Download Small gas engines : fundamentals, service, troubleshooting, repair

Small Gas
Engines
Fundamentals, Service, Troubleshooting,
Repair, Applications
Contents
CONTENT
Hammers
27
Punches
28
Seal Drivers
Cutting
and
Probe and
Vises
29
Forming Tools 29
Pickup Tools 32
32
Engine Tools
Gear and
33
Flywheel Pullers
Holders
Flywheel
Ridge Reamers 34
Ring Spreaders 34
Ring Compressors
SECTION
Cylinder Hones
Spring Compressors 35
Lapping Sticks 36
Engine Test Instruments
Power Tools
CHAPTER
1
Bencn Grinders
Shop Safety 15
Proper Housekeeping
Hazardous Materials
Proper Ventilation
18
Hand Tool
18
Safety
16
Vernier
19
Prepared for Emergencies
Fire Extinguishers 20
43
44
Combination Square
Dial Indicator 49
Screw P/'fcn Gauge
Engine Operating Safety 20
49
50
20
CHAPTER
3
Fasteners, Sealants, and Gaskets
20
Safety Data Sheets
CHAPTER
Tools and
20
Threaded Fasteners
2
Measuring
Instruments
23
eo/fs
54
A/ute
55
Bolt and Nut
Thread
Introduction
23
Hand Tools
23
Wrenches
24
Pliers
Calipers
Gauges
D/g/te/ S//'cfe Caliper 45
D/a/ Caliper 45
Telescoping Gauges 46
Sma// Ho/e Gauge 48
Thickness Gauges 48
17
Be
38
39
Micrometer Depth
Power Tool
Material
37
Measuring Instruments 38
Micrometers
Safety 19
Compressed Air Safety
Lift Properly 19
Electrical Safety 19
37
Cleaning Tools and Equipment
15
15
Personal Protective Gear
36
37
Dr/7/s and Drill Presses
Safety in the
Small Gas Engine Shop
35
Va/ve
Safety
OSHA
34
G/aze Breakers and
1
Shop Equipment, Supplies,
and
33
33
Terminology
Designations 58
and
Fasteners
27
56
59
Tightening
26
Screwdrivers
Screws
53
Loosening Threaded
61
Removing Broken Fasteners
Chasing Threads 61
61
Small Gas
Internal Thread
Repair 63
Tapping New Threads 63
with
Threading
Washers
Pins
Equipment
Jumper Wires 89
Test Lights 90
63
Meters
64
89
90
64
Cotter Pins
64
Clevis Pins
65
Dowel Pins
65
Straight
Pins
65
Grooved Pins
Taper
Pins
65
65
Rolled Pins
65
Retaining Rings
Keys
Die
a
Electrical Test
Engines
65
66
Adhesives and Sealants
Thread Adhesives
Sealants
Antiseize
Gaskets
66
66
67
Compounds
67
SECTION
Basics of Engine
68
Gasket Rules
68
CHAPTER
Magnetism,
Introduction
CHAPTER
4
Fundamentals of
Principles
Electricity,
and Electronics
73
Atoms and Electricity 73
Direct Current and Alternating Current
Electrical Units of Measurement
75
76
76
81
Electrical Wire and Connectors
82
Solenoids
Relays
82
Transformers
in
Operation
Engine
81
85
Semiconductor Diodes
100
100
101
Timing
101
Two-Stroke
Engine 101
Design 102
of
Two-Stroke Operation
Principles
Scavenging and Tuning 105
Variations in
vs.
CHAPTER
Two-Stroke
6
Engine Components
87
89
99
99
86
S///C0/7 Controlled Rectifiers
97
100
Exhaust Stroke
Lubrication
96
98
Engines
Engine Components
86
95
99
Power Stroke
Valve
95
Elementary Engine
an
82
Circuit Protection Devices
Transistors
Constructing
Two-
95
Explosion Must Be Contained
Four-Stroke Engine
82
Electronics
75
Compression Stroke
Magnetic Fields 78
Theory of Permanent Magnets 78
Magnetic Attraction and Repulsion 79
Magnetism and Electricity 80
Switches
Engine Operation
Intake Stroke
77
78
Components
Engines
Gasoline Must Be Atomized
Four-Stroke
Parallel Circuit 77
Electrical
Engine Operation,
Two- and Four-Stroke
Series Circuit 76
Magnetism
of
Simple Engine
Types of Electrical Circuits
Series-Parallel Circuit
of
Operation
5
and Four-Stroke
Principles
73
Ohm's Law
2
Engine
Block
109
109
109
102
Engine
105
Contents
Crankshaft
110
Crankshaft Main Bearings
Crankcase Seals 112
Pistons
112
Piston Construction
113
Piston Thrust Surfaces
Piston Head Size
Piston Head
Piston
Piston
114
114
Shape
114
115
Rings
Piston
111
Ring Types 115
Ring Construction
Tension
Ring
Ring Movement
Piston Pins
118
118
118
SECTION
118
Connecting Rods and Bearings
Friction-Type Rod Bearings 120
Antifriction Bearings 121
Intake and Exhaust Ports
Ports, Reed Valves,
Poppet Valves
and
125
Valve Lifter
126
Valve Train
CHAPTER
Fuel
Valves
122
123
Camshafts and Gears
or
Engine Systems
120
121
Rotary
Tappet
Configurations
153
Engine Fuels
153
Fuel
128
Systems
7
Basic
Force
Work
Performance
161
161
162
165
167
Regulations
167
137
139
Measurements of
Engine Performance
Engine Displacement 142
Compression Ratio 142
142
Engine Horsepower
Engine Torque 147
Torque and Horsepower 147
Volumetric
Efficiency 148
Practical
Efficiency 148
Mechanical Efficiency 149
Thermal
Systems
Emission Control
138
Torque
160
166
Emissions
137
Power
System
Vapor Return Fuel Systems
Mufflers
135
136
Pressure
157
Pumps
Crankcase Breathers
135
135
Energy
157
Air Cleaners and Air Filters
135
Engine Bore and Stroke
Engine
Fittings
157
Air Induction
Terminology
Science of
156
Pressurized Fuel
133
156
156
Fuel Filters
133
Engine
Petroleum Gas and Natural Gas
Fuel Lines and
Measuring Engine Performance
The
153
Fuel Tanks
Fuel
CHAPTER
Air Induction, and
Kerosene and Diesel Fuels
127
Release
8
Emissions
Liquefied
130
Flywheel
Supply,
Gasoline
Starter
Assembly 127
Automatic Compression
3
Efficiency
149
141
CHAPTER
9
Carburetion
173
Principles
of Carburetion
Air-Fuel Mixture
173
174
Carburetor Pressure Differences
Types of Carburetors 176
Float-Type Carburetors 176
Diaphragm-Type Carburetors 182
Vacuum Carburetors
Primers
185
186
Manual Throttle Controls
186
174
Small Gas
Governor Throttle Controls
What an
Types
Engine
187
CHAPTER
Governor Does
of Governors
Governor Features
187
10
Ignition Systems
231
Principles of Engine Cooling
192
Air
CHAPTER
12
Cooling Systems
188
Cooling
231
232
Liquid Cooling 233
Pressurized Cooling Systems 233
Outboard Engine Cooling Systems
195
Basic
Ignition System Operation 195
Ignition System Components 196
Engines
235
Ignition Coil 197
SparkPlugs 197
Spark Plug Wire 200
Switching Devices 200
Magneto Ignition Systems 201
Operation of Capacitive Discharge Ignition
(CDI) System 202
Operation of Transistor-Controlled Ignition (TCI)
System 203
Operation of the Mechanical Breaker Point
Ignition (MB!) System
205
Magneto Ignition Systems
for
Two-Cylinder
Engines 208
SECTION
Battery Ignition Systems 208
Auto-Transformer-Type Ignition
Coil
4
Engine Service
210
The Lead-Acid Battery 210
The
CHAPTER
211
Discharging/Charging Cycle
13
Preventive Maintenance and
CHAPTER
Lubrication
11
Systems
Principles of Lubrication
Friction
Troubleshooting
215
Preventive Maintenance
Checking
Protects Against Rust and Corrosion
Prevents
Foaming
Air Cleaner Service
217
218
218
250
Battery Service
251
249
Cooling System Service 252
Cooling Systems 252
Outboard
Maintaining
Storing an Engine
Aids Fuel Economy 218
Oil
Specifications 218
SAE Viscosity Grade 218
API Engine Oil Service Classification
Selecting the Proper Engine Oil
Muffler Service
Pressurized Liquid
246
248
Crankcase Breather Service
217
Cools Engine Parts 218
Seals Combustion Pressures
244
245
Changing
Lubricating Cables and Linkage
Spark Plug Service 247
Lubricates and Prevents Wear 216
Parts Clean
Oil Level and Condition
Oil
Lubricating Oil 216
Easy Starting 216
Keeps Engine
243
Engine Cleaning 243
215
215
Qualities of
Permits
243
253
Systematic Troubleshooting
Check the Easiest
254
Things
Verify the Fundamental Operating
Requirements 254
Checking RPM 255
Testing Compression 256
219
220
Engine Lubrication Systems 221
Two-Cycle Engine Lubrication 221
Four-Cycle Engine Lubrication 222
Oil Filter Systems 225
Low-Oil Warning and Shutdown Systems (LOS)
254
First
Testing Differential Pressure 257
Service Information
227
Engine
Identification
258
258
Contents
CHAPTER
Fuel
14
Service
System
the Fuel
Troubleshooting
Hard Starts
265
System
Checking Gravity-Fed
Supply
Checking a Fuel Pump 268
Other Checks
267
268
Carburetor
Adjustments 268
High Speed and Idle Mixture Adjustment 269
Carburetor Overhaul
Carburetor Removal
Carburetor
270
CHAPTER
270
Diaphragm Carburetor Disassembly
Cleaning the Carburetor 274
Engine Governor Service 280
Resetting a Centrifugal Governor System
Service
Service
and Piston
329
Cylinder Reconditioning 329
Cylinder Inspection 329
Cylinder Measurement 330
Reboring the Cylinder
Honing
280
281
the
331
332
Cylinder
Crankshaft and Main
Bearing Service
333
Inspecting the Crankshaft 334
Inspecting the Main Bearings 335
15
Piston
and Electrical
Ignition
17
Cylinder, Crankshaft,
273
Inspecting Float Carburetor Parts 274
Assembling Float-Type Carburetors 276
Inspecting Diaphragm Carburetor Parts 278
Assembling a Diaphragm Carburetor 279
CHAPTER
Engine Components 314
Organizing the Job 317
Disassembling the Engine's Mechanical
Systems 318
Removing the Valve Assemblies on an L-Head
Engine 324
Removing the Valve Assemblies on an
Overhead Valve Engine 325
269
Disassembly
Governor Adjustment
314
Removal of Exterior
266
Fuel
313
Engine Disassembly
265
265
Checking Air-Fuel Mixture
312
Engine Inspection
Engine Removal
System
Assembly Service 336
Checking Piston Clearance 337
Ring Side Clearance
291
Removing
Ignition System Service 291
Performing a Spark Test 291
337
Piston Pins
338
Measuring Piston Pins and Bosses 339
Inspecting Connecting Rods
339
292
SparkPlugs
Magneto System Service 295
Servicing Battery Ignition Systems
Electrical
System Service
Batteries
Wiring
297
Camshaft and Valve Train Service
Introduction
302
302
Switches and Solenoids
302
Checking the Charging and Starting System
302
CHAPTER
Inspection
311
311
Valve Service
343
Inspecting
Inspecting
Valve
and
Springs
343
343
343
Refacing Valves
16
341
Valves and Seats
Valve Guides
Engine Disassembly
341
341
Camshaft Service
Ammeters
Introduction
18
297
297
Circuits
CHAPTER
346
Valve Lifter Service
346
Valve Seat Service
348
Lapping Valves 350
Adjusting Valve Lifter-to-Stem Clearance 353
Servicing Overhead Valves, Seats, and
Guides
354
Small Gas
Rules for Safe
19
CHAPTER
Engine Reassembly and
Introduction
Break-In
357
Engine Components 357
Valves
(L-Head Engine) 358
Installing
Installing the Crankshaft, Camshaft, and
Internal
Governor Gear 358
Installing
Head
365
the Crankcase Breather and Valve
Cover
366
Adjusting Crankshaft Endplay and Installing the
Crankcase Cover
Reinstalling
Engine
External
Break-In
367
Engine Components
368
367
388
Design Features 388
Operator Safety 390
Starting and Safe Operation 391
String Trimmer and Brushcutter
Maintenance
the Piston and Rod Assembly 359
Overhead Valves 364
Installing
Installing
Installing the Cylinder
385
385
String Trimmers and Brushcutters
357
Reinstalling
Operation
Chain Saw Maintenance
394
Edger/Trimmers 396
Edger/Trimmer Features 397
Safety Features and Adjustments 397
Rules for Safe Operation 399
Edger/Trimmer Maintenance 400
Edger/Trimmer Storage 400
CHAPTER
21
Lawn and Garden Tractors
Tractor
Protect Children
404
404
Clothing
Operating
Transporting
a
Tractor Uses
403
403
Safety
Protective
Tractor
a
Safely
Tractor
404
405
405
Mowing and Mulching 405
Leaf Collecting 407
Plowing, Throwing, and Blowing Snow
Preparing Soil for Planting 409
Hauling
Rotary
a
Trailer
Broom
Chassis and
5
Sweeping
Applications
Lawn and Brush
Electrical
Equipment
373
Working Safely 373
Lawn Mowers
375
Rotary and Reel Mowers 375
Push-Type and Self-Propelled Mowers 376
Optional Features 376
Engine Starting 377
Minor Checks
379
General Maintenance
Chain Saws
Chain Saw
379
382
Designs
Safety Features
410
412
Variable-Speed Transmission 414
Hydrostatic Transmissions 415
20
CHAPTER
409
410
Steering
Transmissions
407
409
Engine Components
SECTION
Engines
382
382
Safety Systems
421
Safety Interlocks 422
Electric Start Systems 423
Recoil Start System 425
Testing Procedure for Operator Presence
System (Safety Seat) 426
Circuits for
Study
427
General Maintenance
Lubrication
427
434
Engine
Optional Oil Accessories
Air Filter
434
Mufflers
434
Engine Cleaning 435
Radiator Cleaning 435
434
Contents
Battery Maintenance 435
Sharpening and Balancing Mower Blades 435
Fueling and Refueling 436
Storing a Tractor 436
Removing a Tractor from Storage 436
CHAPTER
Operating Safely
Machine
439
Engine Controls 443
Operator Presence Controls
Electric Start Systems 445
Drive Systems 445
Career
Field
Opportunities in the Small Gas Engine
481
481
450
Manufacturer's Technician
General Maintenance
Service Representative
Engineer 483
451
Preventing Freeze-Up
Sen/icing Augers 451
451
Executive
482
483
483
Entrepreneur 483
452
Teacher
Storage 453
after
Starting
Storage 453
Off-Season
457
Maintain
Identification Numbers and Placards
458
Components and Parts
PWC
469
Fuel Filter Screens
470
Workplace 485
Appearance
Management 485
Decision
Making
486
and Problem
Ethical
Workplace
522
489
501
486
Behavior
Interpersonal Skills 487
Belonging to Organizations
Appendix
Solving
486
Customer Relations Skills
Index
485
485
Communication Skills
466
484
484
Professional
Professional Behavior
Glossary
470
Fuel Vent Check Valve
459
a
in the
Work Habits
Time
458
Fuel Filter 469
Certification Test?
on a
Succeeding
General Maintenance
484
Wno Can Ta/ce fhe Test?
457
Engines 462
Basic Engine Parts 462
Engine Cooling System 466
Jet Pump Propulsion System
New Engine Break-In 469
484
Get Certified?
W/?af /s
23
Personal Watercraft
484
Certification
Why
PWC Main
481
Manager 482
Sales Manager 482
General Manager 482
Throwing 451
of PWC
and
Service
Operation
Engine Starting 450
Types
24
Engine Service Technician
449
Snow Thrower
Introduction
476
Opportunities
Certification
443
474
476
Storage
Career
Heavy-Duty Snow Throwers 442
CHAPTER
471
CHAPTER
441
470
471
Cooling System Flushing 473
Jet Pump Water Inlet Screen 474
440
440
Midsize Snow Throwers
Lubrication
Pump Bleeding
Carburetors
PWC
Small Snow Throwers
Snow
Oil
Transporting PWC 475
Towing PWC to Shore
439
Types and Features
Skid Shoes
470
Oil Filter and Oil Filter Screen
External Lubrication Points
22
Snow Throwers
Sediment Bowl
487
487
486