| Parameter | Specification | Testing Standard |
|---|---|---|
| Operating Pressure Range | 5-35 MPa (725-5,076 PSI) | ISO 10766 |
| Temperature Range | -40°C to +120°C (-40°F to +248°F) | ASTM D2000 |
| Seal Material Density | 1.28-1.38 g/cm³ (component specific) | ASTM D792 |
| Compression Set | ≤ 12% (70 hours @ 110°C) | ASTM D395 Method B |
| Tensile Strength | ≥ 18 MPa (2,611 PSI) | ASTM D412 |
| Elongation at Break | ≥ 280% | ASTM D412 |
| Tear Strength | ≥ 40 kN/m | ASTM D624 Die C |
| Volume Swell | ≤ 8% in AW46 hydraulic oil (168 hrs @ 100°C) | ASTM D471 |
| Friction Coefficient | 0.12-0.22 (optimized for cylinder applications) | ASTM D1894 modified |
| Thermal Conductivity | 0.25-0.35 W/m·K | ASTM E1225 |
| Specific Heat Capacity | 1.80-1.95 kJ/kg·K | ASTM E1269 |
| Pressure Cycle Rating | 300,000 cycles at 25 MPa | ISO 10767-1 |
| Leakage Rate | ≤ 0.5 ml/hour at 30 MPa | ISO 10766 |
| Component | COGENG Part Number | Material | Hardness | Special Features | Quantity |
|---|---|---|---|---|---|
| Main Piston Seal | CG-MPS-12450-01 | HNBR with reinforcement | 88 ± 3 Shore A | Pressure-adaptive design | 2 |
| Primary Rod Seal | CG-PRS-12450-01 | Polyurethane (EU) | 90 ± 3 Shore A | Low stiction, high wear resistance | 2 |
| Secondary Rod Seal | CG-SRS-12450-01 | FKM/HNBR composite | 85 ± 3 Shore A | High-temperature backup | 1 |
| Heavy-Duty Wiper | CG-HDW-12450-01 | Dual-density PU | 94/82 Shore A | Triple-lip contamination control | 1 |
| Wear Band Set | CG-WBS-12450-01 | Bronze-PTFE composite | 60 ± 5 Shore D | Self-lubricating, high load | 2 |
| Component | Function | Material | Technical Specification |
|---|---|---|---|
| Backup Ring Set | Anti-extrusion protection | Glass-filled PTFE | Split design for easy installation |
| Cushion Seals | Stroke-end protection | Microcellular PU | Energy-absorbing design |
| Gland Seal Kit | Gland interface sealing | HNBR composite | Includes all gland seals |
| Port Seals | Hydraulic connection sealing | FKM (Grade 75) | High-pressure rated |
| Component Type | Material | Quantity | Application |
|---|---|---|---|
| O-Ring Kit | NBR/FKM mix | 10 | Various static seals |
| Thread Seals | PTFE tape & paste | 1 kit | Fitting installation |
| Retaining Clips | Spring steel | 2 | Component retention |
| Alignment Pins | Hardened steel | 2 | Proper cylinder alignment |
| Equipment Type | Komatsu Models | Typical Cylinder Applications | Kit Suitability |
|---|---|---|---|
| Excavators | PC200, PC210, PC220 | Bucket, Arm, Boom cylinders | Full compatibility |
| Wheel Loaders | WA200, WA250, WA320 | Lift, Tilt cylinders | Full compatibility |
| Crawler Dozers | D31, D37, D39 | Blade lift, tilt cylinders | Full compatibility |
| Motor Graders | GD655, GD675 | Moldboard cylinders | Verify compatibility |
| Model Series | Specific Models | Cylinder Types | Verification Required |
|---|---|---|---|
| PC200 Series | PC200-6, PC200-7, PC200-8 | Bucket, Arm (secondary) | Verify bore size |
| PC300 Series | PC300-6, PC300-7 | Smaller cylinders | Check specifications |
| WA200 Series | WA200-5, WA200-6, WA200-7 | Lift, Tilt | Full compatibility |
| D30 Series | D31, D37, D39 | Blade cylinders | Verify specific application |
| Cylinder Type | Recommended Components | Special Considerations |
|---|---|---|
| High-Pressure | Use all backup rings, heavy cushions | Test to 35 MPa minimum |
| High-Cycle | Use premium rod seals, enhanced wipers | Monitor temperature closely |
| Side-Load | Use extra wear bands, heavy-duty guides | Check alignment regularly |
| Contaminated | Use multi-stage wipers, extra scrapers | Frequent fluid changes recommended |
⚠️ IMPORTANT REQUIREMENTS:
ALWAYS clean components thoroughly before assembly
NEVER reuse old seals or damaged components
ALWAYS use proper installation tools
VERIFY all clearances before final assembly
⚠️ PERFORMANCE CONSIDERATIONS:
Cleanliness: Critical for seal life and performance
Surface Finish: Affects seal performance and wear
Clearances: Must be within specifications
Lubrication: Proper lubrication during installation essential
⚠️ SAFETY PROTOCOLS:
Always depressurize system before service
Properly support cylinder during disassembly
Use personal protective equipment
Follow all safety procedures in service manual
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