Section 2.4

CRANKSHAFT AND CAMSHAFT

CAMSHAFT INSPECTION

Carefully inspect the entire camshaft for wear, nicks, damage. All areas indicated in Figure 4 should be checked for wear.

Figure 4. Points to Check on Camshaft

The following should be measured carefully to check for wear:

MAIN CAMSHAFT BEARING DIAMETER

(FLYWHEEL END)

DESIGN DIAMETER: 1.022-1.023 inch (25.96-25.98mm)

WEAR LIMIT: 1.020 inch (25.91mm) Minimum

MAIN CAMSHAFT BEARING DIAMETER (PTO END) DESIGN DIAMETER: 1.297-1.298 inch (32.96-32.98mm) WEAR LIMIT: 1.295 inch (32.89mm) Minimum

CAMSHAFT BEARING BORE IN CRANKCASE

DESIGN DIAMETER: 1.024-1.025 Inch (26.00-26.03mm)

WEAR LIMIT 1.026 inch (26.06mm) Maximum

CAMSHAFT BEARING BORE IN CRANKCASE COVER DESIGN DIAMETER: 1.299-1.300 inch (33.00-33.03mm)

WEAR LIMIT: 1.302 inch (33.06mm) Maximum

CAM LIFT

DESIGN LIFT: 0.210-0.212 inch (5.34-5.38mm) WEAR LIMIT: 0.206 inch (5.24mm) Minimum

Inspect the crankpin for damage, nicks, scratches, etc. Small nicks and scratches may be polished out using fine emery cloth. ALL EMERY RESIDUE MUST BE REMOVED. Use a solvent (such as kerosene) to remove emery residue.

Carefully measure the outside diameter (O.D.) of the crankpin, crankshaft journal at flywheel end, and crankshaft journal at PTO end. Replace the crankshaft if it is worn smaller than the stated limits.

NOTE: DO NOT regrind the crankpin to any small- er diameter. Undersize connecting rods are NOT available for the GV-220 engines.

Inspect oil passage. Use a length of wire to make sure it is open. Inspect threaded ends of crankshaft.

CRANKPIN OUTSIDE DIAMETER

DESIGN DIAMETER: 1.180-1.181 inch (29.99-30.01mm)

WEAR LIMIT: 1.179 inch (29.96mm) Minimum

CRANKSHAFT BEARING JOURNAL (FLYWHEEL END) DESIGN DIAMETER: 1.102-1.103 inch (28.000-28.012mm)

WEAR LIMIT: 1.100 inch (27.95mm) Minimum

CRANKSHAFT BEARING JOURNAL (PTO END)

DESIGN DIAMETER: 1.102-1.103 inch (28.000-28.012mm)

WEAR LIMIT: 1.186 inch (27.95mm) Minimum

Figure 5. Points to Check on Crankshaft

CRANKSHAFT INSPECTION

CRANKSHAFT PROPER:

Use a commercial solvent to clean the crankshaft. After cleaning, inspect the crankshaft as follows:

Inspect keyways in crankshaft, make sure they are not worn or spread. Remove burrs from edges of keyway, to prevent scratching the bearing.

Inspect timing gear teeth for chipping or cracking. If the timing gear is damaged, the crankshaft assem- bly must be replaced.

Check the crankshaft bearing bore in the crankcase cover. If limits are exceeded, replace the crankcase cover.

CRANKSHAFT BEARING BORE IN CRANKCASE

COVER

DESIGN DIAMETER: 1.104-1.105 inch (28.040-28.065mm)

WEAR LIMIT: 1.106 inch (28.092mm) Maximum

Page 2.3-6

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Generac Power Systems 940-2, 941-2 service manual Camshaft Inspection, Crankshaft Inspection, Crankshaft Proper

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