Small Gas Engines : Fundamentals, Service, Troubleshooting, Repair, Applications

by Roth, Alfred C.

• ISBN13: 9781590701836
• ISBN10: 1590701836
• Edition: 8th
• Format: Hardcover
• Copyright: 2003-04-01
• Publisher: Goodheart-Willcox Pub

Summary

Provides practical information about the construction and operation of one-, two-, and three-cylinder; two- and four-cycle gasoline engines.

Table of Contents

Safety in the Small Gas Engine Shop	13	(8)
Shop Safety
Keep Work Area Clean
Handle Hazardous Materials Properly
Wear Proper Clothing
Maintain Adequate Ventilation
Use Hand Tools Properly
Use Power Tools Properly
Use Compressed Air Carefully
Lift Properly
Use Proper Electrical Wiring/Grounding Procedures
Operate Engines Safely
Be Prepared for Emergencies
Follow OSHA Requirements
Tools and Measuring Instruments	21	(24)
Wrenches
Pliers
Retaining Ring Pliers
Screwdrivers
Hammers
Punches
Cold Chisels
Gear Pullers
Probe and Pickup Tools
Vise
Cleaning Tank
Measuring Instruments
Micrometers
Cleaning and Calibrating a Micrometer
Using a Micrometer
Reading The Standard Micrometer
Reading a Vernier Micrometer
Digital Micrometers
Micrometer Depth Gauges
Vernier Calipers
Reading a Vernier Caliper
Telescoping Gauges
Small Hole Gauge
Thickness Gauges
Valve Spring Tension Tester
Combination Square
Dial Indicator
Screw Pitch Gauge
Fasteners, Sealants, and Gaskets	45	(22)
Threaded Fasteners
Set Screws
Self-Tapping Screws
Bolts
Nuts
Lock Nuts
Bolt and Nut Terminology
Bolt Grades
Thread Types
Thread Fit
Thread Designations
Tightening and Loosening Threaded Fasteners
Tightening to Specific Torque Settings
Chasing Threads
Tapping New Threads
Rules for Hand Tapping
Threading With a Die
Washers
Pins
Cotter Pins
Clevis Pins
Dowel Pins
Straight Pins
Grooved Pins
Taper Pins
Retaining Rings
Keys
Thread Adhesives
Sealants
Antiseize Compounds
Gaskets
Engine Construction and Principles of Operation	67	(14)
Gasoline Engines
Simple Engine in Operation
Gasoline
Gasoline Must Burn Quickly
Fuel is Atomized
Explosion Must be Contained
Further Improvement
Basis for an Engine
Cylinder Block
Crankshaft and Crankcase
Pistons
Connecting Piston to Crankshaft
Intake and Exhaust Ports
Poppet Valves
Valve Spring Assembly
Valve Lifter or Tappet
Camshaft
Flywheel
Two-Cycle and Four-Cycle Engines	81	(14)
Small Engine Identification
Four-Stroke Cycle Engine
Intake Stroke
Compression Stroke
Power Stroke
Exhaust Stroke
Valve Timing
Lubrication
Two-Stroke Cycle Engine
Variations in Design
Principles of Operation
Intake into Crankcase
Fuel Transfer
Ignition-Power
Exhaust
Scavenging and Tuning
Rotary Disc Valve Engine
Reed Valve Engine
Four-Cycle Engine vs. Two-Cycle Engine
Measuring Engine Performance	95	(18)
Basic Terminology
Engine Bore and Stroke
Engine Displacement
Compression Ratio
Force
Work
Power
Energy
Horsepower
Horsepower Formula
Kinds of Horsepower
Brake Horsepower
Indicated Horsepower
Frictional Horsepower
Rated Horsepower
Corrected Horsepower
Torque
Torque is not Constant
Torque and Horsepower
Volumetric Efficiency
Practical Efficiency
Mechanical Efficiency
Thermal Efficiency
Fuel and Emission Control Systems	113	(16)
Engine Fuels
Gasoline
Liquefied Petroleum Gas and Natural Gas
Combustion of LPG
Advantages of LPG
Disadvantages of LPG
Kerosene and Diesel Fuels
Two-Cycle Fuel Mixtures
Tanks, Lines, and Fittings
Fuel Filters
Fuel Pumps
Mechanical Fuel Pumps
Impulse Diaphragm Fuel Pumps
Pressurized Fuel System
Vapor Return Fuel Systems
Emission Controls
Exhaust Emissions
Environmental and Health Impact of Small Engine Emissions
Proposed Phase 1: Small Spark-Ignition Engine Rule
Role of the Consumer
Carburetion	129	(24)
Principles of Carburetion
Air-Fuel Mixture
Carburetor Pressure Differences
Vacuum
Atmospheric Pressure
Venturi Principle
Types of Carburetors
Float-Type Carburetors
Float Bowl Ventilation
Choke System
Throttle System
Load Adjustment
Acceleration System
Acceleration Well
Economizer Circuit
Idling Circuit
Part-Throttle, Full-Throttle Sequence
Primer
Diaphragm-Type Carburetors
Diaphragm Carburetor Operation
Manual Throttle Controls
Governor Throttle Controls
Types of Governors
Governor Features
Air Cleaners and Air Filters
Oil-Wetted Air Cleaner
Dry-Type Air Cleaner
Dual Element Air Cleaners
Ignition Systems	153	(28)
Basic Ignitions System Operation
Fundamental Electrical Principles
The Electron Theory
Electrical Units of Measurement
Ohm's Law
Magnetism
Magnets and Electricity
Ignition Coil
Spark Plugs
Spark Plug Heat Transfer
Measuring Spark Plug Temperature
Types of Electrodes
Switching Devices
Breaker Points
Electronic Switching Devices
The MBI Magneto System
The MBI Magneto Cycle
The Stop Switch
Ignition Advance Systems
Dwell and Cam Angle
Electronic Ignition
Operation of Capacitive Discharge Ignition (CDI) System
Operation of Transistor Controlled Ignition (TCI) System
Magneto Ignition Systems Compared
Battery Ignition Systems
High Voltage Secondary Current
Auto-Transformer Type Ignition Coil
The Lead-Acid Battery
Lubrication Systems	181	(16)
Principles of Lubrication
Friction
Preventing Wear Due to Friction
Lubricating Oil
Permits Easy Starting
Lubricates and Prevents Wear
Protect Against Rust and Corrosion
Keeps Engine Parts Clean
Cools Engine Parts
Seals Combustion Pressures
Prevents Foaming
Aids Fuel Economy
Oil Selection
SAE Viscosity Grade
API Engine Oil Service Classification
Engine Lubrication
Two-Cycle Engine Lubrication Systems
Four-Cycle Engine Lubrication Systems
Splash Lubrication System
Constant Level Splash System
Ejection and Barrel Pumps
Positive Displacement Oil Pumps
Full-Pressure Lubrication Systems
Oil Filter Systems
Bypass Systems
Shunt Filter Systems
Full-Flow Filter Systems
Cooling Systems	197	(10)
Principles of Engine Cooling
How Air Cooling Works
How Exhaust Cooling Works
How Water Cooling Works
Water Pumps
Outboard Water Circulation Systems
Observing Thermostat Operation
Radiators
How Oil Cooling Works
Preventive Maintenance and Troubleshooting	207	(16)
General Preventive Maintenance
Keeping Engines Clean
Checking Oil Level and Condition
When to Change Oil
Changing Oil
Mixing Oil and Fuel
Air Cleaner Service
Crankcase Breather Service
Muffler Service
Maintaining Water Cooling Systems
Systems Cooled with Salt Water
Storing Water-Cooled Engines
Systematic Troubleshooting
Check the Easiest Things First
Verify the Fundamental Operating Requirements
Check RPM
Test Compression
Test Differential Pressure
Service Information
Troubleshooting Charts
Tolerances and Clearances
Torque Specifications
Fuel System Service	223	(22)
Troubleshooting the Fuel System
Fuel Pump
Carburetor Adjustments
High Speed and Idle Mixture Adjustment
Testing Two-Cycle Engine Reeds
Carburetor Overhaul
Carburetor Removal
Carburetor Disassembly
Inspection of Parts
Float-Type Carburetor Repair
Assembling Float-Type Carburetors
Engine Priming
Troubleshooting Float-Type Carburetors
Diaphragm Carburetor Repair
Assembling Diaphragm Carburetors
Troubleshooting Diaphragm Carburetors
Engine Governor Adjustments
Ignition System Service	245	(32)
Ignition System Service
Spark Plugs
Spark Plug Removal
Analysis of Used Spark Plugs
Cleaning Spark Plugs
Gapping Spark Plugs
Spark Plug Installation
Ignition Testing Procedure
Magneto Service
Removing the Flywheel
Inspecting the Flywheel
Testing Ignition System Components
Adjusting Breaker Point Ignition Systems
Servicing Battery Ignition Systems
Batteries
Wiring
Ammeters
Switches
Checking the DC Starter-Generator Circuit
Commutators and Brushes
Maintaining an Alternator
Alternator Output Tests
Voltage Regulator Service
Distributors
Engine Inspection, Disassembly, and Cylinder Reconditioning	277	(10)
Engine Inspection
Engine Disassembly
Organizing the Job
Cylinder Reconditioning
Cylinder Inspection
Cylinder Measurement
Reboring the Cylinder
Honing the Cylinder
Piston and Piston Ring Service	287	(16)
Piston and Piston Ring Service
Piston Construction
Piston Fit
Cam-Ground Pistons
Piston Thrust Surfaces
Piston Head Size
Piston Head Shape
Piston Ring Design
Piston Ring Construction
Piston Ring Types
Compression Rings
Oil Control Rings
Ring Tension
Ring Movement
Ring Side Clearance
Ring End Gap
Rings and Cylinder Walls
Piston Damage
Piston Ring Wear-In
Piston Pins
Removing Piston Pins
Measuring Piston Pins and Bosses
Rod, Bearing, Crankshaft, Valve, and Camshaft Service	303	(34)
Connecting Rods and Bearings
Friction-Type Rod Bearings
Antifriction Bearings
Rod Bolt Locking Devices
Crankshaft
Crankshaft Balance
Crankshaft Main Bearings
Crankshaft Clearances
Measuring Bearing Clearance
Crankcase Seals
Valve Service
Removing Valve Assembly
Inspecting Valves and Seats
Inspecting Valve Springs
Valve Guides
Inspecting Valve Guides
Valve Guide Reaming
Alternate Valve Guide Replacement
Valve Seat Angle and Width
Lapping Valves
Valve Seat Inserts
Removing a Valve Seat Insert
Installing New Valve Insert (Cast Iron Block)
Installing New Valve Insert (Aluminum Alloy Block)
Valve Lifter-to-Stem Clearance
Refacing Valves
Adjusting Valve Clearance
Overhead Valve Systems
Overhead Valve System Disassembly
Removing Valves
Servicing Overhead Valves, Seats, and Guides
Installing Overhead Valves
Installing Cylinder Head
Installing Rocker Arms
Adjusting Valve Clearance
Ports, Reeds, and Rotary Valves
Camshafts and Gears
Automatic Compression Release
Lawn Equipment	337	(34)
Working Safely
Lawn Mowers
Knowing Mowing Program
Purchasing Considerations
Push-Type and Self-Propelled Mowers
Two-Cycle or Four-Cycle Engines
Optional Features
Conveniences
Engine Starting
Blade Brakes
Procedure for Starting an Engine
Minor Checks
General Maintenance
Blade Sharpening
Spark Plugs
Air Cleaners
Changing Oil
Muffler Replacement
V-Belts
Storing a Power Lawn Mower
Removing a Mower From Storage
Chain Saws
Purchasing Considerations
Safety Features
Rules for Safe Operation
Avoiding Kickback
Chain Saw Maintenance
Fuel and Carburetor
Cylinder Fins
Air Cleaner (Filter)
Fuel Filter
Lubrication
Muffler
Spark Plug
Guide Bar
Storage
String Trimmers and Brushcutters
Purchasing Considerations
Operator Safety
Starting and Safe Operation
String Trimmer and Brushcutter Maintenance
Edger/Trimmers
Purchasing Considerations
Safety Features and Adjustments
Rules for Safe Operation
Edger/Trimmer Maintenance
Edger/Trimmer Storage
Lawn and Garden Tractors	371	(38)
Operating Safely
Protect Children
Protective Clothing
Considerations While Mowing
Avoid Tipping the Mower
Parking a Tractor Safely
Transporting a Tractor
Purchasing Considerations
Mowing and Mulching
Proper Mowing
Mower Deck and Blade Adjustment
Proper Mulching
Leaf Collecting
Plowing, Throwing, and Blowing Snow
Transmissions
Variable Speed Transmission
Hydrostatic Transmissions
Hydrostatic Transmission Fluid Flow
Electrical Safety Systems
Safety Interlocks
Electric Start Systems
Testing the Interlock Electrical System
Testing the Safety Reverse Switch
Testing the Solenoid on Electric Start Tractors
Recoil Start System
Testing the Interlock System on the Recoil Start System
Testing the Safety Reverse Switch on the Recoil Start System
Testing Procedure for Operator Present System (Safety Seat)
Disassembly Procedure
Assembly Procedure
Circuits for Study
General Maintenance
Spark Plugs
Engine Lubrication
Air Filter
Mufflers
Engine Cleaning
Radiator Cleaning
Battery Maintenance
Sharpening and Balancing Mower Blades
Fueling and Refueling
Storing a Tractor
Removing a Tractor from Storage
Snow Throwers	409	(22)
Operating Safely
Protect Children
Preparation for using a Snow Thrower
Using a Snow Thrower
Maintenance and Storage
Purchasing Considerations
Machine Size and Type
Small Snow Throwers
Mid-Size Snow Throwers
Heavy-Duty Snow Throwers
Engine Controls
Electric Starting
Drive Systems
Track Drive Snow Thrower
Skid Shoes
Skid Shoe Adjustment
Operator Presence
Snow Thrower Operation
Engine Starting
Snow Throwing
General Maintenance
Spark Plugs
Snow Thrower Engine Fuel
Four-Cycle Engine Lubrication
Air Filter
Muffler
Preventing Freeze-Up
Auger and Auger Gear Box Lubrication
Lubrication
Off-Season Storage
Starting After Storage
Personal Watercraft	431	(38)
General Boating Terms
Operation Precautions
Preride Checklist
Launch Ramp Etiquette
Identification Numbers and Placards
Signs, Symbols, Buoys, and Markers
Courtesy and Common Sense
Navigational Rules
Purchasing Considerations
PWC Engines
Basic Engine Parts
Two-Stroke Cycle Engine
Engine Cooling System
Jet Pump Propulsion System
New Engine Break-In
General Maintenance
Transporting PWC
PWC Storage
Career Opportunities and Certification	469	(5)
Engine Mechanic
Service Manager
Sales Manager
General Manager
Technician
Sales Representative
Engineer
Executive
Entrepreneur
Teacher
Certification
Why Get Certified?
What is on a Certification Test?
Who may take the Test, and Where?
Appendix	474	(30)
Glossary	504	(10)
Index	514