MAJOR CODE: H1

NO.: AH15849b
PARTS & SERVICE NEWS DATE: February 1, 2016
Page 1 of 10
SUBJECT: Hydraulic cylinders with metal guard rings at the piston

PURPOSE: Replacing the metal guard rings by PTFE guard rings / Revision
(Some more shovel types added; piston seal ring change optional)

APPLICATION: PC3000/1, PC3000/6; PC4000/6, PC7000/6

FAILURE CODE: H100FB (FCH 15542)

DESCRIPTION:

:
Before carrying out any repairs, read all the safety instructions
in the Operation and Maintenance Manual of your shovel.
The local safety rules must also be observed.

Content

1. Material for the modification and cylinder numbers

1.1. PC3000/1 BHA
1.2. PC3000/6 BHA
1.3. PC3000/6 FSA
1.4. PC4000/6 BHA
1.5. PC4000/6 FSA
1.6. PC7000/6 BHA
1.7. PC7000/6 FSA

2. Modification
2.1. Disassembly of the hydraulic cylinders
2.2. Inspection of the barrel
2.3. Modification
2.4. Final works

3. Attachment - Mounting sleeves

Pay attention:
Two new PTFE guard rings (scrapers) are needed for the
modification of one hydraulic cylinder.

AH15849b
Page 2 of 10

1. Material and cylinder numbers

1.1. PC3000/1 BHA

Cylinder PN* Material for the modification

(Before = to be modified) (2 x new PTFE ring per cylinder)
No. Type
Before After New PTFE
Seal ring with O-ring
modification modification guard ring
1 Stick 984 935 40 990 007 40 951 987 40 951 294 40
*Punch mark the new PN after modification (Refer to chapter 4)

1.2. PC3000/6 BHA

Cylinder PN* Material for the modification

(Before = to be modified) (2 x new PTFE ring per cylinder)
No. Type
Before After New PTFE
Seal ring with O-ring
modification modification guard ring
982 235 40 990 035 40
984 957 40 990 031 40
1 Boom 979 530 40 990 029 40 951 761 40 951 296 40
973 817 40 990 016 40
977 825 40 990 040 40
982 245 40 990 045 40
984 958 40 990 038 40
982 250 40 990 050 40
984 960 40 990 039 40
2 Stick 973 808 40 990 017 40 951 987 40 951 294 40
979 525 40 990 034 40
973 830 40 990 033 40
979 550 40 990 036 40
977 820 40 990 055 40
982 240 40 990 060 40
984 959 40 990 023 40
3 Bucket 979 520 40 990 021 40 951 984 40 951 291 40
973 825 40 990 018 40
977 815 40 990 065 40
*Punch mark the new PN after modification (Refer to chapter 4)

AH15849b
Page 3 of 10

1.3. PC3000/6 FSA

Cylinder PN* Material for the modification
(Before = to be modified) (2 x new PTFE ring per cylinder)
No. Type
Before After PTFE
Seal ring with O-ring
modification modification guard ring
979 595 40 990 000 40
1 Boom 973 813 40 990 011 40 951 761 40 951 296 40
977 800 40 990 005 40
982 220 40 990 010 40
984 965 40 990 024 40
2 Stick 979 540 40 990 022 40 951 984 40 951 291 40
973 807 40 990 012 40
977 805 40 990 015 40
982 225 40 990 020 40
984 966 40 990 027 40
3 Bucket 979 535 40 990 026 40 951 985 40 951 292 40
973 820 40 990 013 40
977 810 40 990 025 40
984 950 40 990 030 40
4 Clam 982 230 40 990 006 40 951 982 40 951 289 40
973 840 40 990 014 40
*Punch mark the new PN after modification (Refer to chapter 4)

1.4. PC4000/6 BHA

Cylinder PN* Material for the modification
(Before = to be modified) (2 x new PTFE ring per cylinder)
No. Type
Before After New PTFE
Seal ring with O-ring
modification modification guard ring
979 585 40 990 090 40
973 811 40 990 008 40
1 Boom 951 988 40 951 297 40
979 500 40 990009 40
984 967 40 990 019 40
982 215 40 990 095 40
2 Stick 951 761 40 951 296 40
973 815 40 990 028 40
982 205 40 990 099 40
3 Bucket 951 987 40 951 294 40
973 818 40 990 032 40
*Punch mark the new PN after modification (Refer to chapter 4)

AH15849b
Page 4 of 10

1.5. PC4000/6 FSA

Cylinder PN* Material for the modification
(Before = to be modified) (2 x new PTFE ring per cylinder)
No. Type
Before After New PTFE
Seal ring with O-ring
modification modification guard ring
979 590 40 990 070 40
1 Boom 951 988 40 951 297 40
973 805 40 990 001 40
979 580 40 990 075 40
2 Stick 951 986 40 951 293 40
973 810 40 990 002 40
982 210 40 990 080 40
3 Bucket 951 987 40 951 294 40
973 800 40 990 003 40
982 200 40 990 085 40
4 Clam 951 983 40 951 290 40
973 803 40 990 004 40
*Punch mark the new PN after modification (Refer to chapter 4)

1.6. PC7000/6 BHA

Cylinder PN* Material for the modification
(Before = to be modified) (2 x new PTFE ring per cylinder)
Type
Before After PTFE
Seal ring O-ring
modification modification guard ring
Boom 977 830 40 988 950 40 951 764 40 461 292 40 519 498 98
Stick 977 840 40 988 955 40 951 763 40 621 352 40 519 536 98
Bucket 977 850 40 988 960 40 951 761 40 896 587 40 950 953 40
*Punch mark the new PN after modification (Refer to chapter 4)

1.7. PC7000/6 FSA

Cylinder PN* Material for the modification
(Before = to be modified) (2 x new PTFE ring per cylinder)
Type
Before After PTFE
Seal ring O-ring
modification modification guard ring
Boom 964 945 40 988 930 40 951 764 40 461 292 40 519 498 98
Stick 982 270 40 98 935 40 951 961 40 896 587 40 950 953 40
Bucket 964 935 40 988 940 40 951 762 40 324 442 40 519 501 98
Clam 964 940 40 988 945 40 951 760 40 269 474 40 950 964 40
*Punch mark the new PN after modification (Refer to chapter 4)

AH15849b
Page 5 of 10

2. Modification
2.1. Disassembly of the hydraulic cylinders

Cylinders with an inner dia. 120 mm and more

should be assembled in a vertical position.

Remove the port covers and drain the oil of the cylinder.
Place the cylinder upright in such a way that they cannot
be overturned.
Loosen the cover bolts (4).
Extend the piston rod (3) with a crane to gain
access to the retainer flange mounting bolts (1).
Put a protecting sleeve on the piston rod before
removing the bolts to avoid damages in the
chrome surface of the piston rod.
Remove all bolts (1) and retighten two bolts
by hand. So remains the retainer flange in
the lower position.
Now extend the piston rod as much as possible and then remove the last two cover
bolts.

m
Do not use compressed air to extract the retainer flange.
Use two push-out bolts (M12 or M16) if necessary.

Extract the entire piston assembly out of the cylinder using a crane.
Clamp the piston rod in a hydraulic clamping device. Use suitable vee
clamping blocks at the clamping device to clamp the piston rod.
The chrome surface on the piston rod may get damaged by the clamping
device. This will cause leakage at the assembled cylinder.

AH15849b
Page 6 of 10

2.2. Inspection of the barrel

Clean all parts carefully.

Visually inspect the cylinder bore for damage, scoring and pitting
(Rzmax.= 2.5 m).
If any damages or scores are found the cylinder must be refurbished in a
certificated REMAN-shop.

Specifications for the REMAN -shop

Measurement Specification
Maximum chrome thickness 250 m (0.010)
Minimum chrome thickness 30 m (0,0012)
Maximum allowed bend 250 m / m (0.010 / m)
Chrome surface finish Rz = 1.50.5 m
Cylinder bore surface finish Rz max = 2.5m
Grooves, seats of sealing and guide rings Rz = 10
Sealing and guide rings Rz = 20

AH15849b
Page 7 of 10

Barrel Honing*up to H9
Original values
dia. (mm)
430.000
430 430 H8 430.140
430.097
380.000
380 380 H8 380.140
380.089
350.000
350 350 H8 350.140
350.089
330.000
330 330 H8 330.140
330.089
320.000
320 320 H8 320.140
320.089
300.000
300 300 H8 300.130
300.081
280.000
280 280 H8 280.130
280.081
260.000
260 260 H8 260.130
260.081
250.000
250 250 H8 250.115
250.072
240.000
240 240 H8 240.115
240.072
225.000
225 225 H8 225.115
225.072
200.000
200 200 H8 200.115
200.072

* The roughness of the cylinder bore has to be less than Rz 2.5 m.

The max. individual roughness (Rmax or Rt) should be in excess of Rz by 10 %.
We recommend Rz = 1.0 to 2.0 m.

AH15849b
Page 8 of 10

2.3. Modification
Visual inspection of the seal. Replacing the O-ring (2) and the seal ring (3) is
only necessary if damages are visible or if during pressure test an internal leak
occurs.

Remove the metal guard rings (1).

Clean the piston and all grooves carefully.
Inspect all grooves for wear, rust pitting and surface finish.
Use a special mounting sleeve for installing the pos. (2) and (3).
For the dimension of these sleeves refer to the end of this manual.
Install at first the new O-ring (2) and then the piston seal ring (3).
Heat up the piston seal ring before to 60 to 70C using a water bath.
Fit the two new PTFE guard rings in a 180 offset.
Press the seal ring (3) by using a second mounting sleeve carefully into its
groove. Otherwise they can be sheared off during piston assembly.

Place the cylinder barrel upright in such a way that

they cannot be overturned.
Apply a film of oil to the cylinder barrel and all parts of
the piston.
Move the retainer flange against the piston and attach
the piston rod assembly to a crane.
Lift the piston rod assembly and position it over the
cylinder barrel.
Align piston rod assembly and barrel.
Slide the piston rod assembly carefully into the
cylinder barrel.
Check the position of the rings during insertion.
Correct them by hand if necessary.

AH15849b
Page 9 of 10

Align the retainer flange to the barrel.

Assure that the bores in the retainer flange match the threads in the barrel.
Continue sliding the piston rod assembly into the cylinder barrel.
Apply multi-purpose grease (e.g. from the Central Lubrication System) to the
threads of the mounting bolts.

Let the piston rod extracted only so far that the access to the
mounting bolts is ensured.

:
The chrome surface on the piston rod may get damaged by
tools when installing the retainer flange mounting 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.

Insert all bolts and tighten the bolts crosswise to the specified torque (standard
for material 10.9).
Thread MA
M20 510 Nm
M30 1770 Nm
M36 3100 Nm

m
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.

2.4. Final works

Remove the old part number of the cylinder after the

modification by grinding.
Punch mark the new number according to the table on page 2
to 4 at the same place.
Size of the steel stamp number 6 mm.

AH15849b
Page 10 of 10

2.5. Leakage test of the cylinder

Connect a hydraulic test bench to both ports of the cylinder according to the
picture.

Extend and retract the cylinder slowly 8 to 10 times to the end positions to
bleed air from the cylinder.
Fully extend the cylinder with 40 to 60C warm hydraulic oil and
apply 415 bar.
Close both ports and check if the pressure increases at the cylinders piston
rod side over a 5 minute time period.
If the pressure increases more than 60 bar the cylinder has an internal
leakage. (The pressure decreases while the hydraulic oil in the cylinder is
cooling down; 1 less oil temperature correspond to 9 bar.)
Fully retract the cylinder and apply 415 bar.
Close both ports and check if the pressure increases at the piston side over a 5
minute time period.
Visually check if the cylinder shows any leakage at the retainer flange.
If no leakage is found, the cylinder repair was successful. Otherwise the piston
seal ring and the O-ring has to be replaced.
Relieve the pressure at both ports.
Disconnect the test lines.
Cap the ports with blind plugs to avoid contamination.

3. Attachment: Mounting sleeves

AH15849b
Service information Special tools

6.3.2.1 MANUFACTURING OF THE SLEEVE FOR MOUNTING THE PISTON SEAL

RING
1. Refer to Fig. 6-2:
Measure the diameter A and the dimension a of the piston.

* B must be bigger than the outer dia. of the piston nut

2. Manufacture the sleeve according to Fig. 6-3 using the mea-

sured dimensions.

REMARKS: Alternatively contact the KOMATSU area manager

using the cylinder Part No. for the resp. sleeve.

Fig. 6-2

REMARKS: All sharp edges deburred.

.
B must be bigger than the outer dia. of the piston nut

REM_CYL 0213-GB-1 Cylinder REMAN-Manual 6 -5

 Special tools Service information

6.3.2.2 MANUFACTURING OF THE SLEEVE FOR RESIZING THE PISTON SEAL RING
1. Refer to Fig. 6-4:
Measure the diameter A and the distance L of the piston.
B must be bigger than the outer dia. of the piston nut

2. Manufacture the sleeve according to Fig. 6-5 using the mea-

sured dimensions.

REMARKS: Alternatively contact the KOMATSU area manager

using the cylinder Part No. for the resp. sleeve.

Fig. 6-4

Fig. 6-5 Resizing sleeve for piston seal rings

6 -6 Cylinder REMAN-Manual REM_CYL 0213-GB-1