Method for installing important fasteners of diesel engine

At present, some operators and repair personnel have obtained a driver’s license or a junior repairman certificate, but their knowledge of mechanical construction principles and maintenance practices remains limited. This often leads to improper installation techniques, such as using the wrong fasteners or failing to apply proper torque. As a result, diesel engines frequently malfunction during operation, and in severe cases, serious accidents can occur. To raise awareness among operators and technicians, the following precautions for installing critical fasteners on diesel engines are outlined. 1. **Cylinder Head Nut** When tightening the cylinder head nut, it should be done gradually in steps, following the specified torque and the diagonal cross method—starting from the center and moving outward. When removing, the nuts should be loosened in the reverse order. Improper tightening can cause warping of the cylinder head, stretching or breaking of bolts, and damage to threads. If not tightened properly, oil leaks and gasket failure may occur due to high-temperature gas exposure. 2. **Flywheel Nut** For engines like the S195, the flywheel is connected to the crankshaft via a conical fit and a flat key. The flywheel nut must be tightened with a thrust washer to prevent looseness. If not secured correctly, knocking sounds may develop, potentially leading to damage to the crankshaft taper, keyway, or even a broken crankshaft, which could cause serious accidents. Also, the thrust washer should only be folded once. 3. **Connecting Rod Bolts** High-quality steel connecting rod bolts are subjected to significant impact forces and should never be replaced with ordinary bolts. They must be tightened evenly in stages, and finally secured with galvanized wire. Over-tightening can cause deformation or breakage, while under-tightening may lead to bearing clearance issues, knocking noises, and even engine failure. 4. **Main Bearing Bolts** The main bearings must be installed precisely and not left loose. For a four-cylinder engine, the five main bearing bolts should be tightened in sequence—starting from the center, then working outward. Each tightening step should check for smooth crankshaft rotation. Incorrect torque can lead to bearing damage, reduced power, or even engine failure. 5. **Balance Block Bolts** These bolts should be tightened gradually in multiple steps to ensure proper balance. If not tightened correctly, the balance block may shift, leading to vibration and instability. 6. **Rocker Seat Nut** Regular checks are essential. A loose rocker nut increases valve clearance, delays valve opening, and reduces engine performance, leading to poor exhaust, lower power, and increased fuel consumption. 7. **Injector Lock Nut** The injector lock nut should be tightened to the specified torque in multiple steps. Over-tightening can deform the nut and cause the needle valve to stick, while under-tightening may lead to oil leakage, poor atomization, and higher fuel consumption. 8. **Fuel Valve Tight Seat** Proper torque is crucial when installing the fuel injection valve. Over-tightening can damage the plunger sleeve, reduce sealing efficiency, and affect engine performance. Under-tightening can cause oil leakage and improper fuel delivery. 9. **Injector Platen Nut** When installing the injector assembly, ensure that the pressure plate is correctly positioned and the steel pad thickness is appropriate. The platen nut must be tightened to the correct torque. Too much torque may deform the injector body, while too little can cause air leaks and difficulty starting the engine. In addition, when installing the pump slide rotor and high-pressure oil pipe joints on the distribution pump casing, the spring should also be adjusted according to the specified torque to ensure proper function. These details are essential for maintaining the reliability and safety of diesel engines.

CNC Turning

The CNC Turning process is a digital manufacturing process that is implemented by computer numerically controlled (CNC) machines. This process is used to produce parts with complex shapes, and the manufacturing process involves multiple steps. The following are the detailed steps of the general CNC Turning process:Design: First, you need to design a CAD model of the parts you want to produce. A CAD model is a three-dimensional image created using computer-aided design software that can describe the shape, size, and features of a part.Programming: Next, you need to convert the CAD model into G-code, which is a type of computer instruction that controls the movement and operation of the CNC machine. G Code can be written manually or generated automatically using CAM software.Prepare the machine: Before you start machining, you need to check and prepare the CNC machine. This includes checking the machine's coordinate system, setting tools and cutters, and setting parameters such as the machine's speed and feed speed.Processing: After the machine is ready, the processing can begin. The machining process usually consists of multiple steps, such as roughing, finishing and drilling. At each step, the CNC machine moves tools and workpieces according to instructions in the G code to achieve the desired cutting operation.Inspection: After processing, the parts need to be inspected to ensure that they meet the design requirements and specifications. Inspection can be carried out by using measuring instruments, templates and other testing tools.Polishing and surface treatment: Parts can be polished and surface treated if needed to improve their surface finish and corrosion resistance. This can be done through the use of abrasives, chemicals and other tools.In short, the CNC Turning process is a high-precision, high-efficiency manufacturing process suitable for the production of parts with complex shapes. Through the control of CAD model and G code, the precise control of machine motion can be realized, so as to achieve high-precision parts processing.

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