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All engine parts and functions can be divided into five (5) systems.
1. Compression
2. Fuel
3. Electrical
4. Cooling
5. Lubrication
2
Compression System
The compression system includes all of the parts that create,
contain and manage the engine compression.
Parts
Block Valves
Piston Valve springs
Piston rings Connecting rod
Cylinder head Crankshaft
Cylinder bore Gaskets
3
Adiabatic Process
4
Compression Problems
• Two possible problems:
– Inadequate compression
– Excessive compression
• Inadequate compression
– Commonly caused by leaks
– Maverick air: undesirable air entering the engine through leaks.
• Excessive compression
– Harder starting
– Engine performance problems
– Detonation
– Preignition
5
Detonation
• An undesirable engine condition in which pockets of fuel start to
burn at about the same time as the spark plug fires.
• Multiple pressure fronts collide
• Sometimes called knocking, spark knock or pinging.
• Causes large pressure differentials in the combustion chamber.
• Can cause engine damage.
Causes
1. Increased compression
2. High temperatures
3. Lean fuel/air mixture
4. Advanced ignition timing
5. Lower octane fuels
Prevention
Remove any cause
6
Preignition
• Fuel starts to burn before the spark plug fires.
• Decreases engine performance and produces and audible
pinging or knocking sound in the engine.
• Increases the peak combustion pressure in the cylinder.
• Increases internal temperature.
• Will cause engine parts like pistons, connecting rods and
crankshafts to fail.
Causes
1. An overheated spark plug
2. Glowing carbon deposits
3. Over heated exhaust valve
4. A sharp edge in the combustion chamber or on top of a piston
5. Sharp edges on valves that were reground improperly
6. A lean fuel mixture.
7
Valves
• Control flow of air-fuel into and exhaust gases out of the cylinder.
• Types -- Rotation can be enhanced
– One piece through use of valve rotators
– Two piece
– Projection-tip
• Valve hardfacing
• Valve stem surface treatments
• Valve head design
– Interference interface angle
– Face can be resurfaced
• Valve dynamics
– Most valves rotate slightly each
time they open and close.
– Rotation improves temperature
distribution
– Rotation helps clean valve
interface.
8
Valve Guide
9
Valve Seats
10
Pistons
11
Piston--cont.
12
Ring Grooves
13
Piston Rings
• The job of the rings is to fill the
space between the piston and the Compression
cylinder walls.
• The combustion chamber is sealed
by a thin film of oil between the
rings and the piston and between
the rings and the cylinder wall.
• Usually constructed of cast iron.
• The total number of rings per Oil
piston can vary, but there are three
types of rings on each piston.
Wiper
14
Piston Rings--cont.
• Compression
Compression
– Subject to to greatest amount
Ring
of chemical corrosion and
highest temperatures.
Wiper Ring
– Transfers 70% of combustion
heat from piston to cylinder Oil Ring
walls.
• Wiper ring
–Meters oil film on cylinder walls
–Must be installed correctly.
• Oil ring
– Constructed of two thin rails with holes or
slots cut inbetween.
– Has the highest pressure against the
cylinder wall of the three rings.
15
Cylinder Bore
• Three types
– Cast aluminum
– Cast aluminum with cast iron sleeve
– Cast iron
• Usually use a cross-hatch finish to
improves ring lubrication
16
Crankcase Breather
17
Compression Release
18
Fuel System
Introduction
• The function of the fuel • Common Small Engine Fuels
system is to store, meter, include:
atomize, vaporize and start – Gasoline
the mixing with the air. – Diesel
• Fuel system parts: – LPG
– Supply (tank) – LNG
– Lines
– Valves
– Filter
– Pump
– Carburetor
20
Combustion Chemistry
21
Volatility
• Volatility is the propensity of a liquid to become a vapor.
• The volatility of gasoline changes with the seasons.
• Vapor lock: the stoppage of fuel flow caused by internal pressure of fuel
vapor bubbles.
22
Vaporization
23
Oxygenated Gasoline
Additive Function
Anti-icers Prevent fuel from freezing in lines
Anti-oxidants Reduce hum formation in stored gasoline
Corrosion inhibitors Minimize corrosion in fuel system
Detergents Reduce/remove fuel system deposits
Fluidizer oils Control intake valve deposits
Lead replacement additives Minimize exhaust valve seat wear
Metal deactivators Minimize effects of metals present in gasoline
25
Engine Emissions--cont.
• Carbon Monoxide
– Product of incomplete combustion
– The richer the air-fuel ration, the more CO is produced.
• Hydrocarbon emissions
– Product of incomplete combustion
– Contains gasses not readily oxidized at normal engine operating
temperature. Methane, ethane, acetylene, etc.
• Oxides of Nitrogen
– Nitric oxide (CO)
– Nitrogen dioxide (CO2)
– Dinitrogen monoxide (N2O)
26
Octane
27
Octane--cont.
28
Octane--cont.
29
Fuel System--Carburetor
30
Introduction
31
Four Fluid Principles
32
Carburetor Operating Principles
• A carburetor is a tube attached to the intake port of the engine
and open to the atmosphere.
• On the intake stroke a volume with little to no pressure develops
in the combustion chamber.
– Atmospheric pressure outside the engine--14.7 psi
– Low pressure in the combustion chamber--0 to slight vacuum.
• Result: air flows from outside to inside the engine.
33
Carburetor Operating Principles
• As the air flows through the carburetor, the fuel is metered,
atomized and vaporized.
• To have available fuel, the carburetor must have a source of
fuel.
• In the float type carburetor this source is the fuel bowel.
34
Carburetor--Venturi
• A pressure difference is also needed to cause the fuel to flow from
the fuel bowel into the air stream.
• This is accomplished using a venturi, Bernoulli’s principle and a
tube connecting the mouth of the venture to the fuel bowel.
• This is a functioning carburetor and it will operate an engine as
long as it has a constant load and constant speed.
35
Carburetor-Throttle
36
Throttle--cont.
• When the throttle is in the wide
open position, there is maximum
air flow through the carburetor.
• To provide a means to adjust
maximum fuel flow, a needle
valve was added to the orifice in
the emulsion tube.
37
Carburetor-Choke
38
Carburetor-Choke--cont.
39
Carburetor-Idle Circuit
• The addition of a choke/primer
improved engine starting, but
this carburetor still has a
problem if the engine needs to
idle.
• When the throttle is in the idle
position, almost closed, the area
with greatest restriction, and
greatest pressure difference,
moves from the venturi to the
area between the throttle plate
and the wall of the tube.
• This problem was solved with
the addition of an idle circuit and
idle needle valve.
40
Carburetor-Float
41
Complete Carburetor -
Old Style
Carburetor-Additional Features
43
Carburetor Designs
44
Three Types of Briggs & Stratton Carburetors
Vacu-jet
45
Three Types of Briggs & Stratton Carburetors--cont.
Pulsa-jet
• Carburetor is attached to the top
of fuel the fuel tank.
• Two tubes are used.
• Primary is attached to fuel pump
to pump fuel from the main tank
to the secondary tank.
• Secondary tube draws fuel from
secondary tank to the venturi.
• The fuel pump is designed with
excessive capacity, and the
secondary tank has a drain
• The fuel in the secondary tank
stays at a constant level.
• Not included in latest B & S
repair manual.
46
Pulsa Jet Parts
A. Fuel pump
B. Primary fuel tube G. Secondary fuel tank
C. Primary fuel tank H. Secondary fuel tube
D. Primary fuel tube check valve I. Secondary tank drain
E. Fuel screens J. Choke
F. Secondary fuel tube check valve K. High speed needle valve
L. Air horn (inlet)
47
Three Types of Briggs & Stratton Carburetors--cont.
Flow-jet
48
Fuel Injection
• Fuel injection is the
preferred method of
metering the fuel in modern
engines.
• Cost has limited use for
small gas engines.
• BOSH has developed a
system.
49
Fuel System---Governor
Introduction
51
Pneumatic Governor Operation--
Engine Not Operating
1. When preparing to start an
engine the throttle will be
set to the run (choke)
position.
2. The engine is stopped--
there is no air flow.
3. No air flow means the
governor will not be
producing any force.
4. In the choke position the
the governor spring
produces the maximum
force.
5. The throttle is wide open.
52
Pneumatic Governor Operation--Top No Load Speed
When the force on the governor linkage equals the force produced by
the spring, the throttle is held in a constant position and the engine runs
at a constant speed.
53
Pneumatic Governor Operation--Engine Under Load
• When the engine load increases the
engine speed is reduced.
• Less speed = Less air flow
• Less air flow = less force
• When the force produced by the
governor decreases, the force produced
by governor spring is greater and the
spring opens the throttle.
• Opened throttle = more fuel
• More fuel = more speed
• More speed = more air flow.
• More air flow = more force
• The governor and throttle spring are
constantly wrestling for control of the
throttle.
54
Mechanical Governor
• The mechanical governor
operates on the same
principles as the pneumatic
governor.
• The difference is that the force
to balance the governor spring
is produced by rotating weights
not a pneumatic arm.
• The weights are rotated by the
governor gear which meshes • The weights are mounted on a
with the crankshaft gear.
lever arm that pushes the
• As the governor spins the governor shaft up as the weights
governor weights move out move out.
from the center shaft. • The higher the speed the greater
the force produced.
55
Mechanical Governor--cont
56
Electrical System
Introduction
58
Electrical Terms
60
Terms-cont.
• Circuit: A complete path that
controls the rate and
direction of electron flow.
The parts of a circuit
include:
– Voltage source
– Pathway for electrons
– Load or loads
– Controls
• Current: the flow of electrons past a point in the circuit. It may
be alternating or direct.
–Alternating current: the flow of electrons reverses direction at regular
intervals.
–Direct current: the flow of electrons is in one direction.
• Polarity: the state of an object as negative or positive.
• Amperes: the unit of measure for current flow.
61
Alternating Current
62
Direct Current
63
Resistance
• Resistance is opposition to the flow of electrons.
• All circuit components have some resistance.
• Forcing electricity through a resistance uses energy. The
energy is lost as heat.
• Resistance is measured in units of Ohms ().
• The amount of current flow and resistance in a circuit
determines the wire size for the circuit.
Wire Size and Resistance
AWG Number Diameter /1000 ft (68 oF)
12 80.8 1.6
14 64.1 2.5
16 50.8 4.0
18 40.3 6.4
20 32 10.2
22 25.35 16.2
64
Circuits
65
Circuits--Series
66
Circuits--Parallel
67
Circuits--Series-Parallel
68
Circuit--Short Circuit
69
Ohm’s Law
V
I=
R
70
Magnetism
• “Magnetism is an atomic level force derived from
the atomic structure and motion of certain orbiting
electrons.”
• A Magnet field is an area of magnetic force created
and defined by lines of magnetic flux surrounding a
material in three dimensions.
• Magnetic flux: invisible lines of force in a magnetic
field.
• Magnet: a material that attracts iron, cobalt or nickel
and produces a magnetic field.
– Permanent
– Temporary
71
Induction
72
Five Small Gas Engine Electrical Systems
• Small engines may have one or more of five (5) electrical
systems.
1. Charging
2. Ignition
3. Starting
4. Accessories
5. Safety
73
1. Charging System
• Charging systems produces electrical energy to operate
accessories and to replace electrical energy taken from a
battery.
• Two different systems can be used.
– Generator
– Alternator
• Generator produces DC.
• Alternator produces AC. When DC is needed the current is
converted, rectified.
• Some small engines use a stationary coil close to the flywheel.
When the flywheel magnets pass by the coil they induce a
current in the coil.
• Other systems use stationary magnets and a rotating coil.
• Conductors are sized for circuits with low current flow.
74
Charging System--cont.
75
2. Ignition System
• The ignition system provides a high voltage spark in the
combustion chamber at the proper time.
• Two types of ignition systems
– Battery
– Magneto
• Battery
– Battery systems transforms the battery voltage and fires the spark
plug at the correct time.
• Magneto
– Magneto systems must produce the current, transform the voltage
and time the spark plug.
– Most small engines use the magneto system
• Two types of magneto systems:
– Breaker point ignition
– Solid state (electronic) ignition
76
2. Ignition System-cont.
77
Ignition system--Magneto Ignition
• Magnets
• Points (Breaker point only)
• Trigger coil
• Conductors
• Spark plug
• Condenser (Breaker point only)
• Lamination stack
• Primary winding
• Secondary winding
78
Magneto Ignition system
• As magnets in
flywheel rotate past
the magneto, the
points close.
• The magnetic flux of
the magnets in the
flywheel induces a
current in the
primary coil.
79
Magneto Ignition System- Firing Spark Plug
• When the
breaker points
open the
magnetic field
produced by the
current in the
primary winding
collapses.
80
Magneto Ignition system
81
Differences Between Breaker Point and Solid
State Ignition System
82
3. Starting System
83
Staring Systems--cont.
• Single Switch
– For systems with a single
switch the switch must be able
to switch the current for the
starting motor.
– Requires a heavy duty switch
because starter motors drawn
a lot of current.
• Solenoid
– In this system the ignition
switch only switches the
current that powers the
solenoid.
– The solenoid has heavy duty
contacts for switching the
current to the starting motor.
84
4. Accessories
85
5. Safety
86
Questions
87