rev heads advanced

DESIGN AND TECHNOLOGIES

REV HEADSAdvanced

Student Name:

THIRD EDITION

RHAdv

Engineering principles and systems Students analyse how motion, force and energy are used to control electromechanical systems when creating simple, engineered solutions.

Materials and technologies specialisations Students analyse ways to create designed solutions through selecting and combining characteristics and properties of materials, systems, components, tools and equipment.

REV HEADS - ADVANCED

Steven Penna Darren Paxton

DESIGN AND TECHNOLOGIES

ENGINEERING PRINCIPLES AND SYSTEMS and

MATERIALS AND TECHNOLOGIES SPECIALISATIONS

Rev Heads - Advanced Page 1.

©Copyright LAPtek Pty. Ltd. Design and Technologies

Student Learning Guide & Record

TASK PAGE NAME ACHIEVED

S NYS Task 1 8 Risk assessment Task 2 11 Explain the term ‘Configuration' Task 3 11 Identify engine configurations Task 4 12 Identify four stroke engine configurations Task 5 18 Identify and explain the following major engine components Task 6 24 Four stroke principle of operation Task 7 26 Explain four stroke principle of operation Task 8 30 Extension unit – Lead, lag and overlap Task 9 31 Extension unit - Explain a valve timing diagram Task 10 32 Complete four stroke cycle chart Task 11 35 Identify air cooling system components Task 12 35 Identify location and function of major air cooled system components Task 13 40 Review questions – Air and water cooled engines Task 14 42 Identify major components Task 15 44 Review question engine lubricating system Task 16 46 Dismantle and assemble a four stroke petrol engine Task 17 56 Review questions – Welding processes Task 18 62 Review questions – Manual metal arc welding Task 19 64 Weld beads on mild steel plate Task 20 65 Deposit a pad weld on mild steel plate Task 21 66 Deposit a closed butt weld on mild steel plates Task 22 67 Deposit an open butt weld on mild steel plates Task 23 68 Deposit a fillet weld on mild steel plates Task 24 70 Review questions - GMAW Task 25 73 Deposit beads on a mild steel plate using the GMAW process Task 26 74 Deposit a pad weld using the GMAW process Task 27 75 Deposit weld bead on a closed butt joint Task 28 76 Deposit a fillet weld using the GMAW process Task 29 77 Identify & locate major units that require lubricants Task 30 78 Identify lubricant type and grade Task 31 80 Identify equipment Task 32 81 Operate each lubrication unit in accordance with manufacturer procedures Task 33 82 Research vehicle hoist Task 34 83 Operate your hoist Task 35 83 Use tools and equipment required for servicing Task 36 86 Identify jacking points Task 37 86 Before you lift answer the following safety questions Task 38 88 Raise the vehicle and position safety stands Task 39 90 Review questions – Drive belts Task 40 91 Remove, inspect, replace and adjust a fan belt Task 41 92 Review questions – Air filters Task 42 92 Remove, inspect and replace an air filter

Rev Heads - Advanced

Design and Technologies ©Copyright LAPtek Pty. Ltd.

TASK PAGE NAME ACHIEVED

S NYS Task 43 94 Complete vehicle information chart

Task 44 97 Write the manufacturer procedural steps to remove and replace a wheel and tyre assembly

Task 45 98 Remove and replace a wheel and tyre assembly Task 46 99 Inspect brake assemblies for serviceability Task 47 100 Obtain vehicle information Task 48 100 Disc/Drum brake inspection procedures Task 49 109 Check all fluid levels Task 50 112 Identify parts of an outside micrometer Task 51 113 Explain the principle of operation for a micrometer Task 52 117 Metric micrometer reading exercise Task 53 118 Practical use of metric micrometer Task 54 121 Identify the parts of a vernier caliper Task 55 122 Metric vernier reading exercises Task 56 123 Practical use of a vernier to take metric measurements Task 57 124 Review questions - Gaskets Task 58 126 Make a gasket Task 59 130 Review questions on wheels Task 60 131 Explain the function and parts of a wheel Task 61 138 Review questions on tyres and tyre marking Task 62 139 Identify and explain the function of the major components of a tyre Task 63 141 Complete vehicle information chart

Task 64 144 Write the manufacturer procedural steps to remove and replace a wheel and tyre assembly

Task 65 145 Remove and replace a wheel and tyre assembly Task 66 146 Firing order Task 67 147 Ignition timing Task 68 149 Ignition timing questions Task 69 153 Check all components Task 70 155 Mount and solder components Task 71 162 Discuss the life cycle of a packet of potato chips Task 72 162 Check your ecological footprint Task 73 162 Complete a life cycle analysis of a chosen product Task 74 165 Write a design brief Task 75 166 Carry out research Task 76 168 List of materials and components Task 77 168 Evaluation criteria Task 78 170 Concept drawings Task 79 171 Design options Task 80 172 Learn to use drawing software Task 81 172 Create preferred design option Task 82 172 Justification of preferred option Task 83 173 Production plan Task 84 176 Make your battery monitor case Task 85 176 Reflections Task 86 177 Evaluation report Task 87 179 Maintain a record of the production work (50+ words)


© Copyright LAPtek Pty. Ltd. Design and Technologies

ASSEMBLE AND DISMANTLE FOUR STROKE SINGLE CYLINDER BRIGGS AND STRATTON ENGINE This unit provides an introduction to small engines. It covers the theory of operation, the construction and the assembly and disassembly of single cylinder Briggs and Stratton engines. To promote easier readability, particular attention has been placed on simplified explanations of small engine mechanisms and operation, with the aid of many illustrations and pictures.

INTRODUCTION

The four stroke engine has many primary moving parts (crankshaft, connecting rod, piston, camshaft, inlet valve and exhaust valve.).

There is a large variety of design and construction that may be incorporated in a four stroke engine, the engine may be small or large, be air or water cooled and be constructed, basically, of aluminium alloy, cast iron, or a combination of both.

Understanding how a four stroke engine works before you dismantle and assemble it will make the task more worthwhile.

Enjoy gaining the knowledge of how a four stroke engine works and look forward to the feeling you get from assembling and dismantling a Briggs and Stratton engine as per manufacturer specifications.

ENGINE CONFIGURATIONS

Engine configurations are usually described by the number of cylinders, arrangement of the cylinders (inline, horizontal, vee), position of the camshaft and how many camshafts. The alignment of the crankshaft is also sometimes mentioned and can be either horizontal or vertical shaft.

The majority of four stroke engines have one to eight cylinders, although twelve and sixteen cylinders designs are not unknown.

There are several different multi cylinder layouts. The three most common designs are:

1. Inline – In the inline layout, the cylinders are arranged inline with one another.

Inline Engine Layout

2. Horizontal – Horizontal engine layout (also called flat or opposed) are arranged with the pistons set 180° apart.

Horizontal Engine Layout



OPERATION OF A FOUR STROKE CYCLE ENGINE

EQUIPMENT:

Four stroke Briggs and Stratton I/C Series 3.5 HP/127 cc HP engine.

Four Stroke Engine

INTRODUCTION

FOUR STROKE ENGINE

The name ‘four stroke’ comes from the fact that the piston makes four strokes in the cylinder to complete one full cycle. The strokes are induction, compression, power and exhaust. Two of the strokes are down (intake and power) and two are up (compression and exhaust). Valves open and close to route gasses or to create compression.

http://www.briggsandstratton.com/sea/en/engines/horizontal-shaft-engines/ic-horizontal-gas-engine-3-5-hp


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Power Stroke spark, down, closed, heat, closed, BDC

Inlet valve is ........................................................ exhaust valve is ...........................................

piston is moving .................................................. . The gas in the combustion chamber,

ignited by a ......................................................... , burns rapidly. The .....................................

generated causes the gases to exert high pressure on the piston which forces it to descend (go

down) from TDC to ............................................

Exhaust Stroke

remaining, up, closed, valve, open, exhaust

Inlet valve is ........................................................ exhaust valve is ............................................

piston is moving ..................................................

The ascending piston forces out any ....................................................... gases out of the open ................................ ................................... thus scavenging the cylinder. This stroke, which ends just after TDC completes the cycle.

8. What forces the piston up again after it has passed through BDC?

....................................................................................................................................................

....................................................................................................................................................

9. Through how many degrees does the crankshaft of the four stroke engine turn to complete the induction, compression, power and exhaust operations? (1 cycle)

....................................................................................................................................................

....................................................................................................................................................

TASK 7: EXPLAIN FOUR STROKE PRINCIPLE OF OPERATION

How: Without the use of reference material, explain to your teacher the operation of a four stroke cycle reciprocating spark ignition engine.



Step 17

Fit spark plug lead to the top of the spark plug.

Step 18

Fit the carburettor with the supplied gasket and bolts.

Step 19

Install the throttle control and the governor spring.

Step 20

Take the petrol tank from the board fit the tank in position ensuring that the rubber hose from the carburettor is connected correctly to the fuel tank.

Push the fuel hose over the fuel union from the carburettor. (You may need to use long nose pliers to move the spring hose clip over the fuel union.)

Step 21

Fit the fuel tank and secure in position.



4. List three ways to protect yourself from fumes when gas metal arc welding.

i) .............................................................................................................................................

ii) .............................................................................................................................................

iii) .............................................................................................................................................

5. State the name of the part of the welding torch where the welding current is transferred to the wire.

....................................................................................................................................................

FUSION WELDING USING GMAW PROCESS EXERCISES This is another welding process where you improve with practice. You will find this process easier than the earlier welding processes. You will gain the introductory skills for GMAW when you complete Tasks 25 – 28.

You will enjoy this.

Gas Metal Arc Welding Equipment



NOTE: Take care that the same gun is not used for both dirty oil removal and the

addition of new oil to a unit.

4. Drain the oil from a manual gearbox, then use the bulk oil dispenser to refill the gear box in accordance with manufacture specifications. (If available)

Bulk Oil Dispenser

5. Use a battery filler to fill a battery to the correct level in accordance with manufacture specifications.

6. State the advantage of using a battery filler over other methods of filling a battery to the correct level.

.......................................................................

Battery filler

IDENTIFY RECOMMENDED JACKING POINTS ON A VEHICLE AND JACKING UP A VEHICLE To avoid damaging the vehicle it is imperative that you jack up a vehicle using the correct manufacturer jacking points.

There will be times when it is necessary for you to jack up a vehicle to change a tyre, inspect brakes or to get under the vehicle. The following explains how to use a jack safely and efficiently.

CAUTION: Before you attempt to jack up a vehicle, observe the following precautions

• Use jacks only to get a vehicle off the ground. Never use a jack to hold a vehicle in place.

• To prevent serious injury or death, you must use safety stands when you work under a vehicle.

• Never jack up a vehicle without blocking the wheels to keep it from rolling.

• Always park a vehicle on level ground before you jack it up.

After you've observed all the safety precautions, follow these steps to jack up a vehicle:



TYRES AND WHEELS

WHEELS Wheels must be designed to support the tyre while withstanding loads from acceleration, braking and cornering. Most wheels are made of steel.

Aluminium alloy wheels are sometimes used for appearance, but also because aluminium and its alloys are not as heavy as steel.

Steel Rims and Tyres

Alloy Wheels and Tyre

FPV F6 Tornado Ute



REMOVE AND REPLACE A WHEEL AND TYRE ASSEMBLY

Changing a Wheel and Tyre Assembly

Don't forget ……… when jacking

Horizontal handles hurt …….. lift up the jack handle.

Use safety stands.

Never climb under a vehicle supported only by a jack.

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