small engines members manual - 4-h alberta

Project GuideSMALL ENGINES

cindy.kremer

Typewritten Text

The 4-H Motto “Learn To Do By Doing.”

The 4-H Pledge I pledge

My HEAD to clearer thinking, My HEART to greater loyalty, My HANDS to larger service, My HEALTH to better living, For my club, my community and my country.

The 4-H Grace (Tune of Auld Lang Syne)

We thank thee, Lord, for blessings great On this, our own fair land. Teach us to serve thee joyfully, With head, heart, health and hand.

Developed by Elizabeth Webster, M.Ag.

printed August 1999

M-3

Table of Contents

Small Engine Member’s Guide

IntroductionMember Information....................................................................M-7Objectives ......................................................................................M-8To Get the Most From This Project ........................................M-9Observation - Your Most Important Tool............................. M-11Tips From Other 4-H Members and Leaders.......................M-13Working on a Small Engine ........................................................M-15Achievement Day Requirements ..............................................M-16Resources for Learning.............................................................. M-18

Section OneSafety and the Small Engine Project..................................... M-21Who Does an Unsafe Worker Affect? ................................. M-22Safety Steps............................................................................... M-23Safety Contract ......................................................................... M-24Safety #1 - Word Search ....................................................... M-25Safety #2 - Word Search....................................................... M-26Safety Logos ............................................................................... M-27Protect Yourself ........................................................................ M-29Safety Tips for Using Tools ..................................................... M-31

Section TwoHow Small Engines Work Checklist ....................................... M-33What Does an Engine Need to Run? ...................................... M-34Differences Between Two and Four Cycle Engine ............. M-35How Small Engines Work - Crossword .................................. M-37How Small Engines Work - Word Search ............................ M-38

Table of Contents

M-4

Table of Contents


Section Two cont’dChecking Compression Checklist............................................. M-39Ignition Troubleshooting Chart .............................................. M-40Compression - Crossword .........................................................M-41

Section ThreeParts of a Small Engine Checklist .......................................... M-43Nameplate Checklist ................................................................. M-45Owner’s Information Card Checklist..................................... M-45

Section FourCare and Handling Checklist .................................................... M-47Care and Handling - Crossword ............................................... M-48

Section FiveCleaning - A Generic Checklist ................................................ M-49Degreasing the Crankcase - Checklist .................................. M-50Cleaning Engine - Crossword.................................................... M-52Cleaning Engine - Word Search .............................................. M-53

Section SixCooling System Checklist ......................................................... M-55

Section SevenAir Cleaner Checklist ................................................................ M-57Air Cleaner Checklist - Oil Bath Type .................................. M-59Air Cleaner Checklist - Dry Filter Type ............................... M-60

Table of Contents

M-5

Table of Contents


Section EightFuel Strainers Checklist - Screen Type................................M-61Fuel Strainers Checklist - Bowl Type ................................... M-62

Section NineCrankcase Breathers Checklist .............................................. M-65

Section TenLubrication Checklist ................................................................ M-67Lubrication - Crossword ........................................................... M-69Lubrication - Word Search...................................................... M-70

Section ElevenSpark Plugs Checklist ................................................................. M-71Review Checklist for Spark Plugs........................................... M-73Spark Plugs - Crossword........................................................... M-74Spark Plugs - Word Search ..................................................... M-75

Section TwelveCarburetor Checklist ................................................................ M-77Carburetor - Crossword ........................................................... M-78Carburetor - Word Search...................................................... M-79

Section ThirteenServicing Battery Checklist I................................................. M-81Servicing Battery Checklist II ............................................. M-82Servicing Battery Checklist III ........................................... M-83Safety Tips: Working Around Batteries .............................. M-84Battery - Crossword.................................................................. M-85Battery - Word Search ............................................................ M-86

Table of Contents

M-6

Table of Contents


Section FourteenSafety Tips: Working Around Fuel/Oil ................................ M-87Fuel System Troubleshooting Chart ..................................... M-89Fuel - Crossword .........................................................................M-91Fuel - Word Search ................................................................... M-92

Section FifteenEngine Start-up and Shutdown Checklists .......................... M-93

Section SixteenStorage Checklist ...................................................................... M-97Storage - Crossword ................................................................. M-99Storage - Word Search.......................................................... M-100

Appendix AThe Twelve Days of 4-H.......................................................... M-101

Glossary ...................................................................................... M-105

M-7

Introduction


Member Information

Member’s name Year

Address

Postal Code BirthdateAge

Name of Parent or Guardian

Name of Club

Name of Club Leader

Name of 4-H Region

Number of Years in 4-H Number of Years in Project

Project Information

Type of Engine (if one is owned)

Model Type and Serial Number

Cost

M-8

Introduction


Objectives

The club member will:gain knowledge in operation, care and maintenance

of small engines

develop and demonstrate safe work habits

gain knowledge and skill in use of tools and chemicals

related to small engines

demonstrate proper care and maintenance of a work area

develop skills in leadership, problem-solving, communication,

planning, assessment, decision-making, evaluation, money

management and time

M-9

Introduction


To Get The Most From This Project

Attend regularly. You won’t miss important information,

shop time or fun.

Listen, then ask questions. You will learn from other

members as well as your leaders.

Work on your small engine regularly so you become familiar

with it and the tools required. Your skill will grow.

Keep organized. Keep parts together. Label tools.

Take pictures of your engine, before, during and after

working on it. Pictures are good records.

Keep simple records as you go along. Jot notes in a pocket

size notebook as you work. Transfer important material to

your project record book.

M-10

Introduction


To Get The Most From This Project

Work safely. If you hurt yourself or another person all the

fun stops.

Let your parents know what you’re working on. They might

be able to help or encourage you.

Ask for help if you need it. Offer help when you can.

Be patient with yourself and others. We are all learning.

M-11

Introduction


Observation - Your Most Important Tool!

What can you see?What is missing?

is it running?

smoke - volume, colour?

cracks?

worn or missing parts?

any parts discoloured by heat?

how good a job is it doing?

Listen

is it rough, smooth, intermittent?

varying?

vibration?

is something hitting?

M-12

Introduction


Observation - Your Most Important Tool!

Feelvibration, roughness?

power level?

heat?

grit in the oil?

Smellexhaust?

leaks?

burning?

M-13

Introduction


Tips From Other 4-H Members And Leaders

Always take old parts with you when ordering or

picking up new parts

Lay parts out in order of disassembly and keep them in

order. We use numbered zip-lock bags and put only a few

parts in each bag.

Draw a sketch of an assembly before or while you’re

working on it. This will help when you put it back together.

It will also help develop your observation skills.

Cut open a large cardboard box and flatten it to protect

the garage or shop floor.

If a Phillips screw is extremely tight, put a bit of valve

lapping compound on the screwdriver tip. It’ll grip better.

M-14

Introduction


Tips From Other 4-H Members And Leaders

Use an old muffin tin to keep nuts, bolts, washers or

tiny parts together. You can label the contents with

tape if necessary.

Test the simplest and most probable cause of trouble first.

Most small engine service and repair jobs can be done

without taking the whole engine apart!

M-15

Introduction


Working on a Small Engine

! Observe Engine(use 4 senses)see, listen, feel, smell

"" """OK

Engine runsNOTOK

# Compare Engine’sperformance towhat it should be.

$ Test

""""""""""

"""" """"" "

"""""

% Service or repair as needed.

& Trouble ShootWhat is/are problem(s).

"" """"" """

"" """"""""

"" """

M-16

Introduction


Achievement Day Requirements

Many of the requirements for Achievement Day are met during the club

year. E.G. member explained and demonstrated how to clean an engine.

Initial the member’s records at time of completion.

Achievement Day can be a “Recognition/Celebration Day” if checking of

work and records is done regularly during the year. Checking of record

books could be done by a parent helper who knows what the

requirements are.

Junior1. Attends and participates in at least 70% of all club activities.

2. Displays completed records for meeting attended.

3. Displays engine (clean) worked on during year.

4. Scores a pass on safety quiz/questions administered by

leaders or other adults.

5. Correctly identifies at least five tools displayed.

6. Differentiate between two and four cycle engines.

M-17

Introduction


Achievement Day Requirements

Intermediate1. Attends and participates in at least 70% of all club activities.

2. Displays completed records for meeting attended.

3. Displays engine (clean) worked on during the year.

Answers questions regarding work done on engine.

4. Display/exhibit/poster of hazards in the work place, emphasizing

accident prevention.

5. Identifies correctly at least 10 tools displayed.

Senior1. Attends and participates in at least 70% of all club activities.

2. Thorough record of year’s work on a small engine including: before

and after photos, settings, record and costs of work done, hours,

performance of engine.

3. Display and answer questions about small engine worked on.

4. Exhibit of at least five worn or damaged parts, labelled as to cause

of damage and the preventative maintenance or care recommended.

M-18

Introduction


Resources for Learning

Peoplefarmers

parents

local small engine repair people

former 4-H’ers

(especially those in related field of study or line of work)

mechanics

oil field workers

people who use a lot of small engines in the community

Places and Organizationsagricultural societies, exhibitions

colleges, universities

museums

private industry

snowmobile clubs

M-19

Introduction


Resources for Learning

Thingsmagazines, books, newsletters

owners’ manuals

advertisements

comics and cartoons

video tapes

catalogues

sales displays

Web Sites and News Groups1. Briggs & Stratton

http://www.BriggsandStratton.com/

2. Kohler Engines page.

http://www.kohlerco.com/powersystems/engines/index.html

M-20

Introduction


Q. What do you serve at a 4-H Small Engines party?

A. Nuts and Bolts.

3. Tecumseh Engines page.

http://www.tecumseh.com/engines.htm

4. Jacks Small Engines & Generator Service, LLC. Web Div.

http://www.jackssmallengines.com/index.htm

“the largest online lawn mower & generator parts supplier”

Jokes

M-21

Section One


Safety in the Small Engine Project

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M-22

Section One


SELF

Who does an unsafe worker affect?

M-23

Section One


Safety Steps

1. Name the risks.

2. Safeguard the work area.

3. Wear necessary protective equipment.

4. Use the right tools.

5. Follow correct procedure.

6. Monitor work habits.

7. Correct as necessary.

*Ensure all adult helpers follow safe procedures.

M-24

Section One


Safety Contract

I will:

' identify risks of activities

' take actions to eliminate or reduce risk

' ask for help when needed

' select the correct tools, equipment and materials

for the activity

' watch for and allow for proximity of other people

' stop work and move back when asked to

' exit work area on command (in case of emergency)

' return tools and supplies to storage after use

' follow safe disposal procedure

' dress appropriately for club activities

' share responsibility for safety in the club

Member DateLeader

M-25

Section One


Safety #1 - Word Search

M-26

Section One


Safety #2 - Word Search

M-27

Section One


Safety Logos

flammable

corrosive

explosive

crushing hazard

M-28

Section One


Safety Logos

poison

electrical hazard

M-29

Section One


PROTECT YOURSELF

Protect your BACK

Protect your EARS

M-30

Section One


Protect your EYES

Protect your LUNGS

Protect your SKIN, HANDS, FEET

M-31

Section One


Safety Tips for Using Tools

Pull on a wrench rather than push it. You can hurt yourself

if it slips. If you must push, push with an open hand to avoid

scraped knuckles.

Clean all tools. Greasy tools slip and cause accidents.

Store tools carefully. Damaged tools are dangerous.

Keep long hair, clothing, jewellery and body parts away from

equipment and tools.

Use the right size tool for the job.

Use the correct tool for the job. (E.G. do not use a

screwdriver as a pry bar)

M-32

Section One


Safety goggles or a face shield will protect your eyes from

dust, chunks, caustic materials and compressed air.

Grind off mushroomed tops on chisels.

Replace or repair a tool as soon as it shows signs of wear.

Safety Tips for Using Tools

M-33

Section Two


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How Small Engines Work Checklist

M-34

Section Two


Remember this when troubleshootingan engine that won’t start.....

What Does An Engine Need To Run?

How Small Engines Work

Fuel and air mixed

in correct proportions.

Ignition at the

right time.

Compression of the

fuel/air mixture.

Check in this order: !!!!! compression""""" ignition##### carburetor

M-35

Section Two


Differences Between a Two and Four Cycle Engine.

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M-36

Section Two


Differences Between a Two and Four Cycle Engine.

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M-37

Section Two


How Small Engines Work - Crossword Puzzle

M-38

Section Two


How Small Engines Work - Word Search

M-39

Section Two


Checking Compression Checklist


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M-40

Section Two


Ignition Troubleshooting Chart

Problem: Engine will not start.

$$

Spark plug malfunction?

Magneto points burned ormaladjusted?

$ $ Replace plug.

$ YES $ Install new pointsand set gap.

NO

$$

Coil air gap maladjusted? $ $ Reposition coil toget correct air gap.

$$

Crankshaft key sheared orpartially sheared?

$ YES $ Replace key.Recheck ignitiontiming.

YES

YES

NO

NO

M-41

Section Two


Compression - Crossword Puzzle

M-42

Section Two


Notes

M-43

Section Three


Parts of a Small Engine Checklist

Member locates and correctly identifies from a picture oran engine or a display of parts the following:


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M-44

Section Three


Parts of a Small Engine Checklist

By the end of the club year,members must identify the numberof parts for their level.

Junior Members 10 partsIntermediate Members 20 partsSenior Members 30 parts


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M-45

Section Three


Nameplate Checklist


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M-46

Section Three


Notes

M-47

Section Four


Care and Handling Checklist

Members whose engines are not yet running, will be able to explain whatproper care and handling is. Members whose engines and machines areoperating should be demonstrating proper care and handling.


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M-48

Section Four


Care and Handling - Crossword Puzzle

M-49

Section Five


Cleaning - A Generic checklist


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M-50

Section Five


Degreasing the Crankcase Checklist


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M-51


Section Five

Degreasing the Crankcase Checklist


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M-52


Section Five

Cleaning Engine - Crossword Puzzle

M-53


Section Five

Cleaning Engine - Word Search

M-54


Section Five

Notes

M-55


Section Six

Cooling System Checklist


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M-56


Section Six

Cooling System Checklist


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M-57


Section Seven

Air Cleaner Checklist


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M-58


Section Seven


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M-59


Section Seven


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M-60


Section Seven


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tnemeleretlifevomeR.3

tlobdutsevomeR.a

revocevomeR.b

ekatniriaroterubracrevoC.c

tnemeleretliF.4

ecalper,degamaD.a

ecafrustalfnognippatybnaelc-tnemelerepaP.b

retawypaosnihsaw,erbifssoM.c

ylbmessaeR.5

roterubracrevocnU.a

revocretlifnaelC.b

ekatniroterubracnaelC.c

tnemeleretlifecalpeR.d

nethgit,revocecalpeR.e

M-61


Section Eight

Fuel Strainer Checklist

epyTneercS s'redaeLetad/slaitini

ylbmessasiD.1

eriwgulpkrapsehttcennocsiD.a

knatleufniarD.b

evlavffo-tuhsleufesolC.c

knatmorfdevomerenilleuF.d

reniartsleufro/dnaevlavffo-tuhsleufevomeR.e

reniartsleufnaelC.2

tnevlosesU.a

yrD.b

ylbmessA.3

reniartsleufecalpeR.a

ecalperroenilleufotegamadroskcarcoN.b

enilleufecalpeR.c

evlavffo-tuhsleufnepO.d

eriwgulpkrapstcennoceR.e

M-62


Section Eight


epyTlwoB s'redaeLetad/slaitini

lwobtnemidesehtfolavomeR.1

gulpkrapstcennocsiD.a

evlavffo-tuhsleufesolC.b

tun-majnesooL.c

liaberiwevoM.d

eerflwobtsiwT.e

lwobtnemidesehtgninaelC.2

teksagevomeR.a

neercsreniartsevomeR.b

tnevlosnineercshsaW.c

lwobtnemidesyrddnanaelC.d

leufniarD.3

leuffo)lm052(pucenoniarddnaevlavleufnepO.a

M-63


Section Eight

epyTlwoB s'redaeLetad/slaitini

ylbmessaeR.4

noitidnocdoogniteksagllatsnI.a

reniartsllatsnI.b

lwobtnemidesllatsnI.c

lwobtnemideslliF.d

tun-majnethgiT.e

teksagtsniagalwobnethgiT.f

eriwgulpkrapstcennoceR.g

skaelrofkcehcotenigneetarepO.h


M-64


Section Eight

Notes

M-65


Section Nine

Crankcase Breather Checklist


revocrehtaerbesacknarcevomeR.1

eriwgulpkrapsehttcennocsiD.a

skaelrofkcehC.b

ebutrehtaerbesaeleR.c

yrassecenstraprehtofolavomeR.d

ecnaraelcrehtaerbkcehC.2

egaugreleeftcerrocfonoitceleS.a

sevlavdeerfoecnaraelckcehC.b

sevlavcsidfoecnaraelckcehC.c

redronistrapelbmessassiD.3

rehtaerbehtgninaelC.4

desutnevloS.a

naelcdesniR.b

deirD.c

)roop,riaf,doog,tnellecxe(ssenilnaelC.d

ylbmessA.5

)revotfelstrap,tcerrocyllaitrap,tcerroc(redrO.a

M-66


Section Nine

M-67


Section Ten

Lubrication Checklist


retliflioetacoL.1

pacrogulprellifffonaelC.2

pacrogulprellifevomeR.3

kcitspidfoecnesbaroecneserpyfitnedI.4

)tcerroclio,wollio(kcitspidon,levelliO.5

kcitspid,levelliO.6

kcitspidevomeR.a

naelcepiW.b

tresnieR.c

)wol,lamron(levelkcehC.d

noitidnocliokcehC.7

)wolfi(lioddA.8

liognignahC.9

mrawlitnuenigneetarepO.a

gulpkrapstcennocsid,enignepotS.b

M-68


Section Ten

Lubrication Checklist


naelcdnagulpniardetacoL.c

gulpniardevomeR.d

setunimevifniarD.e

gulpniardecalpeR.f

liohtiwesacknarcllifeR.g

snoitacificepss'rerutcafunamybdednemmocerliO.h

denaelcgulpdnuoraaerA.i

enignetrats,gulpkrapstcennoceR.j

skaelliorofdekcehC.k

enignepotS.l

levelliokcehceR.m

desusgarehtnaelcroyortseD.n

M-69


Section Ten

Lubrication - Crossword Puzzle

M-70


Section Ten

Lubrication - Word Search

M-71


Section Eleven

Spark Plug Checklist


gulpkrapsehtgnivomeR.1

eriwgulpkrapstcennocsiD.a

eriwgulpkrapsnesooL.b

gulpdnuoramorftridevomeR.c

desuhcnerwtcerroC.d

sdaerhtgnippirtstuohtiwdevomeR.e

devomerteksaG.f

krapsehtgnikcehC.2

eriwehttcennoceR.a

enigneotgulpdnuorG.b

enigneknarC.c

ytilauqkrapsfonoitacifitnedI.d

krapSoN.3

eriwtcennocsiD.a

enigneknarc,daehrednilycmorfertemitnec2/1eriwdloH.b

noitacifitnedimelborP.c

M-72


Section Eleven

Spark Plug Checklist


gulpehtgnikcehC.4

noitacifitnedinoitidnoC.a

deriuqerfinoitcelesgulP.b

sgulpkrapsgninaelC.5

tnevlosnidenaelC.a

yltcerrocdeirD.b

hsurberiwhtiwdenaelcsdaerhT.c

devomerstisopeddraH.d

devomerlairetamesoolllA.e

htoomsdelifsedortcelE.f

noitisoplanigironiedortcelednuorG.g

gnicapsdnagulpkrapS.6

snoitacificepss'rerutcafunamotgnidroccagnicapsreporP.a

snoitacificepss'rerutcafunamotgnidroccaegaugreleeF.a

noitallatsnigulpkrapS.7

ecalpninethgitdnaH.a

nethgityltcerroC.b

eriwtcennoceR.c

M-73


Section Eleven

Review Checklist for Spark Plugs


enignenevigarofgulpkrapstcerrocyfitnedI

gulpkrapsfoesoprupllaceR

sgulpkrapsfostrapniamyfitnedI

sgulpdesugninimaxeybselbuortenigneyfitnedI

senignelarevesnogulpkrapsetacoL

yltneggulpkrapseldnaH

sgulpgnicivresfosksirlaitnetoptsiL

sgulpnognikrowrofslootetairporppatceleS

enodkrowynadroceR

eruliafgulpkrapsfosesuac)3(eerhttsiL

launamecivresnipagkrapsdniF

Notes:

M-74


Section Eleven

Spark Plug - Crossword Puzzle

M-75


Section Eleven

Spark Plug - Word Search

M-76


Section Eleven

M-77


Section Twelve

Carburetor Checklist


)senignegnitrats-non(kcehcnoitarepO.1

gulpkrapsevomeR.a

elohgulpkrapsrevobmuhT.b

desolcevlavekohC.c

retratshtiwdeknarcenignE.d

leufrofkcehcregniF.e

rebmahcnoitsubmocenilosaG.f

gulpkrapsllatsnieR.g

enignetratS.h

noitacifitnedimelborP.2

tnemtsujdaroterubraC.3

skaelriarofkcehC.a

hctiwspotsdeeps-eldiyfitnedI.b

wercserutxim-eldiyfitnedI.c

tnemtsujda-daoldeepshgihyfitnedI.d

evlavekohcroterubracehtgnitsujdA.4

renaelcriaevomeR.a

lortnocehtgnisukcehcnoitisopevlaV.b

M-78


Section Twelve

Carburetor - Crossword Puzzle

M-79


Section Twelve

Carburetor - Word Search

M-80


Section Twelve

Notes

M-81


Section Thirteen

Servicing Battery Checklist I


selggogrosessalgytefasgniraeW.1

sllecyrettabmorfspacevomeR.2

spacdedaerhT.a)emertxe,etaredom,elttil(egamadroiretxe-)emertxe,etaredom,elttil(egamadroiretni-

)degamadtonegde,degamadegde(pacnwod-panS.b

esacyrettabnonwodedisputesspaC.c

leveldiulfyrettabkcehC.3

desukcitsnaelC.a

yrettabehtotdiulfgniddA.4

retawdellitsiD.a

)naelc(retawpaT.b

leveltcerrocotdelliF.c

dellifrednurorevO.d

spacecalpeR.5

naelcspaC.a

deliosspaC.b

naelcpacnitneV.c

M-82


Section Thirteen

Servicing Battery Checklist II

snoitcennoCelbaCdnaemarF s'redaeLetad/slaitini


spacyrettabevomeR.2

retemordyhehtgnisU.3

retemordyhotninwardetylortcelE.a

noitulosnieerftaolF.b

gnidaerrofyllacitrevdleH.c

leveleyetanekatgnidaeR.d

)flaheno,lla(detsetslleC.e

retawnaelchtiwdesnirretemordyH.f

)tcerroc(ytivargcificepS.g

)tcerroc(noitaterpretnI.h

retemtlov-tseTyticapaCdaoL

retemtlovehtgnitcennoC.1

tsopotdaeltcerroC.a

yrettabotdednuorgeriwlioC.b

egatlovehtgnidaeR.2

retratsehtgninrutelihwnekatgnidaeR.a

dessaptonretratshtiwemitmumixaM.b

M-83


Section Thirteen

Servicing Battery Checklist III

yrettaBehtgninaelC s'redaeLetad/slaitini


partsdnuorgdnaelbaC.2

esehtevomerdedorrocfI.a

tsrifdevomerpartsdnuorG.b

snoitcennoclanimretgaT.c

gninaelC.3

ecafrusedistuo,desuhsurberiW.a

ecafrusedisni,desurepapdnaS.b

denaelcstsopyrettaB.c

denaelcspmalcelbaC.d

potyrettabnonoisorrocrotridesooloN.e

deggulpspacrehtaerB.f

gninaelcrofdesuretawdnaadoS.g

llewdesniR.h

ffodeirdyrettaB.i

gnitcennoceR.4

M-84


Section Thirteen

Safety Tips: Working Around Batteries

Protect hands, eyes and clothes

Batteries give off an explosive gas.

No Smoking! No Flames! No Sparks! (grinding, welding etc.)

Battery acid is very corrosive. Rinse any spills immediately

with lots of fresh water.

Battery acid in the eyes? Wash them immediately with a

gentle flow of clean water, holding lids open.

See a doctor fast.

M-85


Section Thirteen

Battery - Crossword Puzzle

M-86


Section Thirteen

Battery - Word Search

M-87


Section Fourteen

Safety Tips: Working Around Fuel/Oil

Have a fire extinguisher handy and know how to use it.

No smoking, lighting of matches, striking sparks around gas

or gas-soaked rags!

Dispose of gas or oil soaked rags in a sealed metal barrel,

preferably outside. Rags left in a pile could start a fire.

Gas fumes are highly explosive. Store gasoline in a

sturdy, sealed, labelled can.

Gas fumes are dangerous to breathe. Provide good

ventilation.

Clean up spills promptly to avoid falls.

M-88


Section Fourteen

Dispose of used oil according to local environment laws.

Do not fuel a running or hot engine.

Do not use gas for cleaning parts.

Refuel outdoors if at all possible.

Safety Tips: Working Around Fuel/Oil

M-89


Section Fourteen

Fuel System - Troubleshooting

Problem: No fuel reaching the carburetor.

1. Is there gas in the fuel tank?

2. Is fuel flow blocked by a dirty filteror a damaged/blocked line?

Gravity Fed

! NO ! Fill tank

! YES !Clean filter.Replace andclean line.

!

YES

!

M-90


Section Fourteen

Fuel System - Troubleshooting

Problem: No fuel reaching the carburetor.

1. Is there gas in the fuel tank?

2. Are fittings connecting fuel lineto pump and tank tight?

! NO !

3. Is pump filter clean?

4. Is fuel pump working?Check it.

Fill tank

Correct.

Clean it.

Repair orreplace .

With Fuel Pump

! NO !

! NO !

! NO !

!

YES

!!

YES!

!

YES

!

M-91


Section Fourteen

Fuel - Crossword Puzzle

M-92


Section Fourteen

Fuel - Word Search

M-93


Section Fifteen


evlavffo-tuhsleufgninepO.1

noitingocertraP.a

detelpmocytivitcA.b

ekohcehtgnisolC.2

noitingocertraP.a

detelpmocytivitcA.b

)remirpon(ro

ffohctiwsnoitingI.a

retratsknarC.b

elttorhtehtgnitteS.4

noitingocertraP.a

noitisopdednemmocertateS.b

)tneserpfi(hctiwsnoitinginonruT.5

Engine Start-up and Shutdown Checklist

M-94


Section Fifteen



enigneehtknarC.6

epytretratsdniwepoRleehwylfdnuoraepordniW.a

ekortsnoisserpmocotylwolsknarC.b

epordniweR.c

yawaeporlluP.denignetsniagadecarb-

ylnevednathgiartsdellupepor-

epytretratsdniweRepoRekortsnoisserpmocotenigneknarC.a

epornekcalS.b

dniwerotdewollaepoR.c

ylmrifdnaylksirbdellupepoR.d

rafoottuodelluptonepoR.e

eldnahgnidlohelihwdniweroteporwollA.f

M-95


Section Fifteen



)d'tnoc(enigneehtknarC.6

epytretratspudniWnoitisoppudniwnirevelesaelerecalP.a

noitisopgniknarcoteldnahtfiL.b

noitisopgniknarcoteldnahdnetxE.c

retratsdniW.d

noitisopdetcarteroteldnahpudniwdloF.e

noitisop"nur"otrevelesaelerevoM.f

epytretratscirtcelEhctiwsetacoL.a

hctiwsegagnE.b

dlehemiT.c)sdnoces51revo,sdnoces51ot01,sdnoces01rednu(

noitisopffootnruterothctiwswollA.d

M-96


Section Fifteen



enignEehtgnippotS

deepseldiecudeR.7

daoloN.a

deepselttorhttcerroC.b

setunim2ot1,emiT.c

noitingiffonruT.8

evlavffo-tuhsknatleufesolC.9

M-97


Section Sixteen

Storage Checklist

Junior

Give two reasons why an engine should be stored properly.

Recognize, name and assemble at least 5 tools and supplies for

storage preparation.

Identify at least three jobs that need to be done before storing.

(Refer to checklists for those jobs.)

With assistance, perform at least one of the jobs.

With some assistance, record efforts in record book.

Check small engine at least once during storage period.

M-98


Section Sixteen

Storage Checklist

Senior (prerequisite: Intermediate Level)

Assess engine condition and plan for additional service.

Independently assemble tools and supplies for service.

With little assistance, prepare small engine for storage.

(Refer to checklists for the jobs to be done.)

Intermediate (prerequisite: Junior Level)

Give four reasons why an engine should be stored properly.

Recognize, name and assemble at least 8 tools and supplies for

storage preparation.

Identify at least two jobs that need to be done before storing.

(Refer to checklists for those jobs.)

With assistance, perform at least two major jobs before storage.

Independently record efforts in record book.

Check on small engine at least twice during storage period.

M-99


Section Sixteen

Storage - Crossword Puzzle

M-100


Section Sixteen

Storage - Word Search

M-101


Appendix A

The Twelve Days of 4-H

On the first day of 4-H, my leader sent to meA small engine, very dirty.

On the second day of 4-H, my leader sent to meTwo cans of gunk

and a small engine, very dirty.

On the third day of 4-H, my leader sent to meThree air filters, two cans of gunk

And a small engine, very dirty.

On the fourth day of 4-H, my leader sent to meFour bowl gaskets, three air filters, two cans of gunk


On the fifth day of 4-H, my leader sent to meFive piston rings.

Four bowl gaskets, three air filters, two cans of gunkAnd a small engine, very dirty.

On the sixth day of 4-H, my leader gave to meSix new magnetos,Five piston rings.


M-102


Appendix A

On the seventh day of 4-H, my leader gave to meSeven carburetors, six new magnetos,

Five piston rings.Four bowl gaskets, three air filters, two cans of gunk


On the eighth day of 4-H, my leader gave to meEight ring compressors, seven carburetors, six new magnetos,



On the ninth day of 4-H, my leader gave to meNine connecting rods,

eight ring compressors, seven carburetors, six new magnetos,Five piston rings.


On the tenth day of 4-H, my leader gave to meTen crankcase seals,

nine connecting rods, eight ring compressors, seven carburetors, sixnew magnetos,



M-103


Appendix A

On the eleventh day of 4-H, my leader gave to meEleven new torque wrenches,

Ten crankcase seals, nine connecting rods,eight ring compressors, seven carburetors, six new magnetos,



On the twelfth day of 4-H, my leader gave to meTwelve charged batteries,

eleven new torque wrenches, ten crankcase seals, nine connecting rods,eight ring compressors, seven carburetors, six new magnetos,



GLOSSARY

SmallEngines

G-106

Glossary

Small Engine Glossary

Notes

G-107

Glossary


Abrasivea material which is used to wear awaysome surface

Additivechemicals which are added to oil tomake it work better in the engine

Alloya metal made by mixing two or morebase metals (e.g. brass is an alloy ofcopper and zinc)

Alternating Current (AC)the kind that is used in our homes. Thecurrent flows first in one directionthen in the opposite direction.

Antifreezea poisonous liquid which preventsengines from freezing up. It has alower freezing point and higher boilingpoint than water.

Bearingthe surface of any part of a machineon which another part turns or moves.

Borethe diameter of the cylinder

Bushinga friction type of shaft bearing

Camshaftthe shaft in an engine which pushesopen the intake and exhaust valves

Capacitoranother name for condenser

Carbonhard, black material which forms whentoo much fuel is mixed with air incylinder.

Carburetordevice that mixes gas and air in theright amount so they can be ignited

Centrifugalmoving away from the centre

Combustionwhat happens when fuel starts to burn

Condenseran electrical device which can collectand hold electricity

G-108

Glossary


Connecting Rodconnects the piston to the crankshaft

Corrosionchemical process which causes metal orother material to slowly be eaten away

Counterbalanceweight used to balance a force

Crankcasethe part of the cylinder block wherethe crankshaft revolves

Crankshaftthe rotating, main shaft in an engine -the piston and connecting rods make itrotate

Currentthe flow of electrons through aconductor, measured in amperes.

Cylinder Blockthe large, main part of any engine

Cylinder Headmetal cover bolted to the top of thecylinder block

Diaphragmflat disc of rubber or cloth in a fuelpump. It separates the fuel tank sideof the pump from the engine side.

Dieseltype of engine in which fuel is injectedinto very hot, compressed air to ignite.

Direct Current (DC)electric current which flows in only onedirection. Direct current can be foundin batteries and dry cells.

Diodedevice that changes alternatingcurrent to direct current. Also called arectifier.

Electrodestwo wire-like parts in a spark plug thatextend into the cylinder to make a gapfor the electric spark to jump across

G-109

Glossary


Electrolytea liquid that will conduct electricity. Ina battery the electrolyte is water andsulphuric acid.

Extensionpart that adds length

Filterspecial screen with tiny holes in it. Afilter screens out dust and dirt butlets air through.

Flywheelwheel that attaches to the crankshaft.It helps start the engine and keep itrunning smoothly.

Frictionthe resistance between two thingsrubbing together. Friction causes heat.

Gasketa flat piece of material, usually rubber,cork, paper or asbestos which is fittedbetween metal parts to keep fluid orair from escaping.

Governora speed control for an engine

Groundan electrical connection or contact tothe cylinder block

Honean abrasive tool used to enlarge holesand make them very accurate - topolish very smoothly.

Inhibitora chemical that stops or preventsrusting.

Insulatora material that does not conductelectricity. Insulators are used tocontain electricity so it does not causeshock, injury or damage.

Insulatora type of metal that does not conductelectricity.

G-110

Glossary


Intake Manifoldthe pipe that brings fuel/air mixturefrom the carburetor to the cylinderfor combustion.

Jeta tube with a small opening to allow airor liquid to rush through

Lappingpolishing, using an abrasive mounted ona special backing such as brass, wool,leather etc..

Lobea rounded, projecting part of arevolving shaft.

Lubricationadding oil or grease to an engine so themoving parts slide easily and quicklywithout getting too hot.

Magneta piece of metal which has a force fieldaround it which attracts some metals.

Magnetoa device that makes an electric sparkto ignite fuel in the cylinder.

Meshthe fine wire of a net or screen

Peento bend or flatten some material(usually metal)

Pilota device on valve seat cutters andgrinders to guide and hold them in thecorrect position while working

Pistona cast cylindrical piece of metal whichfits in the cylinder of the engine andmoves up and down.

Porcelaina hard brittle material like china.

Porta hole in a cylinder wall, designed to letfuel and air in, or exhaust gases out.

G-111

Glossary


Preignitionthe burning of the air/fuel mixturebefore normal ignition occurs.

Radiatora device designed to give off heat intothe air

Ratcheta mechanical device that allows freemovement in only one direction at atime.

Reamera tool used to make a hole larger

Reeda thin, flat strip of spring material

Rotaryturning on a shaft

r/min or rpmrevolutions per minute

Short Circuitto make a new, shorter path forelectricity (sometimes unintended). Theoriginal circuit would no longer work.

Shrouda covering which acts to direct coolingair. Also can act as a safety cover.

Solventa liquid used as a cleaner. Oftenflammable.

Spark Pluga device designed to let a spark jumpacross a small gap to ignite fuel.

Sprocketa wheel with teeth on its edge. Theseteeth usually catch in holes in chainlinks and make another sprocket turn.

Stationaryfixed in one position

Suctiona force that moves a liquid or air fromhigh pressure to low pressure

Sumpa container for oil or other liquids.

G-112

Glossary


Swivelto swing or turn on a hinge pin.

Terminala point in electrical devices wherewires can be connected.

Thermostata device that helps controltemperatures of an engine

Throttlea valve that controls the amount offuel and air entering the cylinder ofthe engine.

Timing Gearsgears used to turn the camshaft andopen and close the valves at the righttime.

Torquethe amount of turning force applied toor by a shaft.

Transistora small electronic device used tocontrol an electric current.

Troubleshootinga process of figuring out what is wrongor missing

Tungstena hard, white metal that is a very goodconductor of electricity.

Universala double-hinged connector used toapply torque through a hinge (oftencalled a U-joint).

Vacuuman area of very low air pressure. Airalways tries to move into a vacuum.

Valvea device used to control the movementof gas, air or liquid through an opening.

Valve Lifterssmall rods with one flat end, they pushvalve open.

G-113

Glossary


Vanea flat metal or plastic surface fastenedto a shaft and moved by air or wind.

Venturia narrow place in a carburetor thatcauses a low pressure area around thefuel jet.

Viscositythe thickness of a liquid. Maple syruphas a higher viscosity than water.

Volta unit of electrical pressure

Warpto bend or twist out of shape.

cindy.kremer

Typewritten Text

cindy.kremer

Typewritten Text

cindy.kremer

Typewritten Text

small engines members manual - 4-h alberta

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