Dongfeng KL truck parts Right Hydraulic Lock Bolt Assembly with Sensor 5002165-C3100

Designed as a dual-function assembly, it combines reliable hydraulic locking with real-time status sensing. The hydraulic drive unit features a precision-machined piston that pushes the lock bolt into place within 0.8 seconds of hydraulic pressure activation, providing a locking force of 8 kN—enough to secure heavy components (e.g., cab tilt mechanisms or door frames) even under road vibration. The integrated Hall-effect sensor (IP67-rated) detects the lock bolt’s “locked/unlocked” position and transmits a 0–5V analog signal to the truck’s CCU, triggering dashboard indicators to alert drivers of incomplete locking (critical for preventing safety hazards like cab movement during driving). Unlike separate lock and sensor setups that require calibration, this integrated design ensures signal synchronization, reducing false alarms by 90% compared to aftermarket sensor retrofits

Built to withstand the high forces and harsh conditions of truck hydraulic systems, the assembly uses rugged, load-bearing materials. The lock bolt and piston are crafted from hardened 40Cr alloy steel (quenched and tempered to HRC 35–40), which resists bending or deformation even under 120% of the rated locking force (9.6 kN). The outer housing is made of Q345B low-alloy steel with a 6mm wall thickness, protecting internal components from road debris impact and mechanical damage. Unlike lightweight aluminum or cast iron components that crack under stress, this high-strength steel structure endures 200,000+ locking cycles (equivalent to 5 years of heavy use) without performance degradation, ensuring long-term reliability for critical locking functions

Engineered to maintain hydraulic system integrity and sensor performance, the assembly features comprehensive sealing. The hydraulic port uses a nitrile rubber O-ring (70 Shore A hardness) with a backup washer, creating a leak-tight seal that withstands 20 MPa pressure (exceeding the truck’s maximum hydraulic pressure) without fluid seepage. The sensor connector is sealed with a silicone gasket and a threaded locking nut, blocking dust, water, and road salt from entering the electrical interface—meeting IP67 ingress protection standards. Additionally, the lock bolt’s sliding surface is coated with a PTFE-based lubricant that reduces friction and prevents contamination buildup, ensuring smooth actuation even in dusty or muddy environments. Unlike poorly sealed assemblies that cause hydraulic fluid loss or sensor failure, this design minimizes maintenance costs and downtime

The assembly prioritizes operational safety and seamless integration with the truck’s control system. It includes a pressure relief valve that vents excess hydraulic pressure (above 18 MPa) to prevent damage to the lock bolt or piston, protecting the hydraulic circuit from overloading. The sensor’s signal is compatible with Dongfeng KL’s original CCU, enabling automatic safety interlocks—for example, disabling cab tilt functions if the lock is not fully unlocked, or triggering an audible alarm if the lock fails to engage while driving. The assembly also features a manual override lever (accessible via a service port) that allows mechanical unlocking in case of hydraulic system failure, ensuring emergency operability. Each unit undergoes strict testing: hydraulic leak testing (24-hour pressure hold at 16 MPa), sensor signal accuracy verification (±0.05V deviation), and durability cycling (100,000 lock/unlock cycles). Backed by a 24-month warranty against manufacturing defects (e.g., hydraulic leaks, sensor malfunction, bolt deformation), it provides Dongfeng KL truck owners with a secure, intelligent locking solution for critical vehicle components