14/09/2006

L& T Komatsu Limited

Quality Assurance-HW

Guidelines to Judge PC200 Cylinder seal failures.

General.
1. Check for the mode of seal failure –external leakage or internal leakage (drifting).
2. Measure & record the temperature of oil in the tank & on cylinder.
3. Verify whether the cylinder movement is free and noiseless.
4. Observe for any attachment structural problems, which can influence the cylinder seal
failure.
5. Check and report the cylinder part number, description and serial number in the TSI.

External leakage.
a) Confirm whether the leakage is from Rod seals (leakage through wiper seal area) or
between the interfaces of Head cyl & barrel.

b) Wetting on the cylinder Head is acceptable

c) If the Seepage/leakage is from the Wiper seal, observe for oil ring formation on
the chromium-plated diameter of Rod piston. Wipe out the oil and stroke the cylinder
5times. If the ring formation persists, and is visible on every stroke it means Rod seals
have problem. Observe and if the collection of oil is seen in the form of droplets, seals
need to be replaced.

d) If the leakage is between Head cyl & barrel, check O’ring & back up rings on Head
cyl.

e) Check for
- Damages occurred due to external hits on the Chromium plated Rod.
- Scoring lines.
- Chromium plating peel off/ rusting on the Rod.

If the Rod is seen with the reasons mentioned in the point no. “e”, the Rod seal failure is
consequential and take care to Rework or replace the Rod to avoid repeat failures along with
seal replacement.
Drifting & Internal leakage.

Whenever drifting is reported it is important to check rate of drifting & internal leakage in the
cylinder to draw a conclusion on failure.

1. Check the rate of drifting (mm/15min). Extend the cylinders, mark on the Rod and measure.
(Drifting need to be checked always in Engine ON condition only. Refer below given
procedure)

2. Quantify the internal leakage.

Extend the cylinder till end & open the port near guide piston. Pressurize the port near
Barrel Eye end @ relief set pressure and measure the leakage. Repeat the same @ the
other port.
• Leakage value within 20cc/1min is acceptable and hence there is no need to replace the
cylinder seals.
• If the leakage value is more than 20cc/1min, then the seal kit needs replacement.

How to draw conclusion on drifting.

If the internal leakage in the cylinder is within the limit & if drifting persists, then the cause for
drifting is not due to cylinder seals. Please check valve bank/compensator seals.

Reporting
It is important to verify the above factors & observe the condition of failed seals, position &
orientation of seals during replacement. Give as much information as possible in the TSI. A
comprehensive preliminary observation and reporting will help in the analysis of seal failures.
Check list for cylinder seal failures (Tick mark the appropriate selection)

M/c No: Cylinder Part No: Srl.no.:

SMR:

External leakage.

1. Oil leakage through: wiper seal area between Guide Piston & Barrel

2. Oil ring formation on Rod: NO yes

If yes, is it after 5 strokes 10 strokes

3. Oil droplets seen @ wiper seal: yes NO

4. If yes, quantify the oil drops /stroke: after 5 strokes after 10 strokes
( ) ( )

5. Rod condition: Scratch/Scoring Damaged Good

6. Wiper seal condition: Good Damaged

Drifting & Internal leakage.

1. Drifting yes NO

2. Quantify the rate of drifting (mm/15min) :

3. Quantify Internal leakage in the cylinder (c c/1min) :