Common Mechanical Failures and Repair Solutions for Diesel Generator Engine

The diesel generator engine exhibits three critical failure modes requiring immediate attention.

First, wear on the 205 bearing bore at the balance shaft ends demands prompt repair. For minor wear, oxy-acetylene welding can be applied to strategically spot-weld the bearing’s outer ring, followed by precision filing and press-fitting. Severe cases necessitate machining a 2mm-thick steel spacer with a 50mm inner diameter, secured via three threaded fasteners, or boring the housing to install a reinforced sleeve fixed with screws.

Second, frost-induced cracks in winter operations must be addressed through cold welding protocols: drill stop holes at crack termini, insert iron pins along the fracture, weld low-carbon steel patches perpendicularly while hammering the seam for stress relief, and perform post-weld flame straightening. Note that this method applies only to non-load-bearing areas.

Third, stripped cylinder head bolt threads, typically caused by over-torquing or mechanical impacts, may be salvaged by re-tapping individual damaged holes and fabricating custom bolts, though components with multiple stripped threads or structural breaches require complete replacement.

These solutions adhere to industrial repair standards, balancing operational urgency with long-term reliability.