Ah 18851

MAJOR CODE: H1
NO.: AH18851
PARTS & SERVICE NEWS (C)
DATE: April 17, 2018
Page 1 of 1
SUBJECT: Hydraulic cylinder
PURPOSE: Release the Repair Manual
APPLICATION: PC3/4/55/7/8000-6
FAILURE CODE: H100AA
DESCRIPTION:
:
x Before carrying out any repairs, read all the safety instructions
in the Operation and Maintenance Manual of your shovel.
x The Parts & Service News AH10509 (latest edition) and local
safety rules must also be observed.
Attached you will find the latest
Repair Manual REP_CYL 1116-GB-1.pdf
for Hydraulic Cylinders.
AH18851
REP_CYL 1116-GB-1
Cylinder REPAIR-Manual
HYDRAULIC
MINING PC3000
SHOVEL
up to
PC8000
For attachment cylinders with
design version 4 and up
Release 11/2016
Unsafe maintenance or repair work of machine

parts may cause serious injury or death.
Maintenance personnel must read this manual
before repairing or maintaining work.
Komatsu has Manuals written in other languages. If

a foreign language manual is required, contact your
local distributor for availability.
REP_CYL 1116-GB-1 Cylinder REPAIR-Manual

COPYRIGHT
This material is property of Komatsu Germany GmbH and is not to be reproduced, used, or dis-
closed except in accordance with the written authorization of Komatsu Germany GmbH. It is our
policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or add improvements at any time without incurring any obligation to install such
changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that the customer contact their distributor for information on the
latest revision.
Cylinder REPAIR-Manual REP_CYL 1116-GB-1

1 INTRODUCTION........................................................................................ 1-1
1.1 CONTENTS OF THIS BINDER .......................................................................................................... 1-2
1.2 PREFACE........................................................................................................................................... 1-3
1.2.1 CONTACTING THE SERVICE .............................................................................................. 1-3
1.2.2 GUARANTEE......................................................................................................................... 1-3
2 SAFETY ..................................................................................................... 2-1

2.1 OVERVIEW ........................................................................................................................................ 2-3
2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-3
2.2 GENERAL PRECAUTIONS ............................................................................................................... 2-5
2.2.1 GENERAL .............................................................................................................................. 2-5
2.2.2 PERSONAL PROTECTIVE CLOTHING ................................................................................ 2-5
2.2.3 WHEN USING A HAMMER ................................................................................................... 2-6
2.2.4 PROPER TOOLS................................................................................................................... 2-6
2.2.5 PERSONNEL ......................................................................................................................... 2-6
2.2.6 FIRE PREVENTION .............................................................................................................. 2-7
2.2.7 UNAUTHORIZED MODIFICATION ....................................................................................... 2-7
2.3 PRECAUTIONS FOR MAINTENANCE AND REPAIR ...................................................................... 2-8
2.3.1 GENERAL PRECAUTIONS ................................................................................................... 2-8
2.3.2 KEEP WORK PLACE CLEAN AND TIDY.............................................................................. 2-8
2.3.3 PRECAUTIONS WHEN WELDING ....................................................................................... 2-8
2.3.4 PRECAUTION WITH HIGH PRESSURE FLUIDS................................................................. 2-9
2.3.4.1 HANDLING HIGH PRESSURE HOSES AND PIPES ............................................ 2-9
2.3.5 COMPRESSED AIR .............................................................................................................. 2-9
2.3.6 WASTE MATERIALS ............................................................................................................. 2-9
3 SERVICEABLE CYLINDERS AND SEALING TYPES............................... 3-1

3.1 TABLES OF SERVICEABLE CYLINDERS ....................................................................................... 3-2
3.1.1 DESIGN STATE 4 CYLINDERS ............................................................................................ 3-2
3.1.2 DESIGN STATE 5 CYLINDERS ............................................................................................ 3-4
3.2 SEALING DESIGNS, SECTIONAL DRAWINGS............................................................................... 3-6
3.2.1 CYLINDERS WITH CHEVRON® V-RING SEALING ............................................................ 3-6
3.2.2 CYLINDER WITH COMPACT SEALING ............................................................................... 3-8
3.2.3 CYLINDER WITH NOK-3 SEALING .................................................................................... 3-10
3.2.4 CYLINDER WITH CHESTERTON® 11KE SEALING .......................................................... 3-12
4 HYDRAULIC CYLINDER REPAIR............................................................. 4-1

4.1 GENERAL .......................................................................................................................................... 4-2
4.1.1 SCOPE OF REPAIR WORK .................................................................................................. 4-3
4.1.2 MOVING HYDRAULIC CYLINDERS ..................................................................................... 4-4
4.1.3 HYDRAULIC CYLINDER DATA MARKINGS ........................................................................ 4-6
4.1.3.1 HYDRAULIC CYLINDER PART NO. AND INDEX................................................. 4-6
4.1.3.2 KOMATSU JOB NUMBER AND OVERSIZE IDENTIFICATION ........................... 4-6
4.2 DISASSEMBLY OF HYDRAULIC CYLINDERS................................................................................ 4-7
REP_CYL 1116-GB-1 Cylinder REPAIR-Manual TOC - 1

4.3 INSPECTION OF THE COMPONENTS ........................................................................................... 4-10
4.3.1 INSPECTION OF THE PISTON ROD.................................................................................. 4-11
4.3.2 INSPECTION OF THE CYLINDER...................................................................................... 4-11
4.3.3 INSPECTION OF THE CYLINDER HEAD........................................................................... 4-12
4.3.4 INSPECTION OF THE GROOVE NUT (PISTON NUT)....................................................... 4-13
4.3.5 INSPECTION OF THE PISTON........................................................................................... 4-13
4.4 REPAIR PROCEDURES .................................................................................................................. 4-14
4.4.1 REPLACEMENT OF THE HYDRAULIC CYLINDER EYE BUSHINGS ............................... 4-14
4.4.2 REPLACEMENT OF THE PISTON SEAL, GUIDE STRIPS AND WEAR RINGS ............... 4-16
4.4.3 REPLACEMENT OF THE SEALINGS IN THE CYLINDER HEAD ...................................... 4-18
4.4.3.1 REPLACEMENT OF CHEVRON® V-RING SEALING......................................... 4-18
4.4.3.2 REPLACEMENT OF CHESTERTON® 11KE SEALING...................................... 4-20
4.4.3.3 REPLACEMENT OF NOK-3 SEALING................................................................ 4-22
4.4.3.4 REPLACEMENT OF COMPACT SEALING......................................................... 4-24
4.5 MANUFACTURING DIMENSIONS .................................................................................................. 4-26
4.5.1 WEAR RINGS, SPECIFIED SPACE.................................................................................... 4-26
4.5.2 GUIDE STRIPS, SPECIFIED SPACE.................................................................................. 4-27
4.6 WEAR AND TEAR LIMITS FOR COMPONENTS ........................................................................... 4-28
4.6.1 CYLINDER HEAD - WEAR AND TEAR LIMITS .................................................................. 4-28
4.6.2 CYLINDER EYE BUSHES - WEAR AND TEAR LIMITS ..................................................... 4-32
4.6.3 PISTON ROD - WEAR AND TEAR LIMITS ......................................................................... 4-33
4.6.3.1 CHROME LAYER THICKNESS AND SURFACE ................................................ 4-34
4.6.3.2 MAXIMUM ALLOWED BEND / RUNOUT ............................................................ 4-34
4.6.4 CYLINDER - WEAR AND TEAR LIMITS ............................................................................. 4-35
4.7 ASSEMBLY OF HYDRAULIC CYLINDERS .................................................................................... 4-36
4.7.1 LEAKAGE TEST .................................................................................................................. 4-41
5 SERVICE INFORMATION ......................................................................... 5-1

5.1 TORQUE CHARTS ACCORDING TO KOMATSU COMPANY STANDARD.................................... 5-2
5.2 BLIND PLUGS.................................................................................................................................... 5-3
5.2.1 DUMMY PLATES FOR SAE–FLANGES ............................................................................... 5-3
5.3 SPECIAL TOOLS ............................................................................................................................... 5-4
5.3.1 HOOK SPANNERS FOR THE PISTON NUTS (GROOVE NUTS)........................................ 5-4
5.3.2 USE OF THE HYDRAULIC TORQUE WRENCH FOR THE GROOVE
NUTS (PISTON NUTS).......................................................................................................... 5-5
5.3.2.1 PREPARING THE PISTON ROD TO USE THE HYDRAULIC
TORQUE WRENCH............................................................................................... 5-6
5.3.3 CUSTOM BUILD MOUNTING TOOLS .................................................................................. 5-8
5.3.3.1 MANUFACTURING OF THE HEADING TOOL FOR NOK STRIPPERS............... 5-8
5.3.3.2 MANUFACTURING OF THE SLEEVE FOR MOUNTING THE GLYD-RING®...... 5-9
5.3.3.3 MANUFACTURING OF THE SLEEVE FOR RESIZING GLYD-RINGS® ............ 5-10
5.3.3.4 MANUFACTURING OF THE SLEEVE FOR MOUNTING THE
CYLINDER HEAD ................................................................................................ 5-11
5.4 LIST OF RELEVANT PARTS AND SERVICE NEWS ..................................................................... 5-12
6 APPENDIX ................................................................................................. 6-1

6.1 HYDRAULIC CYLINDER INSPECTION FORM................................................................................. 6-2
TOC - 2 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

Introduction
1 INTRODUCTION
REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 1 -1

Contents of this binder Introduction
1.1 CONTENTS OF THIS BINDER

With this Repair Manual, KOMATSU provides you with the description of proper repair procedures of the hydraulic
cylinders of the hydraulic mining shovels PC3000, PC4000, PC5500 and PC8000.
The given procedures in this manual are for qualified and special trained personnel only.
1 -2 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

Introduction Preface
1.2 PREFACE
This manual has been prepared as a SERVICE GUIDE for the mechanic responsible for the upkeep of your
hydraulic mining shovel.
It is compiled into different sections and summarizes the procedures for removal/disassembling and replacing/
reassembling of hydraulic cylinders.
All information, illustrations and specifications contained herein are based on the development at printing time and
may be subject to possible future changes by KOMATSU without prior notice.
Also all materials and specifications may be subject to change without prior notice.
If, after reading this manual, you can give us suggestions and comments for improvements - please do not hesitate
to contact us.
Komatsu Mining Germany GmbH
Service Information
Department 8151.40
P.O. Box 18 03 61
D - 40570 Düsseldorf
GERMANY
1.2.1 CONTACTING THE SERVICE

In all your written or phoned inquiries, please indicate the model and serial number of your shovel.
1.2.2 GUARANTEE
Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturer’s
guarantee.
In order to keep your shovel in first-class operating condition only use genuine spare and wear parts.
The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any
guarantee.

Preface Introduction
Please continue reading on the next page.

Safety
2 SAFETY
IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

INJURY OR DEATH.
Please read and make sure that you fully understand the precautions described in this section and the
safety labels on the machine. When operating or servicing the machine, always follow these precaution
strictly.

Safety

Safety Overview
2.1 OVERVIEW
2.1.1 METHOD OF USING THIS MANUAL

Figure references that appear in the operation procedures use the format (Fig. 4-12, Pos. 4), which means posi-
tion number 4 in figure 12 of section 4.
Table references that appear in the operation procedures use the format (Table 4-12), which means Table 12 of
section 4.
Special requirements such as listing of special tools or size or numbers of blind plugs etc. are listed in a table at
the beginning of each operation procedure.
Special tools that appear in the lists are given with part name, part number, and quantity (2 x thread protector, PN
409 329 40).
The following symbols / labels are used in the manual to designate additional information:
Kind and amount of drained fluids

a (e.g. drain oil, 1500 liters).
Lifting weight of an assembly

(e.g. 140 kg).
d Kind and amount of fluids to fill

(e.g. fill oil, 1500 liters).
b Special tightening torques for bolts etc., if not according to the KOMATSU company standard
(e.g. 129 Nm).
General information concerning a section

(e.g. tightening torques according to the KOMATSU company standard).
Special authorized / qualified personnel is required

(e.g. certified electrician).
REMARKS: Designates additional information or hints.
NOTE! Designates general safety relevant information or hints which have no direct reference to an action.
1. 2. 3. Used to designate working steps.
– Used to designate itemization.
n / p Used in tables to indicate that an entry continues on the previous / next page

Overview Safety
To identify important safety messages in the manual the following signal words are used. This safety messages
have a direct reference to following actions:
DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to machine
components. This precaution is given where the components may be damaged or the service life reduced
if the precaution is not followed.

Safety General precautions
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL
NOTE! Country-specific rules and regulations take precedence over all procedures and safety notes in this
manual.
Always follow the precautions below to prepare for action if any

injury or fire should occur, refer to Fig. 2-1.
– Be sure that fire extinguishers have been provided and read

the labels to ensure that you know how to use them in emer-
gencies.
– Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
– Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary.
Fig. 2-1
2.2.2 PERSONAL PROTECTIVE CLOTHING

Refer to Fig. 2-2:
– Do not wear loose clothing and accessories. If these catch on

the control levers or moving parts, there is a danger that it
may cause the machine to move unexpectedly.
– Wear safety clothing, goggles, respirator and other safety
devices, whenever working conditions make this necessary.
Observe the local safety rules.
– If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine, so
tie your hair up and be careful not to let it get caught.
– Check that all protective equipment functions properly before
using it. Fig. 2-2

General precautions Safety
2.2.3 WHEN USING A HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury.
Always do as follows.
– If hard metal parts such as pins, bucket teeth, cutting edges,

or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety glasses and gloves (Fig. 2-3).
– When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
– There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.
Fig. 2-3
2.2.4 PROPER TOOLS

Refer to Fig. 2-4:
– Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools
or improper use of the tools could cause serious personal
injury.
Fig. 2-4
2.2.5 PERSONNEL
– Assembly, commissioning and operation, disassembly, service (including maintenance and repair) require
basic mechanical, electrical and hydraulic knowledge, as well as knowledge of the appropriate technical
terms.
In order to ensure safety, these activities may therefore only be carried out by qualified technical personnel or
an instructed person under the direction and supervision of qualified personnel.
– Qualified personnel are those who can recognize possible hazards and institute the appropriate safety mea-
sures due to their professional training, knowledge, and experience, as well as their understanding of the rele-
vant conditions pertaining to the work to be done.
– Qualified personnel must observe the rules relevant to the subject area.

Safety General precautions
2.2.6 FIRE PREVENTION

– Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer
fluid. There is a danger they may catch fire. To prevent fire, always observe the following:
Refer to Fig. 2-5:
– Do not smoke or use any flame near fuel or other flammable

substances.
– Tighten all fuel and oil caps securely.
– Be careful not to spill flammable substances on overheated
surfaces or on parts of the electrical system.
– After adding fuel or oil, wipe up any spillage.
– Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace.
– When washing parts with oil, use a non-flammable oil. Do not
use diesel oil or gasoline. There is a danger that they may Fig. 2-5
catch fire.
– Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids.
– Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and do
not allow un authorised persons to enter.
– Before carrying out grinding or welding work on the machine, remove any flammable materials.
– Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
– Keep all electrical connections clean and securely tightened.
– Check the wiring for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or
replace any damaged wiring.
– Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.
2.2.7 UNAUTHORIZED MODIFICATION

– Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting
in modifications made without authorisation from Komatsu.
– Any modifications made without authorisation from Komatsu can create hazards. Before making a modifica-
tion, consult your komatsu distributor.

Precautions for maintenance and repair Safety
2.3 PRECAUTIONS FOR MAINTENANCE AND REPAIR
2.3.1 GENERAL PRECAUTIONS

– Ensure that the maintenance area is adequately secured.
– Carry out maintenance and repair work only if the machine components are positioned on stable and level
ground and has been secured against inadvertent movement and buckling.
– To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
– The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The dogman/rigger giving the instructions must be within sight or sound of the crane operator.
– For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
– Always tighten any screwed connections that have been loosened during maintenance and repair.
– Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immedi-
ately upon completion of the maintenance and repair work.
– Ensure that all consumable and replaced parts are disposed of safely and with minimum environmental
impact.
– Relieve all pressure in the hydraulic system before servicing the hydraulic system.
– Never allow unauthorized persons access to the machine components during repair and maintenance work.
– For cleaning dirty machine components use only fresh water with a salt content of less than 0.05%.
– DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
– Be sure to reinstall safety devices, guards or shields after repair, adjusting, and/or servicing.
2.3.2 KEEP WORK PLACE CLEAN AND TIDY

– Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying
– After servicing, remove oily cloth, inflammable material and all tools from the work place.
2.3.3 PRECAUTIONS WHEN WELDING

– Welding operations must always be carried out by a qualified welder and in a place equipped with proper
equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any
unqualified personnel to carry out welding.

Safety Precautions for maintenance and repair
2.3.4 PRECAUTION WITH HIGH PRESSURE FLUIDS

– If a circuit is under pressure, do not carry out any repair,
inspection, or replacement operation.
– If there is any leakage from the piping or hoses, the surround-
ing area will be wet, so check for cracks in the piping and
hoses and for swelling in the hoses.
– When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves (leather).
– There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly (Fig. 2-6). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash
the place with clean water, and consult a doctor immediately
for medical attention. Fig. 2-6
2.3.4.1 HANDLING HIGH PRESSURE HOSES AND PIPES

– If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and replace the hose if any of the following problems are found.
– Damaged or leaking hydraulic fitting.
– Frayed or cut covering or exposed reinforcement wire layer.
– Covering swollen in places.
– Twisted or crushed movable portion.
– Foreign material embedded in covering.
2.3.5 COMPRESSED AIR

– When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.
2.3.6 WASTE MATERIALS

– Preserve our environment. To prevent environmental pollu-
tion, pay careful attention to the method of disposing waste
materials.
– Always drain fluids from your machine components into con-
tainers. Never drain fluids onto the ground or dump it into the
sewage system, rivers, the sea or lakes. (Fig. 2-7).
– Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.
Fig. 2-7

Precautions for maintenance and repair Safety
2 - 10 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

Serviceable cylinders and sealing types
3 SERVICEABLE
CYLINDERS AND SEALING
TYPES

Tables of serviceable cylinders Serviceable cylinders and sealing types
3.1 TABLES OF SERVICEABLE CYLINDERS

If you do not find your cylinder in the following table check the previous edition of the Cylinder REPAIR-Manual
REP_CYL 0213-GB-1.
Details of the cylinder construction and sealing system can be found on the parts catalogue page of the concerned
"Cylinder Part No." in the Komatsu EKAT-System.
3.1.1 DESIGN STATE 4 CYLINDERS

Cyl. Instal- Over-
Hydraulic Rod Outer
Machine & hydrau- bore lation all Weight
cylinder Ø Stroke cyl. Ø
lic cylinder type Ø length length [kg]
Part No. [mm] [mm]
[mm] [mm] [mm]
989 920 40 PC3000 FSA boom 320 200 2000 3600 419 4055 2576
989 925 40 PC3000 FSA stick 240 170 2045 3390 311 3755 1635
989 930 40 PC3000 FSA bucket 250 170 2150 3530 321 3865 1760
989 935 40 PC3000 FSA clam 200 110 640 1390 258 1960 406
989 940 40 PC3000 BHA boom 320 210 2300 3700 412 4255 2760
989 945 40 PC3000 BHA stick 280 190 2045 3795 361 4210 2380
989 950 40* PC3000 BHA stick 280 190* 2045 3795 361 4210 2520
989 955 40 PC3000 BHA bucket 240 190 1960 3180 311 3665 1650
989 960 40 PC4000 FSA boom 330 220 2750 4150 431 4610 3395
989 965 40 PC4000 FSA stick 260 190 2430 4030 336 4415 2180
989 970 40 PC4000 FSA bucket 280 200 2435 3950 361 4345 2630
989 975 40 PC4000 FSA clam 225 110 750 1640 290 2035 615
989 980 40 PC4000 BHA boom 330 240 3500 4850 425 5345 4080
989 985 40 PC4000 BHA stick 320 210 2000 3840 419 4335 2960
989 990 40 PC4000 BHA bucket 280 190 2200 3510 361 4050 2245
934 650 40 PC5500 FSA boom 400 260 3000 4640 521 5230 5520
911 300 40 PC5500 FSA stick 300 220 2680 4220 407 5060 3340
911 320 40 PC5500 FSA bucket 330 240 2800 4600 431 5065 4005
911 325 40 PC5500 FSA clam 260 125 770 1720 343 2160 862
932 450 40 PC5500 BHA boom 400 270 3500 5100 516 5705 6175
915 830 40 PC5500 BHA stick 350 240 2300 4200 464 4730 4122
924 960 40 PC5500 BHA bucket 300 210 2480 3920 407 4440 3077
988 900 40 PC7000 FSA boom 430 290 3285 4885 559 5490 6692
988 905 40 PC7000 FSA stick 320 230 2535 4560 419 5030 3604
988 910 40 PC7000 FSA bucket 350 240 2800 4520 452 5020 4223
988 915 40 PC7000 FSA clam 300 150 805 1800 398 2280 1243

Serviceable cylinders and sealing types Tables of serviceable cylinders
Cyl. Instal- Over-

Hydraulic Rod Outer
Part No. [mm] [mm]
[mm] [mm] [mm]
988 560 40 PC7000 BHA boom 430 300 3815 5815 553 6435 8163
988 565 40 PC7000 BHA stick 380 250 2410 4360 496 4935 4755
988 570 40 PC7000 BHA bucket 320 210 2670 4045 419 4625 3268
926 800 40 PC8000 FSA boom 460 310 3150 4800 598 5410 7500
957 660 40 PC8000 FSA stick 330 240 2800 4530 431 5000 3916
913 975 40 PC8000 FSA bucket 380 260 2920 4650 496 5180 5358
957 630 40 PC8000 FSA clam 320 160 900 1900 412 2410 1430
962 470 40 PC8000 BHA boom 460 310 3750 5500 595 6140 8650
964 950 40 PC8000 BHA stick 420 270 2350 4470 542 5100 5795
917 805 40 PC8000 BHA bucket 350 240 2840 4380 452 4990 4184
Table 3-1 Serviceable cylinders PC3000, PC4000, PC5500, PC7000 and PC8000 (design state 4)
* With oxy-fuel cut rod head
It is recommended by KOMATSU to have the design state 4 cylinders updated to design state 5 in a certificated
REMAN-shop.

Tables of serviceable cylinders Serviceable cylinders and sealing types
3.1.2 DESIGN STATE 5 CYLINDERS

Cylinders in design state 5 are generally equipped either with the NOK-3 sealing system or with the
CHESTERTON® 11KE sealing system.
All cylinders have standardized cylinder heads which are no longer subject to oversize remanufacturing. As a con-
sequence the seat in the cylinder is different from previous design states.
Cyl. Instal- Over-

Hydraulic Rod Outer
Part No. [mm] [mm]
[mm] [mm] [mm]
992 000 40 PC3000 FSA boom 320 200 2000 3600 419 4055 2576
992 010 40 PC3000 FSA stick 240 170 2045 3390 311 3755 1635
992 020 40 PC3000 FSA bucket 250 170 2150 3530 321 3865 1760
992 030 40 PC3000 FSA clam 200 110 640 1390 258 1960 406
992 040 40 PC3000 BHA boom 320 210 2300 3700 412 4255 2760
992 050 40 PC3000 BHA stick 280 190 2045 3795 361 4210 2520
992 055 40 PC3000 BHA bucket 240 190 1960 3180 311 3665 1650
992 005 40 PC3000 FSA boom 320 200 2000 3600 419 4055 2576
992 370 40 PC3000 FSA stick 240 170 2045 3390 311 3755 1635
992 025 40 PC3000 FSA bucket 250 170 2150 3530 321 3865 1760
992 045 40 PC3000 BHA boom 320 210 2300 3700 412 4255 2760
992 060 40 PC3000 BHA stick 280 190 2045 3795 361 4210 2380
992 070 40 PC3000 BHA bucket 240 190 1960 3180 311 3665 1650
992 300 40 PC4000 FSA boom 330 220 2750 4150 431 4610 3395
992 305 40 PC4000 FSA stick 260 190 2430 4030 336 4415 2180
992 310 40 PC4000 FSA bucket 280 200 2435 3950 361 4345 2630
992 315 40 PC4000 FSA clam 225 110 750 1640 290 2035 615
992 320 40 PC4000 BHA boom 330 240 3500 4850 425 5345 4080
992 325 40 PC4000 BHA stick 320 210 2000 3840 419 4335 2960
992 330 40 PC4000 BHA bucket 280 190 2200 3510 361 4050 2245
992 110 40 PC5500 FSA boom 400 260 3000 4640 521 5230 5520
992 130 40 PC5500 FSA stick 300 220 2680 4220 407 5060 3340
992 125 40 PC5500 FSA bucket 330 240 2800 4600 431 5065 4005
992 105 40 PC5500 FSA clam 260 125 770 1720 343 2160 862
992 115 40 PC5500 BHA boom 400 270 3500 5100 516 5705 6175
992 120 40 PC5500 BHA stick 350 240 2300 4200 464 4730 4122
992 135 40 PC5500 BHA bucket 300 210 2480 3920 407 4440 3077

Serviceable cylinders and sealing types Tables of serviceable cylinders
Cyl. Instal- Over-

Hydraulic Rod Outer
Part No. [mm] [mm]
[mm] [mm] [mm]
992 170 40 PC7000 FSA boom 430 290 3285 4885 559 5490 6692
992 175 40 PC7000 FSA stick 320 230 2535 4560 419 5030 3604
992 180 40 PC7000 FSA bucket 350 240 2800 4520 452 5020 4223
992 185 40 PC7000 FSA clam 300 150 805 1800 398 2280 1243
992 199 40 PC7000 BHA boom 430 300 3815 5815 553 6435 8163
992 195 40 PC7000 BHA stick 380 250 2410 4360 496 4935 4755
992 190 40 PC7000 BHA bucket 320 210 2670 4045 419 4625 3268
992 140 40 PC8000 FSA boom 460 310 3150 4800 598 5410 7500
992 145 40 PC8000 FSA stick 330 240 2800 4530 431 5000 3916
992 150 40 PC8000 FSA bucket 380 260 2920 4650 496 5180 5358
992 100 40 PC8000 FSA clam 320 160 900 1900 412 2410 1430
992 155 40 PC8000 BHA boom 460 310 3750 5500 595 6140 8650
992 160 40 PC8000 BHA stick 420 270 2350 4470 542 5100 5795
992 165 40 PC8000 BHA bucket 350 240 2840 4380 452 4990 4184
Table 3-2 Serviceable cylinders PC3000, PC4000, PC5500, PC7000 and PC8000 (design state 5)

Sealing designs, sectional drawings Serviceable cylinders and sealing types
3.2 SEALING DESIGNS, SECTIONAL DRAWINGS
3.2.1 CYLINDERS WITH CHEVRON® V-RING SEALING
Fig. 3-1 Cylinder with CHEVRON® V-ring sealing (example)

Serviceable cylinders and sealing types Sealing designs, sectional drawings
Fig. 3-2 Detailed view of the CHEVRON® V-ring sealing
Legend for Fig. 3-1 and Fig. 3-2:
(01) Hydraulic cylinder assy. (18) Support ring
(02/03) Cylinder assy. (19) Cylinder head (Pos. 20+21)
(04) Freeze-in bush (20) Cylinder head
(05) Nipple8 (21) Bush
(06) Thread pin (22) Screw
(07) Groove nut (23) Seal kit (V-ring seals)
(08) Guide strip (24) Support ring
(09) Wear ring (25) Cover
(10) O-ring (piston seal part 1) (26) Bolt
(11) Glyd-ring® (piston seal part 2) (27/37) Wiper (Pos. 27) with support ring (Pos. 37)
(12) Piston assy. (Pos. 13+14) (28) Feather key
(13) Piston bush (29) Piston rod assy. (Pos. 28+30)
(14) Piston (30) Piston rod
(15) O-ring (31) Seal ring
(16) Support ring (32) Half shim
(17) O-ring (33) Cover ring
REMARKS: For details of the hydraulic cylinder cylinder’s system refer to the parts catalogue page of the con-
cerned cylinder from the "Tables of serviceable cylinders" on page 3-2.
It is recommended to replace the CHEVRON® V-ring sealing system by the CHESTERTON®
sealing system, refer to the PARTS & SERVICE NEWS No. "AH16825" latest edition.

3.2.2 CYLINDER WITH COMPACT SEALING

REMARKS: This sealing design is still only used in PC5500 clam cylinders.
Fig. 3-3 Cylinder with compact sealing (example)

Fig. 3-4 Detailed view of the compact sealing
(01) Hydraulic cylinder assy. (17) Cylinder head
(02) Cylinder (18) Bush
(03) Thread pin (19) Bolt
(04) Groove nut (20) Rod seal
(05) Piston (22) Cover ring
(08) Guide strip (23) Bolt
(09) Wear ring (24) Wiper
(10) Glyd-ring® (piston seal part 2) (25) Feather key
(11) O-ring (piston seal part 1) (26) Piston rod assy. (Pos. 27...30)
(12) Back-up ring (27) Piston rod
(13) O-ring (28) Flanged bush
(14) O-ring (29) Nipple
(15) Support ring (30) Lock ring
(16) Cylinder head (Pos. 17+18+30) (32) Support ring
REMARKS: For details of the hydraulic cylinder’s sealing system refer to the parts catalogue page of the con-

3.2.3 CYLINDER WITH NOK-3 SEALING
Fig. 3-5 Cylinder with NOK 3 sealing (example)

Fig. 3-6 Detailed view of the NOK-3 sealing
(01) Hydraulic cylinder assy. (17) O-ring
(03) Cylinder head (18) Support ring
(04) Piston (19) Feather key
(05) Groove nut (20) Seal ring
(06) Collar (21) Bolt
(07) Scraper (22) Thread pin
(08) Glyd-ring® (two-piece) (23) Grease nipple
(10) Wear ring (24) Bolt
(11) Guide strip (25) Dust seal
(12) Back-up ring (26) Sub dust seal
(13) Rod seal (27) Snap ring
(14) Freeze-in bushing (31/32) Cylinder
(15) O-ring (33/34) Piston rod
(16) Support ring
NOK-3 cylinder heads do not have a replaceable red brass bush to guide the piston rod.
REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 3 - 11

3.2.4 CYLINDER WITH CHESTERTON® 11KE SEALING
Fig. 3-7 Cylinder with CHESTERTON® sealing (example)

Fig. 3-8 Detailed view of the CHESTERTON® 11KE sealing
(1) Cylinder (15) Rod sealing kit (Pos. 26...28)
(2) Piston rod (16) Scraper
(3) Cylinder head (17) Support ring
(4) Piston (18) O-Ring
(5) Groove nut (19) Support ring
(6) Cover (20) O-Ring
(7) Cover ring (21) Feather key
(8) Freeze-in bushing (22) Grease nipple
(9) Seal ring (23) Bolt
(10) Thread pin (24) Bolt
(11) Glyd-ring® (two-piece) (25) 1st sealing element
(12) Wear ring (26) 2nd sealing element
(13) Guide strip (27) O-Ring
(14) Anti-Extrusion-Ring (28) Bush


Hydraulic cylinder repair
4 HYDRAULIC CYLINDER
REPAIR
NOTE! In addition to the provisions listed here, full compliance with general safety regulations in chapter
"Safety" is required.

General Hydraulic cylinder repair
4.1 GENERAL
The procedures in this chapter are general workshop repair procedures for all KOMATSU attachment hydraulic
cylinders for the machines PC3000 up to PC8000 with design state 4 and 5.
NOTE! Make sure that the correct parts are used at any repair work. Parts as bolts, washers, and nuts, etc.
must eventually be from a special material because they are used in special environmental. These
parts must be for example
• of a cold weather design or
• sea water proof...
Always use the parts catalogue page for the hydraulic cylinder, refer to the corresponding Part No. in
Table 3-1 on page 3-3!
Design state 4
Hydraulic Cylinders in design state 4 are equipped with the NOK-3 sealing system, the CHEVRON® V-ring sealing
system, or the compact sealing system (hydraulic cylinders for PC5500 clam only).
The hydraulic cylinder designs follow previous design states which can also be found in the previous edition of the
Cylinder Reman Manual REM_CYL 0213-GB-1.
Design state 5
Hydraulic Cylinders in design state 5 are generally equipped either with the NOK-3 sealing system or with the
CHESTERTON® 11KE sealing system.
Additionally all hydraulic cylinders have standardized cylinder heads which are no longer subject to oversize
remanufacturing. As a consequence the seat in the cylinder is different from previous design states.
Oversize parts (remanufactured hydraulic cylinders only)
A new oversizing system was invented by KOMATSU. In a certificated REMAN-shop hydraulic cylinders are now
remanufactured and honed up to a larger cylinder bore Ø in three tiers, depending on the original cylinder bore Ø.
In order to simplify stock-keeping all oversized parts as well as the original parts are standardized and may be re-
used when remanufacturing a hydraulic cylinder. No custom made parts are required, refer to the following table:
Oversize [mm]
Cyl. bore
Ø [mm] Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier
1 2 3 1 2 3 1 2 3 1 2 3
Ø200
+0.2 +0.4 +0.6
< Ø260
Ø260
+0.3 +0.6 +0.9
< Ø360
Ø360
+0.4 +0.8 +1.2
< Ø460
Ø460
+0.5 +1.0 +1.5
Table 4-1 Oversize tiers for the different cylinder diameters

Hydraulic cylinder repair General
Oversize sealing kits for the CHESTERTON® 11KE sealing system
For the CHESTERTON® 11KE sealing system two sealing sizes are available, original size and oversize:
– The original size sealing kit is used with the original cylinder bore diameters and tier 1 oversize diameters.
– The oversize sealing kit is used with the tier 2 and tier 3 oversize diameters.
4.1.1 SCOPE OF REPAIR WORK

Carry out the following repair procedures as required:
– Disassembly of hydraulic cylinders refer to section 4.2 on page 4-7

– Inspection of the components refer to section 4.3 on page 4-10
– Replacement of defective or worn components and parts
– Replacement of the hydraulic cylinder eye bushings refer to section 4.4.1 on page 4-14
– Replacement of the piston seal, guide strips and wear rings refer to section 4.4.2 on page 4-16
– Replacement of the sealings in the cylinder head refer to section 4.4.3 on page 4-18
– Assembly of hydraulic cylinders refer to section 4.7 on page 4-36
– Performing a hydraulic cylinder leakage test refer to section 4.7.1 on page 4-41
REMARKS: Any other than the described repair work is scope of the hydraulic cylinder remanufacturing and has
to be done in a certificated REMAN-shop.

4.1.2 MOVING HYDRAULIC CYLINDERS

Special tools: n/a
Additional equipment: – Crane

– Swivel hoist rings M30
Refer to Table 3-1 on page 3-3 and Table 3-2 on page 3-5
(hydraulic cylinder weight)
Dogman/rigger
– For disassembly and assembly place the hydraulic cylinder into a secured vertical position using the crane.
– For storage place the hydraulic cylinder into a secured horizontal position using the crane.
Vertical moving
1. Insert swivel hoist rings M30 into the threads (Fig. 4-9,
Pos. 1) at the cylinder head of the hydraulic cylinder (Fig. 4-9,
Pos. 2).
2. Attach a crane at the swivel hoist rings.
Fig. 4-9
DANGER
CRUSHING HAZARD FROM FLOATING LOADS!
Death or serious injury will result due to crushing by swinging or downfalling of heavy machine parts.
When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.
3. Carefully lift the hydraulic cylinder into a vertical position using the crane. The hydraulic cylinder may now be
moved in vertical position.

Hydraulic cylinder repair General
Horizontal moving
1. Insert swivel hoist rings M30 into the threads (Fig. 4-10,
Pos. 1) at the cylinder head of the hydraulic cylinder
(Fig. 4-10, Pos. 2)
2. Attach a crane at the swivel hoist rings.

Attach the other end of the stick cylinder to the crane using a
sling.
Fig. 4-10
DANGER
3. Carefully lift the hydraulic cylinder using the crane. The hydraulic cylinder may now be moved in horizontal
position.

4.1.3 HYDRAULIC CYLINDER DATA MARKINGS

Cylinder data markings, with the following information, are located at the cylinders.
Fig. 4-1 Example of cylinder data markings
(1) Cylinder bore Ø [mm] (7) Last two digit of production year (16 = 2016)
(2) Piston rod diameter [mm] (8) Hydraulic cylinder Part No.
(3) Piston stroke [mm] (9) Index letter (optional)
(4) Manufacturer symbol (10) Komatsu job number (optional)
(5) Annual counting number of the cylinder (11) Oversize identification (REMAN only)
(6) Production month (06 = June)
4.1.3.1 HYDRAULIC CYLINDER PART NO. AND INDEX

The hydraulic cylinder’s Part No. (Fig. 4-1, Pos. 8) and index letter (Fig. 4-1, Pos. 9) are used to identify the
hydraulic cylinder and must not be changed in any way until the designated use of the hydraulic cylinder will be
changed (e.g. other machine).
4.1.3.2 KOMATSU JOB NUMBER AND OVERSIZE IDENTIFICATION

A Komatsu job number (Fig. 4-1, Pos. 10) is assigned by Komatsu as an internal note for
– repair work (e.g. a hydraulic cylinder got a new sealing after a long storage period) or
– remanufacturing by certificated REMAN-shops (e.g. honing the cylinder to an oversize diameter).
The oversize data (Fig. 4-1, Pos. 11) after remanufacturing follows the respective Komatsu job number.

Hydraulic cylinder repair Disassembly of hydraulic cylinders
4.2 DISASSEMBLY OF HYDRAULIC CYLINDERS

Special tools: Hook spanner, refer to section 5.3.1 on page 5-4
Additional equipment: – Crane

– Clamping device with vee clamping blocks
– Swivel hoist rings M30
Dogman/rigger
NOTE! All hydraulic cylinders should be disassembled in a secured vertical position with the piston rod fac-
ing upwards.
It is recommended to put the hydraulic cylinder into a pit in the workshop floor in which the hydraulic
cylinder can be appropriately secured.
1. Remove the blind plugs at the hydraulic oil ports of the hydraulic cylinder.
a Drain hydraulic oil from the hydraulic cylinder. Catch it in an oil pan.
2. For disassembly move and place the hydraulic cylinder into a secured vertical position using the crane refer to
section 4.1.2 on page 4-4.
Disassembling of the piston rod assembly
3. Extend the piston rod (Fig. 4-2, Pos. 1) to gain access to the
cylinder head mounting bolts (Fig. 4-2, Pos. 1).
NOTICE
RISK TO DAMAGE PISTON ROD SURFACE!
The chrome surface on the piston rod may get damaged by
tools when removing the cylinder head mounting bolts. This
will cause leakage at the assembled hydraulic cylinder.
Put a protecting sleeve on the piston rod to avoid damages

in the chrome surface of the piston rod before removing the
bolts.
Fig. 4-2
4. Remove the bolts (Fig. 4-2, Pos. 1).
WARNING
HAZARD FROM FAULTY DISASSEMBLING OF CYLINDER HEADS!
Energy is stored in compressed air which will result in abrupt straight movement of the piston rod. This
may cause serious injuries or death.
Do not use compressed air to extract the cylinder head.

Always use the push-out bolts.

Disassembly of hydraulic cylinders Hydraulic cylinder repair
5. Extract the cylinder head (Fig. 4-2, Pos. 2) out of the cylinder using two push-out bolts (M12) in the threads in
the cylinder head.
REMARKS: Heavily deformed cylinder heads can not be extracted from the cylinder any more. In that case the
complete hydraulic cylinder assembly must be replaced.
6. Attach the piston rod assembly (Fig. 4-2, Pos. 3) to a crane.
DANGER
7. Together with the piston and the cylinder head extract the piston rod assembly from the cylinder using the
crane.
Removing of the piston and the cylinder head
NOTICE
RISK TO DAMAGE PISTON ROD SURFACE!
The chrome surface on the piston rod may get damaged by the clamping device. This will cause leakage at
the assembled hydraulic cylinder.
Use suitable vee clamping blocks at the clamping device to clamp the piston rod.
8. Clamp the piston rod (Fig. 4-2, Pos. 3) in a hydraulic clamping device.
9. Drill out the prick punched material at the thread pin (Fig. 4-3,
Pos. 1), see sub-section "Locking the groove nut (piston nut)"
on page 4-37.
10. Remove groove nut (Fig. 4-3, Pos. 2):
– Using a hook spanner, refer to section 5.3.1 on page 5-4

– Using the Hydraulic torque wrench, refer to section 5.3.2
on page 5-5.
11. Remove the piston (Fig. 4-3, Pos. 3) from the piston rod
(Fig. 4-3, Pos. 5).
12. Remove the feather key (Fig. 4-3, Pos. 6) from the piston rod.
Fig. 4-3
13. Attach a crane at the swivel hoist rings at the cylinder head
and remove the cylinder head (Fig. 4-3, Pos. 4) from the pis-
ton rod using the crane.
14. Carry out the inspection work, refer to section 4.3 on page 4-10.
REMARKS: Do not clean the piston seals and wear bands when shipping these parts to KOMATSU for failure
analysis.

Hydraulic cylinder repair Disassembly of hydraulic cylinders

Inspection of the components Hydraulic cylinder repair
4.3 INSPECTION OF THE COMPONENTS

Measurement Specification
Maximum chrome thickness 250 μm (0.010”)
Minimum chrome thickness 30 μm (0,0012”)
Maximum allowed bend (runout) 250 μm / m (0.010” / m)
Piston rod chrome surface finish Rz = 1.2±0.4 μm and Ra = 0.3±0.1 μm
Mr = 80...95%*1
Cylinder bore surface finish Rz = 1.0±0.6 μm and Ra = 0.05... 0.20 μm
Mr = 50...70%*2
Surface finish of cylinder head mounting surface at cyl- Rz = 25 μm
inder
Surface finish of cylinder head seat in cylinder Rz = 10 μm
Table 4-2 Specifications

*1 Material contact area according DIN 4776 should be 80...95%; measured in a depth of 25% of Rt-value based on a reference level zero line
set at Mr = 5% bearing area.
*2 Material contact area Rmr should be 50...70%, determined at a cut depth c = 0.25 x Rz, relative to a reference line of Cref 5%.
Fig. 4-4 Measurements of diameters and test points
L= 0 mm...2000 mm a = 200mm b = 200 mm

L = 2000 mm...5000 mm a = 500mm b = 500 mm
Table 4-3 Testing distances for Fig. 4-4

Hydraulic cylinder repair Inspection of the components
4.3.1 INSPECTION OF THE PISTON ROD

1. Visually inspect and record any scores or damage in the chrome surface.
If any damages or scores are found the hydraulic cylinder must be remanufactured in an certificated
REMAN-shop.
2. Refer to Fig. 4-4: Measure the rod diameter (A-A) in even distances "a" along the piston rod and repeat the
measurement in a 90º offset (B-B) to check for ovality. Use the distances given in Table 4-3.
Note the measured dimensions in the "Hydraulic Cylinder inspection form" on page 6-2.
3. Compare the noted dimensions with the wear and tear limits for the piston rod, refer to section 4.6.3 on
page 4-33. If the dimensions do not match the specifications replace the piston rod or have the piston rod
remanufactured in a certificated REMAN-shop.
4. Measure the chrome thickness of the rod in three even distances. Check if the measurement fits the specifica-
tion in Table 4-2. If the values do not match the specifications replace the piston rod or have the piston rod
remanufactured in a certificated REMAN-shop.
5. Refer to Fig. 4-4: Measure the diameter "ØA" of the eye bushing and compare the dimensions with the wear
and tear limits for the bushes, refer to section 4.6.2 on page 4-32. If the dimensions do not match the specifi-
cations replace the bushing in the piston rod, refer to section 4.4.1 on page 4-14.
6. Perform a magnetic particle crack test at the eye welding seam (Fig. 4-4, Pos. 1) and piston contact area
(Fig. 4-4, Pos. 2) at the rod. In the case of precarious findings contact the KOMATSU area manager for further
actions. Remanufacturing in a certificated REMAN-shop may be possible.
7. Check the straightness of the rod by placing it on rollers and use a dial gauge to measure the total runout.
Check if the measurement fits the specification in Table 4-2. If the runout exceeds the specification replace the
piston rod.
4.3.2 INSPECTION OF THE CYLINDER

1. Refer to Fig. 4-4: Measure the cylinder’s inner diameter (D-D) in even distances "b" along the cylinder and
repeat the measurement in a 90º offset (B-B) to check for ovality. Use the distances given in Table 4-3.
Note the measured dimensions in the "Hydraulic Cylinder inspection form" on page 6-2.
2. Compare the noted dimensions with the wear and tear limits for the cylinder, refer to section 4.6.4 on
page 4-35. If the dimensions do not match the specifications replace the cylinder or have it remanufactured
(honed) in a certificated REMAN-shop.
1. Visually inspect the cylinder bore for damage, scoring, and pitting. Check if the bore surface finish fits the
specification in Table 4-2.
If any damages or scores are found the cylinder must be remanufactured in a certificated REMAN-shop.
2. Refer to Fig. 4-4: Measure the diameter "ØB" of the eye bushing and compare the dimensions with the wear
and tear limits for the bushes, refer to section 4.6.2 on page 4-32. If the dimensions do not match the specifi-
cations replace the bushing in the cylinder, refer to section 4.4.1 on page 4-14.
3. Measure the bore diameter and compare the dimensions with the wear and tear limits for the cylinder, refer to
Cross-check the dimensions with the wear and tear limits for the cylinder head, refer to section 4.6.1 on
page 4-28. Fit between cylinder and cylinder head must be H7 / g6.
If the dimensions do not match the specifications have the cylinder remanufactured in a certificated REMAN-
shop.
4. Perform a magnetic particle crack test at all oil port holes (Fig. 4-4, Pos. 4), the eye welding seam (Fig. 4-4,
Pos. 3), and at the flange end welding seam (Fig. 4-4, Pos. 5) if present. In the case of precarious findings
contact the KOMATSU area manager for further actions. Remanufacturing in a certificated REMAN-shop may
be possible.

Inspection of the components Hydraulic cylinder repair
4.3.3 INSPECTION OF THE CYLINDER HEAD

1. Remove the sealing kit from the cylinder head, refer to section 4.4.3 on page 4-18.
REMARKS: Note that not all cylinder heads have an installed bearing bush made of red brass.
Cylinder heads may also be equipped with a PTFE coated bearing bush made of steel. These steel
bushings are not subject to wear under normal conditions.
2. Visually check the cylinder head for deformations, inspect all

grooves for wear, rust pitting and surface finish.
If any damages or scores are found replace the cylinder
head.
3. Perform a magnetic particle crack test at the spigot area, par-

ticularly on the edge (Fig. 4-5, arrow) between shoulder and
spigot diameter.
In the case of precarious findings replace the cylinder head.
4. Refer to Fig. 4-5: Measure the spigot diameter "ØSp" and

compare the dimensions with the manufacturing dimensions
of the cylinder head, refer to section 4.6.1 on page 4-28.
Cross-check the dimensions with the wear and tear limits for
the cylinder, refer to section 4.6.4 on page 4-35.
Fit between cylinder and cylinder head must be H7 / g6.
If the dimensions do not match the specifications replace the
cylinder head.
Fig. 4-5 Example of cylinder head with
red brass bearing bush
5. In case a red brass bearing bush is installed:

Refer to Fig. 4-5: Measure the inner diameter "ØA" at the installed bearing bush (Fig. 4-5, Pos. 2) and com-
pare the dimensions the wear and tear limits for the respective bush, refer to section 4.6.1 on page 4-28.
If the dimensions do not match the specifications replace the cylinder head or have the bearing bush replaced
in a certificated REMAN-shop.
6. In case a coated steel bearing bush is installed:

Visually check the coated steel bush.
If the bearing bush is worn or the coating is defective replace the cylinder head, the steel bush can not be
replaced separately.

Hydraulic cylinder repair Inspection of the components
4.3.4 INSPECTION OF THE GROOVE NUT (PISTON NUT)

1. Visually inspect the groove nut for damage and ensure it is burr free. Replace damaged groove nuts.
2. Screw the nut onto the piston rod to ensure that its fit is appropriate. Replace damaged groove nuts.
4.3.5 INSPECTION OF THE PISTON

1. Remove the Glyd-ring® (two-piece), wear rings and guide strips, refer to section 4.4.2 on page 4-16.
2. Visually inspect the piston, especially the contact surface to the groove nut.
If any damages, metal abrasions, scratches, and scoring are found replace the piston; additionally the cylinder
must be checked, refer to section 4.3.2 on page 4-11.
3. Perform a magnetic particle crack test on all surfaces.

In the case of precarious findings replace the piston.
Fig. 4-6 Piston, test dimensions
4. Check the ovality of the piston’s inner fit diameters Ø di and Ø ds at different positions, each displaced by
120°.
Consider the piston to be OK when differences in measurement are d0.1 mm.
REMARKS: The fitting areas are normally not subject to wear tear.
5. If the piston is not OK replace the piston and check the complete cylinder.

Repair procedures Hydraulic cylinder repair
4.4 REPAIR PROCEDURES

Only carry out the repair procedures that are given in this section. Any other action of remanufacturing has to be
done by approved REMAN-shops only.
4.4.1 REPLACEMENT OF THE HYDRAULIC CYLINDER EYE BUSHINGS

Special tools: n/a
Additional equipment: – Welding torch

– Personal Protective Equipment (PPE)
– Liquid nitrogen
Removal
The bushes are press fitted into the cylinder resp. the piston rod. to remove the bushes the radial pressing force
must be released.
1. Remove the seal ring(s) from within the bush.
NOTICE
RISK TO DAMAGE BUSH SEAT!
The bore for the bush may be damaged due to excessive
heat or by gas fusion welding with the bush.
Do not melt down the bush material completely.
2. Heat up the inner bush (Fig. 4-7, Pos. 1) in a narrow straight

band over the whole length of the bush using a welding torch
Fig. 4-7
(Fig. 4-7, Pos. 2).
REMARKS: When the bush has cooled down again the radial
pressing force is reduced.
3. Drive out the bush from the bore.
4. Measure the eye bore diameter and check for ovality after the bush is removed.
5. Compare the dimensions with the wear and tear limits for the cylinder bushes, refer to section 4.6.2 on
page 4-32.
If the dimensions do not match the specifications have the cylinder remanufactured in a certificated REMAN-
shop.

Hydraulic cylinder repair Repair procedures
Installation
DANGER
FROSTBITE FROM LIQUID NITROGEN!
Serious injuries caused by cryogenic burns or frostbite will result when it comes in contact with unpro-
tected skin. As liquid nitrogen evaporates it will reduce the oxygen concentration in the air and might act
as an asphyxiant in confined spaces.
Wear Personal Protective Equipment (protective gloves, shoes, and a face shield) to avoid caused by
cryogenic burns or frostbite
Always work in well vented areas to avoid asphyxia.
Follow the safety instructions given in the PARTS & SERVICE NEWS "AH11511" latest edition.
6. Cool down the bush according to the PARTS & SERVICE NEWS "AH11511" latest edition.
7. Insert the cooled down bush into the cylinder until fully home.
Note that the groove for the pin seal rings inside the bush must always face outwards.
REMARKS: Pay attention to the position of the lubricating holes and the lubrication grooves when installing the
bush refer to the PARTS & SERVICE NEWS "AH06545" latest edition.

4.4.2 REPLACEMENT OF THE PISTON SEAL, GUIDE STRIPS AND

WEAR RINGS
Special tools: Mounting and resizing sleeve, refer to section 5.3.3.2 on page 5-9
Additional equipment: Water or oil bath to heat up the Glyd-ring®
Pre-condition: Hydraulic cylinder is disassembled, refer to section 4.2 on page 4-7
The Glyd Ring® seal used as piston seal is a double-acting O-ring energized piston seal for dynamic applications.
So the piston seal is always a set consisting of an Glyd Ring® and an inner O-ring.
Removal
1. Dismantle the O-ring (Fig. 4-8, Pos. 2) and the back up rings
(Fig. 4-8, Pos. 1) from the piston (Fig. 4-8, Pos. 8).
2. Remove the piston seal from the piston respectively the pis-
ton bushing (Fig. 4-8, Pos. 5):
Remove the Glyd Ring® (Fig. 4-8, Pos. 4), then remove the
O-ring (Fig. 4-8, Pos. 3) from the groove.
3. Remove the two guide strips from the groove (Fig. 4-8,
Pos. 6) in the piston respectively the piston bushing.
4. Remove the wear rings from the wide grooves (Fig. 4-8,
Pos. 7) in the piston respectively the piston bushing.
Fig. 4-8 Example
Installation / pre-assembling
5. Install the back up rings (Fig. 4-8, Pos. 1) and the O-ring (Fig. 4-8, Pos. 2) into the inner groove in the piston
(Fig. 4-8, Pos. 8).
6. Install piston seal:
– Install the O-ring (Fig. 4-8, Pos. 3) into the groove in piston respectively the piston bushing using the
respective mounting sleeve (refer to section 5.3.3.2 on page 5-9).
– Heat up the Glyd Ring® to 90°C using a water bath.
– Install the hot Glyd Ring® (Fig. 4-8, Pos. 4) into the groove in piston respectively the piston bushing using
the same mounting sleeve as used at the O-ring.
NOTE! For the CHESTERTON® 11KE sealing system two Glyd Ring® sealing kit sizes are available, origi-
nal size and oversize:
The original size sealing kit is used with the original cylinder bore diameters and tier 1 oversize diam-
eters.
The oversize sealing kit is used with the tier 2 and tier 3 oversize diameters.
7. Slip the respective resizing sleeve (refer to section 5.3.3.2 on page 5-9) over the piston and resize the wid-
ened seal rings (Fig. 4-8, Pos. 3+4) by compressing O-ring and Glyd Ring® with the resizing sleeve.
REMARKS: The wear rings and the guide strips will be fitted while the hydraulic cylinder is assembled, refer to
section 4.7 on page 4-36.
The wear rings will be fitted into the wide grooves (Fig. 4-8, Pos. 7), the two guide strips will be fitted
into the two narrow grooves (Fig. 4-8, Pos. 6) at each end of the piston respectively the piston bush-
ing.


4.4.3 REPLACEMENT OF THE SEALINGS IN THE CYLINDER HEAD
4.4.3.1 REPLACEMENT OF CHEVRON® V-RING SEALING
Special tools: n/a
Additional equipment: – Seal kit (uncut)

– MPG (Multi Purpose Grease)
REMARKS: Order the correct seal kit for the hydraulic cylinder from the resp. catalogue page, refer to
When ordering the seal kit add the information "uncut" behind the Part No.
The uncut seal kit must be put in an oil bath for one day before installation.
Fig. 4-9 Detailed view of the CHEVRON® V-ring sealing
Removal
1. Remove the bolts (Fig. 4-9, Pos. 26) from the cover ring.
2. Remove the cover ring (Fig. 4-9, Pos. 33), the cover (Fig. 4-9, Pos. 25), and all halve shims (Fig. 4-9,
Pos. 32).
3. Dismantle the wiper (Fig. 4-9, Pos. 27) with support ring (Fig. 4-9, Pos. 37) from the cover.
4. Remove the support ring (Fig. 4-9, Pos. 24) from the cylinder head (Fig. 4-9, Pos. 20).
5. Remove the V-ring seal kit (Fig. 4-9, Pos. 23) from the cylinder head.
6. Remove the O-ring (Fig. 4-9, Pos. 17) and the support ring (Fig. 4-9, Pos. 18) from the cylinder head.

Installation
NOTE! When replacing the V-ring seal kit (Fig. 4-9, Pos. 23) the wiper with support ring (Fig. 4-9, Pos. 27)
must always be replaced also.
7. Moisten the grooves of the cylinder head with MPG (or roller bearing grease) to prevent corrosion.
Do not use excessive grease otherwise the hydraulic oil may become contaminated.
8. Install the new V-ring seal kit (Fig. 4-9, Pos. 23) into the cylinder head.
9. Install the support ring (Fig. 4-9, Pos. 24), observe the mounting position (see Fig. 4-10).
REMARKS: One side of the new support ring (Fig. 4-10, Pos. 1)
is marked black (Fig. 4-10, arrows). This side must
rest against the cover. On used support rings the
black paint has vanished. The side with the chamfer
must rest against the cover.
Fig. 4-10
10. Fit a new O-ring (Fig. 4-9, Pos. 17) and the support ring (Fig. 4-9, Pos. 18).
REMARKS: Observe the mounting position of the rings.
11. Fit a new wiper (Fig. 4-9, Pos. 27) with support ring (Fig. 4-9, Pos. 37) into the cover (Fig. 4-9, Pos. 25).
Observe the mounting position.
12. Install a number of halve shims (Fig. 4-9, Pos. 32) according to the PARTS & SERVICE NEWS "AH00507"
latest edition.
13. Install the cover (Fig. 4-9, Pos. 25) and the cover ring (Fig. 4-9, Pos. 33).
14. Insert the cover ring mounting bolts (Fig. 4-9, Pos. 26) and tighten the bolts to the specified torque.
15. Reassemble the hydraulic cylinder, refer to section 4.7 on page 4-36.

4.4.3.2 REPLACEMENT OF CHESTERTON® 11KE SEALING
Special tools: n/a
Additional equipment: – Seal kit (uncut)

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 5.1 on page 5-2.
REMARKS: Order the correct seal kit for the hydraulic cylinder from the resp. catalogue page, refer to
When ordering the seal kit add the information "uncut" behind the Part No.
Removal
Fig. 4-11 Detailed view of the CHESTERTON® 11KE sealing
1. Remove the bolts (Fig. 4-11, Pos. 24) and the cover ring (Fig. 4-11, Pos. 7).
2. Remove the cover (Fig. 4-11, Pos. 6) from the cylinder head (Fig. 4-11, Pos. 3).
3. Dismantle the scraper (Fig. 4-11, Pos. 16) from the cover.
4. Remove the anti-extrusion-ring (Fig. 4-11, Pos. 14) from the cylinder head.
5. Dismantle the rod sealing kit (Fig. 4-11, Pos. 15) from the cylinder head.

Installation
NOTE! When replacing the rod sealing kit (Fig. 4-11, Pos. 15) the scraper (Fig. 4-11, Pos. 16) must always
be replaced also.
7. Install the new piston rod seal kit (Fig. 4-12, Pos. 15) into the
cylinder head (Fig. 4-12, Pos. 3).
Observe the mounting position (refer to Fig. 4-11 for details):
– 2nd sealing element (Fig. 4-11, Pos. 26) with O-ring

(Fig. 4-11, Pos. 27)
– 1st sealing element (Fig. 4-11, Pos. 25)
REMARKS: It is recommended to push rod seal kit into position
using the cover (Fig. 4-12, Pos. 6), see step 10.
The gap "A" of 3...6 mm will be adjusted by itself
when operating the hydraulic cylinder under pres-
sure.
Fig. 4-12
8. Fit the anti-extrusion-ring (Fig. 4-11, Pos. 14).
9. Insert a new scraper (Fig. 4-11, Pos. 16) into the cover (Fig. 4-11, Pos. 6).
10. Install the cover.

Use the cover to move the seal kit and the anti-extrusion-ring into position while installing the cover.
11. Assemble the cover and the cover ring (Fig. 4-11, Pos. 7) onto the cylinder head using the bolts (Fig. 4-11,
Pos. 24) and tighten the bolts to the specified torque.

4.4.3.3 REPLACEMENT OF NOK-3 SEALING
Special tools: n/a
Additional equipment: – Seal kit

Pre-condition: Hydraulic cylinder is disassembled, refer to section 4.2 on page 4-7.

Fig. 4-13 Detailed view of the NOK-3 sealing
1. Remove the bolts (Fig. 4-13, Pos. 24) from the collar (Fig. 4-13, Pos. 6).
2. Remove collar assembly (Fig. 4-13, Pos. 6).
3. Remove the dust seals (Fig. 4-13, Pos. 25 & 26) from the collar.
4. Dismantle the snap ring (Fig. 4-13, Pos. 27) from the collar.
5. Remove the scraper (Fig. 4-13, Pos. 7) from the collar.
6. Remove the rod seal (Fig. 4-13, Pos. 13) from the cylinder head (Fig. 4-13, Pos. 3).
7. Remove the buffer ring (Fig. 4-13, Pos. 12) from the cylinder head.
8. Remove the O-ring (Fig. 4-13, Pos. 15) and the support ring (Fig. 4-13, Pos. 16) from the cylinder head.

Installation
NOTE! When replacing the rod seal (Fig. 4-13, Pos. 13) the scraper (Fig. 4-13, Pos. 7) and the dust seals
(Fig. 4-13, Pos. 25 & 26) must always be replaced also.
REMARKS: Observe the mounting position of the seals and rings, refer to the details shown in Fig. 4-13.
10. Fit a new scraper (Fig. 4-13, Pos. 7) into the collar. Press the scraper in until fully home.
11. Install the snap ring (Fig. 4-13, Pos. 27) into the collar to secure the scraper.
12. Fit a new dust seal (Fig. 4-13, Pos. 26) into the cylinder head, press the dust seal in until fully home.
13. Fit a new dust seal (Fig. 4-13, Pos. 25) into the cylinder head, press the dust seal in until fully home.
14. Fit a new O-ring (Fig. 4-13, Pos. 15) and a support ring (Fig. 4-13, Pos. 16).
15. Install the collar assembly (Fig. 4-13, Pos. 6) at the cylinder head.
16. Insert the collar mounting bolts (Fig. 4-13, Pos. 24) and tighten the bolts to the specified torque.

4.4.3.4 REPLACEMENT OF COMPACT SEALING
Special tools: n/a
Additional equipment: – Seal kit

Pre-condition: Hydraulic cylinder is disassembled, refer to section 4.2 on page 4-7.

Fig. 4-14 Detailed view of the compact sealing
Removal
1. Remove the bolts (Fig. 4-14, Pos. 23) from the cover ring.
2. Remove cover ring (Fig. 4-14, Pos. 22).
3. Dismantle the wiper (Fig. 4-14, Pos. 24) with support ring (Fig. 4-14, Pos. 32) from the cylinder head
(Fig. 4-14, Pos. 17).
4. Dismantle the rod seal (Fig. 4-14, Pos. 20) from the cylinder head.
5. Remove the O-ring (Fig. 4-14, Pos. 14) and the support ring (Fig. 4-14, Pos. 15).

Installation
NOTE! When replacing the rod seal (Fig. 4-14, Pos. 20) the wiper with support ring (Fig. 4-14, Pos. 24) must
always be replaced also.
7. Insert the new piston rod seal (Fig. 4-14, Pos. 20) into the cylinder head (Fig. 4-14, Pos. 17).
8. Fit a new O-ring (Fig. 4-14, Pos. 14) and the support ring (Fig. 4-14, Pos. 15).
REMARKS: Observe the mounting position of the rings.
9. Fit a new wiper (Fig. 4-14, Pos. 24) with support ring (Fig. 4-14, Pos. 32) into the cylinder head (Fig. 4-14,
Pos. 17).
Observe the mounting position.
10. Install the cover ring (Fig. 4-14, Pos. 22).
11. Insert the cover ring mounting bolts (Fig. 4-14, Pos. 23) and tighten the bolts to the specified torque.

Manufacturing dimensions Hydraulic cylinder repair
4.5 MANUFACTURING DIMENSIONS
4.5.1 WEAR RINGS, SPECIFIED SPACE

Basically two different materials are used for the wear rings:
– C380 (cyan coloured) with 2.5 mm thickness is always used if

the piston is equipped with a replaceable red brass piston
bush and in PC5500 & PC8000 clam cylinders.
– HM062 (anthracite coloured) with 6 mm thickness is always
used with full steel pistons without a replaceable red brass
piston bush but not in PC5500 & PC8000 clam cylinders.
Fig. 4-15
C380 (cyan coloured)*1 HM062 (anthracite coloured)

Cyl. bore Ø [mm] Thickness Thickness
Space*2 "Z" Space*2 "Z"
[mm] [mm] [mm] [mm]
200 9±10% 2.5 8.8±1,8 6

225 10±10% 2.5 8.8±1,8 6
240 11±10% 2.5 11±1 6
250 11±10% 2.5 11±1.5 6
260 12±10% 2.5 11±1 6
280 13±10% 2.5 11±2 6
300 14±10% 2.5 11±2 6
320 15±10% 2.5 11±2 6
330 15±10% 2.5 11±2 6
350 16±10% 2.5 11±2 6
380 18±10% 2.5 11±2 6
400 20±10% 2.5
n/a
420 23±10% 2.5
430 23±10% 2.5 11±2 6
460 23±10% 2.5 n/a
Table 4-4 Wear rings, specified space
*1 Only used in cylinders with piston bush and in PC5500 & PC8000 clam cylinders
*2 Space is measured while piston is installed

Hydraulic cylinder repair Manufacturing dimensions
4.5.2 GUIDE STRIPS, SPECIFIED SPACE

Guide strips are generally used with all pistons.
REMARKS: Guide strips are available as bulk stock, PN 269 494 40. The ends must be trimmed with 30°.
Thick- Space* straight

Cyl. bore Ø Width +2
ness Z + 0.5 length
[mm] B [mm
[mm] [mm] L [mm]
200 21 595
225 22 672
240 21 720
250 23 750
260 28 776
280 30 837
300 32 898
320 9.5 4.0 35 989

Fig. 4-16
330 35 989
350 38 1049
380 41 1140
400 43 1201
420 45 1262
430 46 1292
460 50 1383
Table 4-5 Guide strips, specified space
* Space is measured while piston is installed

Wear and tear limits for components Hydraulic cylinder repair
4.6 WEAR AND TEAR LIMITS FOR COMPONENTS
4.6.1 CYLINDER HEAD - WEAR AND TEAR LIMITS

The spigot diameter "ØSp" is no subject to wear but should be
checked to assure that the spigot is not expanded or bulged.
Note that at already remanufactured cylinders are equipped with
standardized design state 5 cylinder heads and the spigot diame-
ter "ØSp" is larger than the cylinder bore diameter, refer to the fol-
lowing Table 4-6.
the wear and tear limits of the for the bush diameter "ØA" is given
in Table 4-7 on page 4-31.
Note that not all cylinder heads have an installed bearing bush
made of red brass.
Cylinder heads may also be equipped with a PTFE coated bear-
ing bush made of steel. These steel bushings are not subject to
wear under normal conditions.
Fig. 4-17
Seat limits for cylinder heads
Design state 4 cylinder Part No. standardized design state 5 cylinder head
Cyl. heads cpl. cpl.
bore Cylinder CHESTER-
Ø type Part No. ØSp of NOK-3 ØSp of
Compact TON®
[mm] cylinder cylinder cylinder
head head [mm] sealing *1 sealing 11KE seal-
head [mm]
ing
PC8000
953 840 40 n/a n/a 992 132 40
FSA boom
460 460 g6 463 g6
PC8000
962 468 40 n/a n/a 992 142 40
BHA boom
PC7000
964 946 40 n/a n/a 992 147 40
FSA boom
430 430 g6 433 g6
PC7000
977 807 40 n/a n/a 992 174 40
BHA boom
PC8000
420 953 867 40 420 g6 n/a n/a 992 144 40 423 g6
BHA stick
PC5500
953 861 40 n/a n/a 99 2114 40
FSA boom
400 400 g6 403 g6
PC5500
953 855 40 n/a n/a 992 124 40
BHA boom
PC7000
908 124 40 n/a n/a 992 168 40
BHA stick
380 380 g6 383 g6
PC8000
953 846 40 n/a n/a 992 137 40
FSA bucket

Hydraulic cylinder repair Wear and tear limits for components
Cyl. heads cpl.
Compact TON®
head [mm]
ing
PC5500
n/a n/a 992 127 40
BHA stick
PC7000
350 953 849 40 350 g6 n/a n/a 992 127 40 353 g6
FSA bucket
PC8000
n/a n/a 992 127 40
BHA bucket
PC4000
982 242 40 992 048 40 n/a n/a
FSA boom
PC4000
982 243 40 992 068 40 n/a n/a
BHA boom
330 330 g6 333 g6
PC5500
953 843 40 n/a n/a 992 119 40
FSA bucket
PC8000
967 750 40 n/a n/a 992 134 40
FSA stick
PC3000
982 239 40 990 552 40 n/a n/a
FSA boom
PC3000
990 573 40 n/a n/a
BHA boom
982 241 40
PC4000
990 573 40 n/a n/a
BHA stick
320 320 g6 323 g6
PC7000
964 928 40 n/a n/a 992 153 40
FSA stick
PC7000
430 963 40 n/a n/a 990 575 40
BHA bucket
PC8000 967 750 40

n/a n/a 992 139 40
FSA clam 957 636 40
PC5500
953 858 40 n/a n/a 992 117 40
FSA stick
PC5500
300 953 852 40 300 g6 n/a n/a 992 129 40 302 g6
BHA bucket
PC7000
964 928 40 n/a n/a 992 166 40
FSA clam
PC3000
982 237 40 990 590 40 n/a n/a
BHA stick
PC4000
280 982 238 40 280 g6 992 058 40 n/a n/a 282 g6
FSA bucket
PC4000
982 237 40 990 590 40 n/a n/a
BHA bucket

Cyl. heads cpl.
Compact TON®
head [mm]
ing
PC4000
982 236 40 992 054 40 n/a n/a
FSA stick
260 260 g6 262 g6
PC5500 projected
915 829 40 n/a 992 122 40
FSA clam 2017
PC3000
250 982 233 40 250 g6 990 567 40 n/a n/a 251.5 g6
FSA bucket
PC3000
982 232 40 990 563 40 n/a n/a
FSA stick
240 240 g6 241.5 g6
PC3000
982 234 40 992 036 40 n/a n/a
BHA bucket
PC4000
225 982 231 40 225 g6 992 064 40 n/a n/a 226.5 g6
FSA clam
PC3000
200 984 952 40 201 g6 992 004 40 n/a n/a 201.5 g6
FSA clam
Table 4-6 Seat limits cylinder head spigot diameters

Wear limits for cylinder head red brass bushes
Inner diameter ØA of bush [mm] Inner diameter ØA of bush [mm]
original original
max. wear max. wear
(machined after frozen in) (machined after frozen in)
310.049 210.044
310 G6 310.149 210 G6 210.144
310.017 210.015
300.049 200.044
300 G6 300.149 200 G6 200.144
300.017 200.015
290.049 190.044
290 G6 290.149 190 G6 190.144
290.017 190.015
270.049 170.039
270 G6 270.149 170 G6 170.139
270.017 170.014
260.049 160.039
260 G6 260.149 160 G6 160.139
260.017 160.014
250.044 150.039
250 G6 250.144 150 G6 150.139
250.015 150.014
240.044 125.039
240 G6 240.144 125 G6 125.139
240.015 125.014
230.044 110.034
230 G6 230.144 110 G6* 110.134
230.015 110.012
Table 4-7 Wear and tear limits cylinder head bushes
* Piston rods with Ø110 mm are generally equipped with a PTFE coated bearing bush made of steel.
REMARKS: If the wear exceeds the limit replacement of the bush can only be done in a certificated REMAN-
shop.

4.6.2 CYLINDER EYE BUSHES - WEAR AND TEAR LIMITS
Fig. 4-18
Original inner bush Inner bush diameter

diameter Ødi Ødi - max. wear limit Original eye bore diameter ØDo for bush
(when frozen in) (when frozen in) [mm]
[mm] [mm]
290.000
260.8 263.8 290 H7
290.052
280.000
250.7 253.7 280 H7
280.052
210.000
180.7 183.7 210 H7
210.046
200.000
170.7 173.7 200 H7
200.046
180.000
160.6 163.6 180 H7
180.040
150.6 153.6 170.000

170 H7
140.6 143.6 170.040
140.000
120.6 123.6 140 H7
140.040
130.000
110.5 113.5 130 H7
130.040
Table 4-8 Wear and tear - cylinder eye bushes
REMARKS: The diameters of the bushes are smaller when the bushes are frozen in the cylinder eye bores due to
compression of the bush material.

4.6.3 PISTON ROD - WEAR AND TEAR LIMITS
Fig. 4-19 Piston, test dimensions
Min. permissi- Min. permissi-

Original piston rod ØA Original piston rod ØA
ble piston rod ble piston rod
hard-chromium plated hard-chromium plated
Ø Ø
[mm] [mm]
[mm] [mm]
309.944 209.955
310 f7 309.892 210 f7 209.904
309.892 209.904
299.944 199.955
300 f7 299.892 200 f7 199.904
299.892 199.904
289.944 189.955
290 f7 289.892 190 f7 189.904
289.892 189.904
269.944 169.957
270 f7 269.892 170 f7 169.917
269.892 169.917
259.944 159.957
260 f7 259.892 160 f7 159.917
259.892 159.917
249.944 149.957
250 f7 249.892 150 f7 149.917
249.892 149.917
239.955 124.957
240 f7 239.904 125 f7 124.917
239.904 124.917
229.955 109.964
230 f7 229.904 110 f7 109.929
229.904 109.929
219.955
220 f7 219.904
219.904
Table 4-9 Wear and tear - piston rod

4.6.3.1 CHROME LAYER THICKNESS AND SURFACE

The minimum original chrome layer thickness at manufacturing is 30 μm (0.0012”).
NOTICE
RISK TO DAMAGE THE SEALING SYSTEM!
a faulty chrome surface finish will damage the sealing system due to lubrication failing, which results in
burned sealings.
Only use the specified chrome surface finish.
The original chrome surface finish is Rz = 1.2±0.4 μm and Ra = 0.3±0.1 μm and Mr = Material contact area according
DIN 4776 of 80...95%; measured in a depth of 25% of Rt-value based on a reference level zero line set at Mr = 5%
bearing area.
REMARKS: If the chrome plating does not match the specifications remanufacturing can only be done in a certif-
icated REMAN-shop.
4.6.3.2 MAXIMUM ALLOWED BEND / RUNOUT

The maximum allowed bend / runout of a piston rod must not exceed 250 μm / m (0.010” / m).
REMARKS: If the bend exceeds the limit remanufacturing can only be done in a certificated REMAN-shop.

4.6.4 CYLINDER - WEAR AND TEAR LIMITS

Original bore Ø (H8) [mm]
Original cylinder bore Ø [mm] (add current oversize tier from Maximum wear (H9) [mm]
Table 4-1 on page 4-2)
460.000
460 460.155
460.097
430.000
430 430.155
430.097
420.000
420 420.155
420.097
400.000
400 400.140
400.089
380.000
380 380.140
380.089
350.000
350 350.140
350.089
330.000
330 330.140
330.089
320.000
320 320.140
320.089
300.000
300 300.130
300.081
280.000
280 280.130
280.081
260.000
260 260.130
260.081
250.000
250 250.115
250.072
240.000
240 240.115
240.072
225.000
225 225.115
225.072
201.000
200* 201.115
201.072
Table 4-10 Wear and tear - original cylinder (no oversize)
* At the Ø200 mm cylinders the upper flange diameter (spigot for the cylinder head) is 201 H8.
REMARKS: If the wear exceeds the limit remanufacturing can only be done in a certificated REMAN-shop.
Note that at already remanufactured cylinders the oversize tier (refer to Table 4-1 on page 4-2) must
be added to the original cylinder bore Ø in Table 4-10.

Assembly of hydraulic cylinders Hydraulic cylinder repair
4.7 ASSEMBLY OF HYDRAULIC CYLINDERS

Special tools: – Custom-built mounting sleeve, refer to section 5.3.3.4 on
page 5-11
– Auxiliary tool M12 (depending on cylinder): PN 947 173
40(optional)
– Auxiliary tool M16 (depending on cylinder): PN 947 178 40
(optional)
– Hydraulic torque wrench, refer to section 5.3.2 on page 5-5. or
alternatively an appropriate hook spanner, refer to section 5.3.1 on
page 5-4
Additional equipment: – MPG (Multi Purpose Grease)

– HLP hydraulic oil
– Crane
Dogman/rigger
Pre-condition: – Piston is pre-assembled, refer to section 4.4 on page 4-14

– Cylinder head is pre-assembled, refer to section 4.4 on page 4-14

Assembling the piston and the cylinder head onto the piston rod
1. Position the piston rod on an assembly in horizontal position supported by ”Vee” blocks, approximately one
third distance from piston end of rod.
2. Coat all seals at the pre-assembled cylinder head and at the pre-assembled piston with a light film of HLP
hydraulic oil.
3. Place the custom-built mounting sleeve (refer to

section 5.3.3.4 on page 5-11) over the thread at the piston rod
end, the beveled end of the sleeve facing outwards.
NOTE! Always use the mounting sleeve when assembling

the piston. Otherwise the back up and O-rings (refer
to Fig. 4-8, Pos. 1 and 2 on page 4-16) may get
sheared.
4. Slip the pre-assembled cylinder head (Fig. 4-20, Pos. 4) over

the mounting sleeve onto piston rod using a crane.
5. Remove the mounting sleeve.
6. Install the feather key (Fig. 4-20, Pos. 6). Fig. 4-20
7. Carefully support the pre assembled piston (Fig. 4-20, Pos. 3)

and slide it onto the piston rod (Fig. 4-20, Pos. 5).
8. Clean the threads of the groove nut and the piston rod with solvent to ensure that the threads are absolutely
free from dirt, oil, and grease.

Hydraulic cylinder repair Assembly of hydraulic cylinders
9. Clean groove nut and piston with solvent to ensure it is absolutely free of oil and grease. Make sure that the
contact surfaces of the nut and the piston are absolutely free from dirt, oil, and grease.
10. Apply HLP hydraulic oil at the threads of the groove nut and the piston rod. Make sure that the contact sur-
faces of the nut and the piston stay free of oil.
REMARKS: Check if the groove nut and the piston rod are prepared for the use of the hydraulic torque wrench.
Piston rod must have bores for the hydraulic torque wrench, refer to section 5.3.2.1 on page 5-6.
11. Screw the new groove nut (Fig. 4-20, Pos. 1) onto the thread of the piston rod and tighten it to the specified
torque:
b Tighten the groove nut to the specified torque according Table 5-5 on page 5-5.
It is recommended to use the hydraulic torque wrench, refer to section 5.3.2 on page 5-5.
Locking the groove nut (piston nut)
NOTE! Hydraulic cylinders are safety critical assemblies. Therefore it is essential to follow the below proce-
dure step by step.
Thread pin Ø a Ød
[mm] [mm] [mm]
M12 15 9
M16 17 12.5
Table 4-11
12. Use a drill for the locking seat for the thread pin (Fig. 4-21,
Pos. 3) and bore a hole into the piston (Fig. 4-21, Pos. 1)
(refer to Table 4-11 and Fig. 4-21).
REMARKS: It is recommended to drill a 5 mm hole lengthwise in Fig. 4-21

a M12 or M16 bolt and use this as a tool for marking
the center for the new hole in the piston.
NOTE! Once the bore in the piston is made the groove nut must not be manipulated/moved in any way.
13. Clean the bore with compressed air carefully.
14. Install the thread pin into the groove nut (Fig. 4-21, Pos. 2) and tighten it handtight.
15. Check dimension Xmin. Specification: 2.4 mm
16. Push up the auxiliary tool (Fig. 4-22, Pos. 1) against the
thread pin (Fig. 4-22, Pos. 2).
17. Mark the position for the center-punch using a felt pen
(Fig. 4-22, Pos. 3).
18. Lock the thread pin by means of a center punch mark.
Fig. 4-22

19. Check the punch mark depth using the other side of the auxil-
iary tool (Fig. 4-23, Pos. 1). If the dimension Ymax is correct,
the tool can not touch the thread pin (Fig. 4-23, Pos. 2).
Specification: 11 mm for M12
Specification: 15 mm for M16
NOTE! The dimensions Xmin and Ymax are reference dimen-

sions and must be observed.
20. Repeat step 18 if Ymax is too big and check again.
21. Check the thread pin with a hexagon socket wrench. If no

turning in or turning out is possible, the locking of the thread
pin and of the groove nut is correct. Fig. 4-23
Otherwise repeat from step 18.
22. Put each new wear ring into the cylinder bore and check the space between the wear ring’s ends, refer to
section 4.5.1 on page 4-26. Remove the wear ring from the cylinder bore after checking.
Assembling the hydraulic cylinder
NOTE! All hydraulic cylinders should be assembled in a secured vertical position with the piston rod facing
upwards.
It is recommended to put the hydraulic cylinder into a pit in the workshop floor in which the hydraulic
cylinder can be appropriately secured.
23. For assembly move and place the cylinder into a secured vertical position using the crane refer to
24. Apply a film of hydraulic oil to the cylinder.
25. Move the cylinder head against the piston and attach the piston rod assembly to a crane.
DANGER
26. Lift the piston rod assembly (with assembled piston and cylinder head) and position it over the cylinder.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.
Align the parts with great caution. Never put hands through or into the bushings when aligning parts.
27. Carefully align piston and cylinder using a crane and insert the piston into the cylinder.
Stop just before the lower groove for the guide strip in the piston enters the chamfer in the cylinder bore.
NOTICE
RISK TO SHARE OFF SEALS!
Damages to the wear rings and guide strips may result if the
open ends of the rings are within the oil port openings in the
cylinder.
To avoid damage to the rings the space (Fig. 4-24, arrow)

between the open ends of the wear rings / guide strips
(Fig. 4-24, Pos. 1) must not face the hydraulic oil port open-
ing (Fig. 4-24 Pos. 2) in the cylinder.
REMARKS: Assemble the space between the open ends of the

wear rings and guide strips in a 180° offset to guar-
antee the correct pressure balance.
The amount of wear rings may differ depending on
the cylinder. Fig. 4-24 Example
28. Insert the new guide strip (Fig. 4-25, Pos. 1) into the lower
groove of the piston.
29. Check the space between the guide strip’s open ends, refer
to section 4.5.2 on page 4-27.
30. Continue to slide the piston rod assembly (Fig. 4-25, Pos. 4)
carefully into the cylinder (Fig. 4-25, Pos. 5) while installing
the wear rings (Fig. 4-25, Pos. 2) one after another in a 180°
offset.
31. Install a new guide strip (Fig. 4-25, Pos. 3) into the top groove
of the piston.
32. Check the space between the guide strip’s open ends, refer
to section 4.5.2 on page 4-27.
33. Continue to slide the piston rod assembly carefully into the
cylinder. Fig. 4-25

34. Align the cylinder head (Fig. 4-26, Pos. 2) to the cylinder
bore. Assure that the bores in the cylinder head match the
threads in the cylinder.
REMARKS: Normally the hole pattern in the cylinder head is

asymmetric so the cylinder head does only fit in
defined positions.
35. Apply small quantities of MPG (or roller bearing grease) to the
threads of the mounting bolts (Fig. 4-26, Pos. 1).
36. Continue to slide the piston rod assembly (Fig. 4-26, Pos. 3)
into the cylinder. While doing so apply pressure to the cylinder
head until it is fully home.
Fig. 4-26
REMARKS: Let the piston rod extracted to keep access to the
mounting bolts.
NOTICE
RISK TO DAMAGE THE PISTON ROD SURFACE!
The chrome surface on the piston rod may get damaged by tools when installing the cylinder head mount-
ing bolts. This will cause leakage at the assembled cylinder.
Put a protecting sleeve on the piston rod to avoid damages in the chrome surface of the piston rod before
inserting the bolts.
37. Insert the bolts (Fig. 4-26, Pos. 1). and tighten the bolts crosswise to the specified torque (standard).
38. Cap the hydraulic oil ports at the hydraulic cylinder with blind plugs to avoid contamination.
39. Perform a leakage test at the assembled hydraulic cylinder, refer to section 4.7.1 on page 4-41.

4.7.1 LEAKAGE TEST

Special tools: n/a
Additional equipment: Hydraulic test bench according to Fig. 4-27
For further information about the needed blind plugs, refer to

section 5.2 on page 5-3.
1. Remove the blind plugs from the hydraulic oil ports of the
hydraulic cylinder. Then connect a hydraulic test bench to
both ports according to Fig. 4-27.
WARNING
HAZARD FROM JERKY CYLINDER MOVEMENT!
May result in personal injury due to slightly jerky movements
of the cylinder when it is operated. The jerky movements are
caused by the air in the cylinder which is compressible.
Make sure that nobody is in close range to the cylinder when

it is operated.
2. Extend and retract the cylinder slowly 8...10 times to the end
positions to bleed air from the cylinder.
Fig. 4-27
3. Fully extend the cylinder with 50°C warm hydraulic oil and
apply 415 bar.
4. Close both ports and check if the pressure increases at the cylinder’s piston rod side over a 5 minute time peri-
ode.
If the pressure increases the cylinder has an internal leakage.
REMARKS: The pressure at the cylinder’s piston side decreases while the hydraulic oil in the cylinder is cooling
down.
5. Fully retract the cylinder with 50°C warm hydraulic oil and apply 415 bar.
6. Close both ports.
7. Visually check if the cylinder shows any leakage at the cylinder head.
8. Check if the pressure increases at the piston side over a 5 minute time period.
If the pressure increases the cylinder has an internal leakage.
REMARKS: The pressure at the cylinder’s rod side decreases while the hydraulic oil in the cylinder is cooling
down. This will happen slightly faster than at the other side because of the smaller amount of hydrau-
lic oil.
9. If no leakage is found, the cylinder repair was successful.
10. Relieve the pressure at both ports.
11. Disconnect the test lines.
12. Cap the hydraulic oil ports at the hydraulic cylinder with blind plugs to avoid contamination.


Service information
5 SERVICE INFORMATION
NOTE! In addition to the provisions listed here, full compliance with general safety regulations in chapter
"Safety" is required.

Torque charts according to KOMATSU company standard Service information
5.1 TORQUE CHARTS ACCORDING TO KOMATSU

COMPANY STANDARD
Bolt Wrench size Tightening torque
diameter [mm] [Nm]
Metric regular Bolt quality grades
8.8 10.9 12.9
M 8 13 6 21 31 36
M 10 17 8 43 63 73
M 12 19 10 74 108 127
M 14 22 12 118 173 202
M 16 24 14 179 265 310
M 18 27 14 255 360 425
M 20 30 17 360 510 600
M 22 32 17 485 690 810
M 24 36 19 620 880 1030
M 27 41 19 920 1310 1530
M 30 46 22 1250 1770 2080
M 33 50 24 1690 2400 2800
M 36 55 27 2170 3100 3600
M 39 60 2800 4000 4700
M 42 65 32 3500 4950 5800
M 45 70 4350 6200 7200
M 48 75 35 5200 7500 8700
M 52 80 6700 9600 11200
M 56 85 41 8400 12000 14000
M 60 90 10400 14800 17400
M 64 95 46 12600 17900 20900
M 68 100 15200 21600 25500
Table 5-1 Tightening torques for metric regular bolts
REMARKS: Threads and bolts must be greased carefully with MPG (or roller bearing grease). Contact surfaces
which should be screwed together must be free of grease.

Service information Blind plugs
5.2 BLIND PLUGS
5.2.1 DUMMY PLATES FOR SAE–FLANGES
Fig. 5-1 Forms / types of dummy plates for SAE–flanges
Up to 6000 PSI
Form / type
DN
SAE size according to PN
(hose / pipe)
Fig. 5-1
3/4" A 506 580 98 20
1" A 506 519 98 25
1 1/4" A 506 520 98 32
1 1/2" A 506 581 98 40
2" A 506 582 98 50
1" B 506 524 98 25
1 1/4" B 506 525 98 32
1 1/2" B 506 526 98 40
2" B 506 527 98 50
1 1/4" C 516 499 98 32
1 1/2" C 509 375 98 40
2" C 509 376 98 50
Table 5-2 Blind plugs according to Fig. 5-1

Special tools Service information
5.3 SPECIAL TOOLS
5.3.1 HOOK SPANNERS FOR THE PISTON NUTS (GROOVE NUTS)

Ø groove nut / hook wrench size [mm] Part No. hook wrench
110...115 232 818 40
120...130 232 275 40
135...145 114 479 99
155...165 232 276 40
180...195 232 277 40
205...220 232 278 40
230...245 232 819 40
260...270 232 279 40
280...300 232 280 40
300...340 232 820 40
350...375 232 821 40
380...400 232 822 40
Table 5-3 Hook spanners

Service information Special tools
5.3.2 USE OF THE HYDRAULIC TORQUE WRENCH FOR THE GROOVE

NUTS (PISTON NUTS)
– Hydraulic torque wrench, see list below
Special tools:
– Electro-hydraulic pump set, PN 793 375 73
NOTE! For the use of the hydraulic torque wrench the KOMATSU company standard 655 973 40 latest edi-
tion must be considered if its release date is newer than October 2016.
If so the latest edition has absolute priority over the following procedure.
Part No. Pin pitch circle Ø Pin pitch circle Ø

(1) in piston rod (2) in groove nut
[mm] [mm]
685 099 40 50 (3 pin) 139
685 100 40 79 (2 pin) 175
685 101 40 93 (2 pin) 215
685 102 40 127 (2 pin) 260
Table 5-4
Choose the appropriate hydraulic torque wrench concerning

design and size of the piston nut (groove nut).
The pins in the inner pitch circle (1) fit into the holes in the piston
rod. The pins in the outer pitch circle (2) fit into the grooves of the
piston nut.
1. Clean the threads of the piston nut and the piston rod with
solvent to ensure that the threads are absolutely free from
dirt, oil, and grease.
2. Clean the piston nut and the piston with solvent to ensure it is
absolutely free of oil and grease. Make sure that the contact
surfaces of the nut and the piston are absolutely free from Fig. 5-2
dirt, oil, and grease.
3. Apply HLP hydraulic oil at the threads of the piston nut and the piston rod. Make sure that the contact surfaces
of the nut and the piston stay free of oil.
4. Screw the new piston nut onto the piston rod and tighten it to the specified torque according Table 5-5:
Piston rod thread Ø Tightening torque ±3% Piston rod thread Ø Tightening torque ±3%
[Nm] [Nm]
M76x3 2680 M150x6 5550
M85x3 3030 M160x3 5940
M90x3 3220 M180x3 6710
M95x3 4000 M185x3 6910
M110x3 4380 M185x6 6910
M120x3 4580 M205x3 7680
M125x3 4970 M205x6 7680
M150x3 5550 M220x3 8260
Table 5-5 Tightening torques for groove nuts according to KOMATSU company standard 655 973 40

5.3.2.1 PREPARING THE PISTON ROD TO USE THE HYDRAULIC TORQUE WRENCH
As torque support for the hydraulic torque wrench the piston rod must be equipped with holes to fit the torque sup-
port pins of the hydraulic torque wrench.
Fig. 5-3 Piston rod - hole pattern for hydraulic torque wrench
1. Determine the pin pitch circle diameter for the hydraulic torque wrench from the piston rod / piston combination
in Table 5-6 and manufacture the borings in the piston rod according to Fig. 5-3.
Prison rod / piston combination Pin pitch circle Prison rod / piston combination Pin pitch circle
ØA (2 pin) ØB (3 pin)
Piston rod Ø piston / cyl. Ø Piston rod Ø piston / cyl. Ø
[mm] [mm]
[mm] [mm] [mm] [mm]
150 300 225
110
160 320 200 50 ±0.05
79 ±0.05
240 125 260
170
250
260 93 ±0.05
190
280 79 ±0.05
280
200
320
300
210
320 93 ±0.05
300
220
330
230 320
240 240 79 ±0.05
240 330 127 ±0.05
Table 5-6 Pin pitch circle Ø depending on piston rod / piston combination


5.3.3 CUSTOM BUILD MOUNTING TOOLS

All mounting tools are custom build tools. Machine the tools according to the specifications in this section. Alterna-
tively contact the KOMATSU area manager using the hydraulic cylinder Part No. for the resp. sleeves but it is rec-
ommended to manufacture the tools because of the higher adaption especially to oversize parts.
REMARKS: The given dimensions are approximate and should fit all types of cylinders, only the dimensions to be
measured are reference dimensions.
5.3.3.1 MANUFACTURING OF THE HEADING TOOL FOR NOK STRIPPERS
Fig. 5-4 Heading tool for NOK strippers

REMARKS: All sharp edges deburred.
1. Measure the diameter Ødi and the depth a and the width b of the first inner groove in the cylinder head
(Fig. 5-4, Pos. 1).
2. Dress the heading tool (Fig. 5-4, Pos. 2) from PTFE or an other synthetic material, using the measured dimen-
sions.

5.3.3.2 MANUFACTURING OF THE SLEEVE FOR MOUNTING THE GLYD-RING®

1. Refer to Fig. 5-5:
Measure the diameter ØA, the diameter ØB, and the dimen-
sion a of the piston.
2. Manufacture the sleeve according to Fig. 5-6 using the mea-

sured dimensions.
REMARKS: Alternatively contact the KOMATSU area manager

using the hydraulic cylinder Part No. for the resp.
sleeve.
Fig. 5-5
Fig. 5-6 Glyd-ring® mounting sleeve

Refer to the surface roughness transcription table, refer to section 4.5.1 on page 4-26.

5.3.3.3 MANUFACTURING OF THE SLEEVE FOR RESIZING GLYD-RINGS®

1. Refer to Fig. 5-7:
Measure the diameter ØA, the diameter ØB, and the distance
L of the piston.
2. Manufacture the sleeve according to Fig. 5-8 using the mea-

sured dimensions.
REMARKS: Alternatively contact the KOMATSU area manager

using the hydraulic cylinder Part No. for the resp.
sleeve.
Fig. 5-7
Fig. 5-8 Resizing sleeve for glyd-ring®

5.3.3.4 MANUFACTURING OF THE SLEEVE FOR MOUNTING THE CYLINDER HEAD
Fig. 5-9 Measurements for manufacturing the sleeve
Fig. 5-10 Cylinder head mounting sleeve

Refer to the surface roughness transcription table, refer to section 4.5.1 on page 4-26.
1. Measure the diameter Øa of the piston seat (Fig. 5-9, Pos. 2), the diameter Øb of the rod (Fig. 5-9, Pos. 3),
and the distance L.
2. Manufacture the sleeve (Fig. 5-9, Pos. 1) according to Fig. 5-10 using the measured dimensions, D = 30°.
REMARKS: Alternatively contact the KOMATSU area manager using the hydraulic cylinder Part No. for the resp.
sleeve.

List of relevant PARTS AND SERVICE NEWS Service information
5.4 LIST OF RELEVANT PARTS AND SERVICE NEWS
SB-No. Subject
AH00507 Hydraulic cylinder – replacing of chevron seals, strippers and support rings
AH06545 Hydraulic cylinder bushings
AH08501 Improved safeguard of the piston groove nut
AH11511 Bearing bushes
AH16825 Hydraulic cylinder – Piston Rod Seal
REMARKS: The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that always
the latest edition is used.

Appendix
6 APPENDIX

Hydraulic Cylinder inspection form Appendix
6.1 HYDRAULIC CYLINDER INSPECTION FORM
Fig. 6-11 Measurement of diameters
L= 0 mm...2000 mm a = 200 mm b = 200 mm

L = 2000 mm...5000 mm a = 500 mm b = 500 mm
Piston rod
1 2 3 4 5 6 7 8 9 10
A-A
[mm]
B-B
[mm]
Cylinder
1 2 3 4 5 6 7 8 9 10
C-C
[mm]
D-D
[mm]

Ah 18851

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Ah 18851

Încărcat de

Drepturi de autor:

Formate disponibile

MAJOR CODE: H1

PURPOSE: Release the Repair Manual

FAILURE CODE: H100AA

Attached you will find the latest

Repair Manual REP_CYL 1116-GB-1.pdf

for Hydraulic Cylinders.

Unsafe maintenance or repair work of machine

Komatsu has Manuals written in other languages. If

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual

Cylinder REPAIR-Manual REP_CYL 1116-GB-1

2 SAFETY ..................................................................................................... 2-1

3 SERVICEABLE CYLINDERS AND SEALING TYPES............................... 3-1

4 HYDRAULIC CYLINDER REPAIR............................................................. 4-1

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual TOC - 1

5 SERVICE INFORMATION ......................................................................... 5-1

6 APPENDIX ................................................................................................. 6-1

TOC - 2 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 1 -1

1.1 CONTENTS OF THIS BINDER

1 -2 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

Komatsu Mining Germany GmbH

1.2.1 CONTACTING THE SERVICE

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 1 -3

Please continue reading on the next page.

1 -4 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 2 -1

Please continue reading on the next page.

2 -2 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

2.1.1 METHOD OF USING THIS MANUAL

Kind and amount of drained fluids

Lifting weight of an assembly

d Kind and amount of fluids to fill

General information concerning a section

Special authorized / qualified personnel is required

REMARKS: Designates additional information or hints.

1. 2. 3. Used to designate working steps.

– Used to designate itemization.

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 2 -3

2 -4 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

2.2 GENERAL PRECAUTIONS

Always follow the precautions below to prepare for action if any

– Be sure that fire extinguishers have been provided and read

2.2.2 PERSONAL PROTECTIVE CLOTHING

– Do not wear loose clothing and accessories. If these catch on

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 2 -5

2.2.3 WHEN USING A HAMMER

– If hard metal parts such as pins, bucket teeth, cutting edges,

2.2.4 PROPER TOOLS

2 -6 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

2.2.6 FIRE PREVENTION

– Do not smoke or use any flame near fuel or other flammable

2.2.7 UNAUTHORIZED MODIFICATION

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 2 -7

2.3 PRECAUTIONS FOR MAINTENANCE AND REPAIR

2.3.1 GENERAL PRECAUTIONS

2.3.2 KEEP WORK PLACE CLEAN AND TIDY

2.3.3 PRECAUTIONS WHEN WELDING

2 -8 Cylinder REPAIR-Manual REP_CYL 1116-GB-1

2.3.4 PRECAUTION WITH HIGH PRESSURE FLUIDS

2.3.4.1 HANDLING HIGH PRESSURE HOSES AND PIPES

2.3.5 COMPRESSED AIR

2.3.6 WASTE MATERIALS

REP_CYL 1116-GB-1 Cylinder REPAIR-Manual 2 -9