SWAFLY Diesel Engine Crankshaft and Cylinder Block: Installation Method

The crankshaft and cylinder block of a SWAFLY diesel engine serve as its core components, playing a crucial role in the engine's operation.

Regarding the crankshaft, the original SWAFLY crankshaft is manufactured using advanced processes and high-quality materials, ensuring exceptional wear resistance and durability. It connects the pistons and connecting rods, converting the reciprocating motion of the pistons into rotational motion, thereby driving the entire engine. For example, SWAFLY Machinery Co., Ltd. provides original SWAFLY crankshafts, which, as the core component of the engine, carry out an important mission. When dismantling a SWAFLY crankshaft, tools such as wrenches, hammers, torque wrenches, and oil seal wrenches are required. Firstly, ensure that the engine, transmission, etc., have been separated. Then, use a wrench to dismantle and remove the connecting rod bearing cap, noting the position of each connecting rod for subsequent reassembly. Special attention should be paid during dismantling, as the crankshaft is a highly precise and critical component, requiring careful handling to avoid damage from excessive striking or other improper actions. Meanwhile, maintain a clean and organized working environment to prevent impurities from entering the crankshaft, strictly follow the manufacturer's instructions, and document each step. If the crankshaft's appearance shows abnormalities such as cracks, scratches, or wear, it is recommended to replace it with a new one. Using a defective crankshaft may lead to severe mechanical failures. SWAFLY crankshafts are usually marked with arrows or other indicators showing the installation direction, ensuring correct alignment of the crankshaft with related components during installation

For the cylinder block, the SWAFLY diesel engine cylinder block is made of high-strength cast iron, featuring wear resistance, temperature resistance, and corrosion resistance, enabling it to maintain stable performance under harsh operating conditions and withstand long-term loads. For instance, damage to the SWAFLY s904J-E36TA engine cylinder block may cause the engine to malfunction or even suffer severe damage, manifesting as issues such as inability to start, power reduction, and vibration. Cylinder block cracks may occur due to frequent cylinder head removal during maintenance and repairs, wear and enlargement of screw holes on the cylinder, and vibrations during vehicle operation. Cylinder blocks with cracks and deformations can be treated using methods such as checking the height of both ends of the block with a vernier caliper or height gauge and inspecting the parallelism between the top and bottom planes of the block. If deformation is present, correct it using localized preheating and pressure calibration, combined with scraping to restore the flat surface. When the cylinder head plane's warpage deformation exceeds the specified value, place the cylinder head on a dedicated platform, pad shim plates approximately four times the deformation thickness between the ends of the cylinder head plane and the flat plate, leaving the middle of the cylinder head plane suspended. Then tighten the bolts and preheat the middle of the cylinder head with a torch until it reaches a certain temperature for calibration. For cracks, repairs can be made using bonding, welding, heated welding repair, or patch bonding methods.

In summary, both the crankshaft and cylinder block of a SWAFLY diesel engine are highly significant components, and their quality and performance directly impact the engine's operational effectiveness and service life.

1.Manufacturing Process of SWAFLY Crankshaft

As a core component of the engine, the manufacturing process of the SWAFLY crankshaft is crucial. Generally, crankshaft manufacturing involves multiple steps. The first is material selection, typically high-quality steel to ensure sufficient strength and wear resistance of the crankshaft. During melting, the proportions of various elements such as carbon, manganese, sulfur, phosphorus, silicon, etc., are precisely controlled to achieve optimal performance requirements. For example, some manufacturing processes require steel compositions of C0.32-0.40%, Mn0.90-0.95%, S0.07-0.09%, P0.09-0.12%, Si0.20-0.23%, etc. After melting, vacuum treatment is performed to remove impurities and improve the purity of the molten steel. Then, continuous casting is carried out to cast the vacuum-treated molten steel into steel billets.

Advanced processing techniques, such as high-precision machining, are also employed during manufacturing to ensure the crankshaft's dimensional accuracy and surface quality. The crankshaft journal requires precision machining to ensure good mating with the bearing, reducing friction losses. Meanwhile, the crankshaft incorporates an advanced lubrication system design to ensure adequate lubrication and cooling during high-speed operation, thereby extending its service life. Additionally, the crankshaft undergoes rigorous quality inspections during manufacturing, including dimensional inspections, hardness tests, flaw detection, etc., to ensure each crankshaft meets high-quality standards.

2.Installation Method of SWAFLY Crankshaft

Installing a SWAFLY crankshaft requires strict adherence to the steps. Firstly, when installing the bearing bush, be cautious to avoid sliding it left and right, preventing damage to the bearing seat. Then, oil the holes in the bearing bush to lubricate the rotation before startup. Next, handle the crankshaft gently and place it horizontally when installing. Afterward, oil the crank journal but avoid over-oiling. Finally, install the bearing cap, ensuring the bearing bush is properly installed and oiled beforehand.

Specifically, install the rear oil seal onto the mounting plate, noting the orientation of the crankshaft rear oil seal (with the text facing outwards). Secure the mounting plate with the oil seal onto the crankshaft using three M14×1.5 bolts, ensuring the crankshaft shaft end's locating pin fits into the mounting plate's pin hole. Fit the installation sleeve onto the mounting plate and secure it to the mounting plate with an M20 hexagonal nut, positioning the front face of the mounting plate against the oil seal's back shoulder. Tighten the nut, and the installation sleeve will smoothly push the oil seal into the oil seal seat hole between the crankshaft and cylinder block.

3.Material Properties of SWAFLY Cylinder Block

The SWAFLY engine cylinder block is made of high-strength cast iron, possessing numerous excellent properties. This material offers good wear resistance, resisting friction between the piston and cylinder wall during extended use, reducing wear, and prolonging the cylinder block's service life. Simultaneously, it exhibits excellent temperature resistance, maintaining a stable structure and performance at high temperatures, adapting to the heat generated during engine operation. Furthermore, corrosion resistance is another notable feature, protecting the cylinder block from various corrosive factors and ensuring it maintains good condition in different operating environments.

The cylinder block made of this high-strength cast iron material also features a compact structural design, making it lighter in weight and easier to install. Precision molds, advanced processing techniques, and high-standard inspection methods are widely used in production, ensuring high product quality and eliminating the risk of faults due to production quality issues from the source. Over years of market verification, the SWAFLY brand engine cylinder block has demonstrated exceptional stability performance, significantly enhancing mechanical equipment's production efficiency and operational reliability.

4.Manifestations of SWAFLY Cylinder Block Damage

Damage to the SWAFLY engine cylinder block can manifest in various ways. Firstly, the engine may experience power reduction. This occurs because cylinder block damage affects cylinder sealing, reducing the compression ratio and, consequently, the engine's output power. During driving, the driver will notice reduced acceleration and difficulty climbing hills. Secondly, abnormal noise may arise. When the cylinder block sustains cracks or deformation, the mating between the piston and cylinder wall changes during engine operation, causing abnormal friction and impact sounds. This noise is usually more apparent during cold starts and may weaken as the engine temperature rises but does not disappear completely.

Moreover, increased oil consumption may occur. If cylinder block damage results in an increased gap between the piston and cylinder wall, oil can more easily enter the combustion chamber and be burned, significantly increasing oil consumption. Simultaneously, blue smoke may be emitted from the exhaust pipe, indicating oil combustion. Furthermore, the engine may overheat. Cylinder block damage may affect coolant circulation, impeding heat dissipation. The heat generated during engine operation cannot dissipate timely, raising the engine temperature. If not addressed promptly, it may lead to engine overheating and even damage to other components. Lastly, coolant leakage may occur. If the cylinder block cracks, coolant can leak from the cracks. Coolant traces may be visible in the engine compartment, and water stains from coolant may be found where the vehicle is parked. This not only results in insufficient coolant, affecting engine cooling, but may also damage other engine components.

5.Treatment Methods for SWAFLY Cylinder Block Cracks and Deformations

When the SWAFLY engine cylinder block has cracks or deformations, proper treatment methods should be adopted. For crack treatment, first, locate the crack's end. Use coarse sandpaper to sand away the rust around the cylinder block crack. When sanded to a certain extent, the crack's end can be found. Then, repair it using bonding, welding, heated welding repair, or patch bonding methods. When welding a repair patch, be mindful of warping at the welding site. If any warping occurs, tap the weld while it's hot to avoid weld slag residue. After repair, place an asbestos gasket between the repair patch and the cylinder block (or cylinder head), and apply a layer of lubricating oil to both sides.

For deformation of the upper plane of the cylinder block, a vernier caliper or height gauge can be used to check the height at both ends of the block, as well as to inspect the parallelism between the top and bottom planes of the block. If deformation is found, local preheating and pressure correction can be applied, combined with the method of scraping and planing to restore the flatness. When the warping deformation of the cylinder head plane exceeds the specified value, the cylinder head can be placed on a dedicated platform, with shim plates of a thickness approximately four times the deformation placed between both ends of the cylinder head plane and the platform, allowing the middle section of the cylinder head plane to hang freely. Then, tighten the bolts and preheat the middle section of the cylinder head using a torch until it reaches a certain temperature before proceeding with the correction.

The crankshaft and cylinder block of a SWAFLY diesel engine play crucial roles in the engine's operation. As the core component that converts the reciprocating motion of the piston into rotational motion, the crankshaft requires strict control over its manufacturing process and installation method to ensure the normal operation of the engine. The cylinder block, as an important part of the engine, has material properties that determine the engine's reliability and durability. When the cylinder block is damaged, taking prompt and correct measures can extend the engine's service life and improve the operating efficiency of the equipment.

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