Westerbeke BCGB - Generator Electrical Testing and Troubleshooting; Generator Troubleshooting Chart

SERVICE DATA I STJ'NDARDS AND LIMITS • BCGB ENGINEiGENERJ'TOR
Component Specified Value I Standard Repair Limit
inches(mm) inches(mm)
FRONT CASE/COUNTERBALANCE SHAFT
Oil Pump Side Clearance
Driven Gear .......................... 0.0024-0.0047 (0.06-0.12)
Drive Gear. ........................... 0.0027 -0.0051 (0.07.0.13)
Counterbalance Shaft Front Joumal Diameter
................................ 0.7869-0.7874 (19.987-20.000)
Counterbalance Shaft Rear Joumal Diameter
· . . ............................. 1.7317-1.7322 (43.984-44.000)
Counterbalance Shaft Front Joumal Oil Clearance
· ............................... 0.0014 - 0.0027 (0.035 - 0.068)
Counterbalance Shaft Rear Joumal Oil Clearance
· ............................... 0.0014 - 0.0028 (0.035 - 0.071)
CYLINDER BLOCK
Cxlinder Bore
2.5591-2.5602 (65.00-65.03)
Out-of-Roundness and
Taper of Cylinder Bore 0.0004 (less than 0.05)
Gasket Surface Flatness 0.0020 (less than 0.05)
CYLINDER HEAD
0.0039 (0.1)
Flatness of Gasket Surface ... 0 .. 0019 (Less than 0.05) ............ 0.0079 (0.2)
Overall Height... .................. .4.287 -4.295 (108.9-109.1)
Cylinder Head oversize rework dimension of valve seat hole
Intake 0.3 0.S ...... 1.2323 - 1.2333 (31.300 - 3.325)
Intake 0.6 0.S ..... 1.2441 -1.2451 (31.600 - 31.625)
Exhaust 0.3 O.S .... 1.1535 - 1.1544 (29.300 - 29.321)
Exhaust 0.6 O.S .... 1.1653 - 1.1662 (29.600 - 29.621)
Cylinder Head rework of valve guide hole (both intake and exhaust)
0.05 O.S .................. 0.4744 - 0.4751 (12.050 - 12.068)
0.25 O.S .........•........ 0.4823 - 0.4830 (12.250 - 12.268)
0.50 O.S .................. 0.4921 - 0.4928 (12.500 - 12.518)
Intake Valve Seat Angle ........................ .45°
Exhaust Valve Seat Angle ...................... 30°
Intake Valve Seat Width .................. 0.079 (2.0) ........................ 0.004 (0.1)
Exhaust Valve Seat Width ............... 0.079 (2.0) ........................ 0.004 (0.1)
Valve Clearance ........................................ .
Exhaust... ................................... 0.D12 (0.30)
Intake ..................................... : ... 0.008 (0.20)
Valve Head Thickness (margin)
(Intake) ......................................... 039 (1.0) ........................... 020 (.5)
(Exhaust) ...................................... 051 (1.3) ............................. 031 (8)
Valve Length
(Intake) ..................................... 3.960 (100.6)
(Exhaust) .................................. 3.968 (100.8)
Valve Stem 0.0.
Intake ....................... :0.2585 - 0.2591 (6.565 - 6.580)
Exhaust... ................... 0.2571 - 0.2579 (6.530 - 6.550)
Stem to Guide Clearance
Intake ......................... 0.0008 - 0.0020 (0.02 - 0.05) ...... 0.0039 (0.10)
Exhaust ................... 0.0020 - 0.0033 (0.0050 - 0.0085) .. 0.0059 (0.15)
Valve Guide Length
(Intake) ......................................... 1.73 (44)
(Exhaust) ................................... 1.949 (49.5)
Component
VALVES
Specified Value I Standard
inches(mm)
Valve Guide Service Size 0.05, 0.25, 0.50 oversize
Valve Seat Width of
Seat Contact ............................... 035-.051 (0.9-1.3)
Valve Seat Angle .............................. 300/44°/65°
Repair Limit
inches(mm)
Valve Seat Sink ............................................................................ 0.008 (0.2)
Valve Spring Free Length ................ 1.823 (46.3) ...................... 1.783 (45.3)
Valve Spring
Load/Installed Height
IbsJin (Nlmm) .......................... .4611.48 (210137.7)
Squareness .................................... ..Iess than 2° ............................. .40
TIMING BELT
................................................... .47 (12)
ROCKER ARM
Camshaft Height
No.1 (Intake) .......................... 1.3815 (35.09) .................. 1.3618 (34.59)
No.2 (Intake) .......................... 1.3807 (35.07) .................. 1.3610 (34.57)
No.3 (Intake) .......................... 1.3803 (35.06) .................. 1.3606 (34.56)
No.1 (Exhaust) ....................... 1.3839 (35.15) .................. 1.3642 (34.65)
No.2 (Exhaust) ....................... 1.3831 (35.13) .................. 1.3634 (34.63)
No.3 (Exhaust) ...................... 1.3854 (35.190) ................ 1.3657 (34.69)
Camshaft Joumal
Diameter .......................... 1.6118-1.6124(40.940-40.955)
Bearing Oil Clearance .......... 0.0018.o.0033 (.45-0.085)
End Play .................................... 0024-.0055 (.06-.14) ................. 118 (.03)
Rocker Shaft Length ........................ 9.134 (232)
Rocker Ann Shaft
Outer Diameter ....... 0.6687 - 0.6692 (16.985 - 16.998)
Clearance ................... 0.0005 - 0.0017 (0.012 - 0.043) ...... 0.004 (0.1)
PISTON AND CONNECTING ROD
Piston Outer Diameter ...... 2.5579-2.5591 (64.97-65.00)
Piston to Cylinder Clearance
.................................. 0.0008 - 0.0016 (0.02 - 0.04)
Pistcm Ring Grove Width
No.1 ............................. 0.0480 - 0.0488 (1.22 - 1.24)
No.2 ............................. 0.0476 - 0.0484 (1.21 -1.23)
Oil .............................. 0.1108 - 0.1116 (2.815 - 2.835
Piston Service Size ............... 0.25, 0.50, 0.75, 1.00 OS
Piston Ring End Gap
No.1 ............................. 0.0059 - 0.0118 (0.15 - 0.30) ........ 0.0315 (0.8)
No.2 ............................. 0.0138 - 0.0197 (0.35 - 0.50) ........ 0.0315 (0.8)
Oil .................................... 0.008 - 0.028 (0.2 - 0.7) ............ 0.0394 (1.0)
Piston Side Clearance
No.1 ............................. 0.0012 - 0.0028 (0.03 - 0.07) ...... 0.0047 (0.12)
No.2 .....................•....... 0.0008 - 0.0024 (0.02 - 0.06) ...... 0.0039 (0.10)
Piston Pin 0.0 .............. 0.6300 - 0.6302 (16.001 - 16.007)
Piston Pin Press-in Load Ibs(N)
................................... 1102 - 3307 (5000 - 15000)
End Play ............................ 0.0059 - 0.0118 (0.15 - 0.28)
Engines & Generators
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