| Parameter | Specification | Testing Standard |
|---|---|---|
| COGENG Part Number | COGENG-878000486-HSK | Internal Quality Standard QS-509 |
| Replaces OEM Part No. | Komatsu 878000486 | Direct OEM Replacement |
| Primary Seal Material | Polyurethane (PU) Grade 95A | ISO 6072 |
| Secondary Seal Material | Nitrile (NBR) with PTFE fill | ISO 6072 |
| Wiper Material | Polyurethane double-lipped | ISO 6194 |
| O-Ring Material | Nitrile (NBR) 70 Durometer | ISO 3601-1 |
| Wear Ring Material | PTFE-filled composite | ISO 6811 |
| Backup Ring Material | Nylon 6.6 | ISO 1874-1 |
| Temperature Range | -45°C to +120°C (-49°F to +248°F) | ISO 2230 |
| Pressure Rating | Up to 42 MPa (6090 PSI) | ISO 10766-1 |
| Fluid Compatibility | Komatsu Super Hydraulic Fluid, mineral oil, synthetic, biodegradable | ISO 6743-4 |
| Shelf Life | 5 years in original packaging | ISO 2230 |
| Component | Material | Size Range | Quantity | Function |
|---|---|---|---|---|
| Piston Seals | Polyurethane | 80-160mm ID | 2 | Primary pressure sealing |
| Rod Seals | NBR with PTFE | 60-120mm ID | 2 | Dynamic rod sealing |
| Buffer Seals | Polyurethane | 80-160mm ID | 2 | Pressure peak protection |
| Wiper Seals | Polyurethane double-lipped | 60.5-120.5mm ID | 2 | Contaminant exclusion |
| Wear Rings | PTFE composite | 80-160mm OD | 4 | Piston guidance |
| O-Rings | Nitrile (NBR) | Various sizes AS568 | 12 | Static sealing |
| Backup Rings | Nylon 6.6 | Various sizes | 6 | Anti-extrusion support |
| Guide Rings | PTFE-filled fabric | 80-160mm OD | 4 | Bearing surface protection |
| Gland Seals | NBR | Various sizes | 2 | Gland static sealing |
| Model Series | Specific Models | Cylinder Applications | Year Range |
|---|---|---|---|
| Komatsu PC200 | PC200-7, PC200-8 | Boom, Arm, Bucket Cylinders | 2001-2015 |
| Komatsu PC210 | PC210-7, PC210-8, PC210-10 | Main Hydraulic Cylinders | 2003-2018 |
| Komatsu PC220 | PC220-7, PC220-8 | All Hydraulic Cylinders | 2002-2016 |
| Komatsu PC228 | PC228-3, PC228-5 | Boom and Arm Cylinders | 2004-2017 |
| Komatsu PC240 | PC240-7, PC240-8 | Swing Motor, Travel Motor | 2005-2019 |
| Parameter | Specification | Tolerance | Application |
|---|---|---|---|
| Cylinder Bore Range | 80-160 mm | +0.10/-0.00 mm | Various cylinder sizes |
| Rod Diameter Range | 60-120 mm | +0.00/-0.05 mm | Rod seal compatibility |
| Operating Pressure | 34.3 MPa (350 kg/cm²) | ±2% | System design pressure |
| Burst Pressure | 68.6 MPa (700 kg/cm²) | +10% | Safety margin |
| Fluid Temperature | -20°C to +80°C | N/A | Operating range |
| NO | Number | Name | Qty |
| 1 | 395012014 | JACK, ASSY. | 1 |
| 2 | 390658013 | • BUSHING | 1 |
| 3 | 395077012 | • CYLINDER | 1 |
| 4 | 801920220 | • NUT | 1 |
| 5 | 3F4588604 | • PISTON | 1 |
| 6 | 395183013 | • ROD | 1 |
| 7 | 391964011 | • CYLINDER HEAD | 1 |
| 8 | 500217005 | • BUSHING | 1 |
| 878000486 | • GASKET KIT | 1 | |
| 9 | 855661048 | •• SCRAPER RING | 1 |
| 10 | 855021237 | •• O-RING | 1 |
| 11 | 855661052 | •• GASKET | 1 |
| 12 | 855661050 | •• SEAL | 1 |
| 13 | 855080619 | •• RING | 1 |
| 14 | 855021619 | •• O-RING | 1 |
| 15 | 855661205 | •• O-RING | 1 |
| 16 | 855661204 | •• GASKET | 1 |
| Performance Parameter | Value | Test Method |
|---|---|---|
| Seal Service Life | 5,000 operating hours | ISO 7983 |
| Friction Coefficient | 0.06-0.10 | ASTM D1894 |
| Extrusion Resistance | 45 MPa sustained | ISO 1829 |
| Compression Set | <12% after 24h @ 100°C | ISO 815 |
| Abrasion Resistance | >70,000 cycles | ISO 4649 |
Preventive Maintenance Schedule:
Visual inspection: Every 500 operating hours
Leakage check: Monthly or 250 hours
Performance monitoring: Daily operational checks
Fluid analysis: Every 2,000 hours
Troubleshooting Common Issues:
External Leakage: Verify seal installation and surface conditions
Internal Leakage: Check piston seal integrity and cylinder wear
Slow Operation: Inspect for contamination or viscosity issues
Jerky Movement: Check for air in system or seal damage
Overheating: Verify proper lubrication and pressure settings
Warranty Period: 18 months or 3,000 operating hours
Quality Certifications: ISO 9001:2015, ISO 14001:2015
Testing Protocol: 100% dimensional and material verification
Material Traceability: Full batch tracking available
Technical Support: Expert assistance for installation and troubleshooting
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