • 2.2.8 PREVENTING BURNS
  • 2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
  • 2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT
  • 2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE
  • 2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT
• 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
  • 2.3.1 SAFETY ON THE WORK SITE
  • 2.3.2 FIRE PREVENTION
  • 2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB
  • 2.3.4 ROOM VENTILATION
  • 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS
  • 2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES
• 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
  • 2.4.1 STARTING THE ENGINE
  • 2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE
  • 2.4.3 CHECKS FOR TRAVELLING IN REVERSE
  • 2.4.4 MOVING THE MACHINE
  • 2.4.5 MOVING ON SLOPES
  • 2.4.6 WORKING ON SLOPES
  • 2.4.7 UNAUTHORIZED OPERATIONS
  • 2.4.8 PREVENTING ELECTROCUTION
  • 2.4.9 VISIBILITY
  • 2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES
  • 2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.4.12 WORKING ON LOOSE GROUND
  • 2.4.13 PARKING THE MACHINE
• 2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES
  • 2.5.1 LOADING AND UNLOADING
  • 2.5.2 TRANSPORT
• 2.6 BATTERY
  • 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
  • 2.6.2 STARTING WITH BOOSTER CABLES
• 2.7 PRECAUTIONS FOR THE REMOVAL
• 2.8 PRECAUTIONS FOR MAINTENANCE
  • 2.8.1 WARNING PLATES
  • 2.8.2 TOOLS
  • 2.8.3 PERSONNEL
  • 2.8.4 EQUIPMENT
  • 2.8.5 WORKING UNDER THE MACHINE
  • 2.8.6 CLEANING THE MACHINE
  • 2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS
  • 2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
  • 2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
  • 2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP
  • 2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
  • 2.8.12 USING LAMPS
  • 2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
  • 2.8.14 PRECAUTIONS CONCERNING THE STARTER
  • 2.8.15 HANDLING HIGH-PRESSURE PIPES
  • 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL
  • 2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
  • 2.8.18 COOLING FAN AND BELT
  • 2.8.19 WASTE MATERIALS
  • 2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES
• 3.1 SAFETY LOCKS
  • 3.1.1 MACHINE LOCKS
• 3.2 GENERAL VIEWS
  • 3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB
  • 3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY
  • 3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT
• 3.3 INSTRUMENTS AND CONTROLS
  • 3.3.1 INSTRUMENTS
  • 3.3.2 WARNING LIGHTS
  • 3.3.3 SWITCHES AND PUSH BUTTONS
  • 3.3.4 ELECTRICAL ACCESSORIES
  • 3.3.5 MACHINE CONTROLS
    • LEVER 1 (BASIC MANOEUVRES)
    • LEVER 2 (BASIC MANOEUVRES)
    • LEVER 1 (COMBINED MANOEUVRES)
    • LEVER 2 (COMBINED MANOEUVRES)
• 3.4 FUSES AND RELAYS
  • 3.4.1 FUSES
    • 3.4.1.1 EQUIPMENT FUSES
    • 3.4.1.2 MAIN FUSE
  • 3.4.2 RELAYS
• 3.5 GUARDS AND DRIVER’S SEAT
  • 3.5.1 ENGINE HOOD
  • 3.5.2 RIGHT COUNTERWEIGHT
  • 3.5.3 CANOPY
  • 3.5.4 CAB
  • 3.5.5 VENTILATION AND HEATING
  • 3.5.6 SEAT
  • 3.5.7 SAFETY BELT
  • 3.5.8 EMERGENCY EXIT
  • 3.5.9 TECHNICAL DOCUMENTATION CASE
  • 3.5.10 FIRE EXTINGUISHER
  • 3.5.11 FIRST AID KIT
• 3.6 USE OF THE MACHINE
  • 3.6.1 CHECKS BEFORE STARTING THE ENGINE
    • 3.6.1.1 VISUAL CHECKS
    • 3.6.1.2 DAILY CHECKS
    • 3.6.1.3 OPERATIONAL CHECKS
  • 3.6.2 STARTING THE ENGINE
    • 3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES
    • 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
  • 3.6.3 WARMING THE ENGINE
  • 3.6.4 HEATING THE HYDRAULIC OIL
  • 3.6.5 HOW TO MOVE THE MACHINE
    • 3.6.5.1 STEERING (CHANGING DIRECTION)
    • CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING
    • CHANGING DIRECTION WHEN THE MACHINE IS MOVING (the left and right travel levers are in the same p…
    • HOW TO CARRY OUT A COUNTER-ROTATION (with the machine not moving)
    • 3.6.5.2 MOVING ON SLOPES
    • 3.6.5.3 MAXIMUM IMMERSION DEPTH
• 3.7 PARKING THE MACHINE
  • 3.7.1 PARKING ON LEVEL GROUND
  • 3.7.2 PARKING ON SLOPES
• 3.8 STOPPING THE ENGINE
• 3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES
  • 3.9.1 LOADING AND UNLOADING THE MACHINE
  • 3.9.2 TRANSPORT
• 3.10 LIFTING THE MACHINE
• 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON
  • 3.11.1 FUEL AND LUBRICANTS
  • 3.11.2 COOLANT
  • 3.11.3 BATTERY
  • 3.11.4 OTHER PRECAUTIONS
  • 3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
• 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
• 3.13 USING THE WORK EQUIPMENT
  • 3.13.1 ORGANIZING THE WORK AREA
  • 3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS
  • 3.13.3 DIGGING METHOD
  • 3.13.4 CHANGING THE BUCKET
• 3.14 LONG PERIODS OF INACTIVITY
  • 3.14.1 BEFORE THE PERIOD OF INACTIVITY
  • 3.14.2 DURING THE PERIOD OF INACTIVITY
  • 3.14.3 AFTER THE PERIOD OF INACTIVITY
• 3.15 TROUBLESHOOTING
  • 3.15.1 OCCURRENCES THAT ARE NOT FAILURES
  • 3.15.2 HOW TO REMOVE THE MACHINE
  • 3.15.3 AFTER THE FUEL HAS RUN OUT
  • 3.15.4 IF THE BATTERY IS DOWN
    • 3.15.4.1 STARTING WITH BOOSTER CABLES
  • 3.15.5 OTHER TROUBLES
    • 3.15.5.1 ELECTRICAL CIRCUIT
    • 3.15.5.2 HYDRAULIC SYSTEM
    • 3.15.5.3 ENGINE
• 4.1 GUIDE TO MAINTENANCE
• 4.2 MAINTENANCE NOTES
  • 4.2.1 NOTES REGARDING THE ENGINE
    • 4.2.1.1 ENGINE OIL
    • 4.2.1.2 COOLANT
    • 4.2.1.3 FUEL
  • 4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM
  • 4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM
  • 4.2.4 NOTES REGARDING LUBRICATION
  • 4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
• 4.3 FUEL, COOLANT AND LUBRICANTS
  • LUBRICATION WITH GREASE
  • 4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS
• 4.4 TIGHTENING TORQUES FOR SCREWS AND NUTS
  • 4.4.1 STANDARD TIGHTENING TORQUES
  • 4.4.2 SPECIFIC TIGHTENING TORQUES
• 4.5 LUBRICATION
  • 4.5.1 LUBRICATION DIAGRAM
• 4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY
  • 4.6.1 CRITICAL PARTS FOR SAFETY
    • FUEL SUPPLY SYSTEM
    • HYDRAULIC SYSTEM
• 4.7 MAINTENANCE PLAN
  • 4.7.1 WHEN REQUIRED
  • 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)
  • 4.7.3 CHECKS BEFORE STARTING
  • 4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…
  • 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION
  • 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION (Operations to be carried out together w…
  • 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
  • 4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…
  • 4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
  • 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
  • 4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
  • 4.7.1 WHEN REQUIRED
    • 4.7.1.a WASHING THE COOLING CIRCUIT
    • 4.7.1.b DRAINING THE FUEL TANK
    • 4.7.1.c CHECKING THE ELECTRICAL SYSTEM
    • 4.7.1.d CHECKING THE STEEL TRACK TENSION
    • CHECK
    • ADJUSTMENT
    • 4.7.1.e CHECKING THE RUBBER TRACKS
    • 4.7.1.f CHECKING THE RUBBER TRACK TENSION
    • CHECK
    • ADJUSTMENT
    • 4.7.1.g CHANGING THE RUBBER TRACK
    • REMOVING THE RUBBER TRACK
    • INSTALLING THE RUBBER TRACK
    • 4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE
  • 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)
    • 4.7.2.a CHANGING THE HYDRAULIC OIL FILTER
    • 4.7.2.b CHANGING THE HYDRAULIC OIL
  • 4.7.3 CHECKS BEFORE STARTING
    • 4.7.3.a VARIOUS CHECKS
    • 4.7.3.b CHECKING THE COOLANT LEVEL
    • 4.7.3.c CHECKING THE FUEL LEVEL
    • 4.7.3.d CHECKING THE ENGINE OIL LEVEL
    • 4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT
    • 4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR
    • 4.7.3.g CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER
  • 4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…
  • 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION
    • 4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING
    • BALL-BEARING RING AND BLADE LUBRICATION POINTS
    • EQUIPMENT LUBRICATION POINTS
  • 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
  • 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
    • 4.7.7.a ADJUSTING THE FAN BELT TENSION
    • 4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL
    • 4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS
    • 4.7.7.d CHANGING THE ENGINE OIL
  • 4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…
  • 4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
    • 4.7.9.a CHANGING THE ENGINE OIL FILTER
    • 4.7.9.b CHANGING THE FUEL FILTER
    • 4.7.9.c CLEANING THE WATER SEPARATOR
    • 4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS
    • 4.7.9.e CHANGING THE HYDRAULIC SYSTEM OIL FILTER
    • 4.7.9.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o…
  • 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
    • 4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS
  • 4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
    • 4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER
    • 4.7.11.b CHANGING THE COOLANT
    • 4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
    • 4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER
• 5.1 TECHNICAL DATA
  • 5.1.1 STANDARD OVERALL DIMENSIONS (for PC35R only)
    • MACHINE WITH CAB
    • MACHINE WITH CANOPY
  • 5.1.2 TECHNICAL CHARACTERISTICS PC35R
  • 5.1.3 STANDARD OVERALL DIMENSIONS (for PC45R only)
    • MACHINE WITH CAB
    • MACHINE WITH CANOPY
  • 5.1.4 TECHNICAL CHARACTERISTICS PC45R
  • 5.1.5 LIFTING CAPACITY WITH CAB AND RAISED BLADE (for PC35R only)
  • 5.1.6 LIFTING CAPACITY WITH CAB AND LOWERED BLADE (for PC35R only)
  • 5.1.7 LIFTING CAPACITY WITH CANOPY AND RAISED BLADE (for PC35R only)
  • 5.1.8 LIFTING CAPACITY WITH CANOPY AND LOWERED BLADE (for PC35R only)
  • 5.1.9 LIFTING CAPACITY WITH CAB AND RAISED BLADE (for PC45R only)
  • 5.1.10 LIFTING CAPACITY WITH CAB AND LOWERED BLADE (for PC45R only)
  • 5.1.11 LIFTING CAPACITY WITH CANOPY AND RAISED BLADE (for PC45R only)
  • 5.1.12 LIFTING CAPACITY WITH CANOPY AND LOWERED BLADE (for PC45R only)
• 6.1 AUTHORIZED OPTIONAL EQUIPMENT
  • 6.1.1 PRECAUTIONS REGARDING SAFETY
  • 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
  • 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
  • (FOR MODEL PC35R ONLY)
  • (FOR MODEL PC45R ONLY)
• 6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)
  • 6.2.1 DESCRIPTION AND CONTROL
  • 6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED
    • FOR A CORRECT USE, IT IS NECESSARY TO:
    • ALWAYS AVOID THE FOLLOWING INCORRECT USES:
  • 6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER
    • 6.2.3.1 INSTALLING THE HAMMER
    • 6.2.3.2 REMOVING THE HAMMER
  • 6.2.4 MAINTENANCE
• 6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT
  • 6.3.1 SELECTION VALVE (1)
  • 6.3.2 CONTROL PEDAL (2)
  • 6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT
  • 6.3.4 MAINTENANCE

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