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

by: Roth, Alfred C.

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

by: Roth, Alfred C.

ISBN 13:
9781590701836
ISBN 10:
1590701836
Edition: 8th
Format: Hardcover
Copyright: 04/01/2003
Publisher: Goodheart-Willcox Pub
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Summary

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

Safety in the Small Gas Engine Shop

(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

(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

(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

(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

(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

(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

Amazon no longer offers textbook rentals. We do!

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

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

9781590701836

1590701836

Summary

Table of Contents

Supplemental Materials

Write a Review

Amazon no longer offers textbook rentals. We do!

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

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

9781590701836

1590701836

Summary

Table of Contents

Supplemental Materials

Write a Review

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