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Electrical System

Introduction
• Electricity is a predictable force, yet it
is often challenging to service
electrical systems because it can not
been seen and there is the concern of
electrical shock.
• Because almost all small engine
electrical systems operate on 12 volts,
the danger of severe electrical shock is
reduced.
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Electrical Terms
• Before attempting to understand small engine electrical
systems, it is important to know the terms and parts
associated with electricity and the electrical systems.
• Electricity • Polarity • Diodes
• Conductor • Amperes • Voltage Regulator
• Electron • Resistance • Battery
• Free Electron • Short circuit • Primary winding
• Voltage • Series Circuits • Secondary winding
• Load • Parallel Circuits • Condenser
• Current • Ohm’s Law
• Direct Current • Magnetism
• Alternating Current • Induction
• Solenoid

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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

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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

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Induction
• Induction: the production of voltage
and current by the proximity and
motion of a magnetic field or electric
charge.
• With a conductor, either current, a
magnetic field or motion can be
produced as long as the other two are
present.

• Magnetic field: When electricity passes through a conductor it


forms a magnetic field around the conductor.
• Current: When a conductor passes through a magnetic field or
when magnetic field moves and/or varies in strength around a
conductor, electrons are made to flow. A current is induced in the
conductor.
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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

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1. Charging System
• Charging systems produces electrical to operate accessories
and the 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.
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Charging System--cont.
• The components of a charging system
may include:
– Coil
– Magnets
– Voltage regulator
– Rectifier
– Switches
– Conductors

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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
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2. Ignition System-cont.
• Breaker point ignition
– Older system. Most manufacturers have replaced
them with solid state.
– Uses a set of points to break the primary circuit.
• Solid state ignition
– Uses a transistor to break the primary circuit.

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Magneto Ignition System Parts
• Magnets
• Points (Breaker point only)
• Trigger coil
• Conductors
• Spark plug
• Condenser (Breaker point
only)
• Lamination stack
• Primary winding
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• Secondary winding
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.
• With current flowing in the primary circuit, a magnetic
field develops around the primary coil.
• This magnetic field also surrounds the secondary coil.
• As the flywheel continues to rotate the breaker points
open.
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Magneto Ignition System- Firing Spark Plug

• When the
breaker points
open the
magnetic field
produced by the
current in the
primary winding
collapses.
• The collapsing magnetic field flows across the secondary coil which induces
a current in the secondary coil.
• Because there is a 60:1 ratio of windings in the two coils, the voltage is
transformed to the 10,000 and 15,000 volts needed to fire the spark plug.
• As long as the flywheel is rotating and the ignition switch is on, the spark
plug fires every time the magnets move past the magneto.

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3. Starting System
• The purpose of the starting system is to use energy
to turn the engine until it starts.
• System components may include:
– Electrical source
– Starting motor
– Conductors
– Ignition switch
– Solenoid switch
• Two primary electrical systems.
– Single switch
– Solenoid

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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
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the current to the starting
motor.
4. Accessories
• Small engines are used on machines that may require
electricity to operate accessories.
• Accessories may include:
– Lights
– Electrical clutches
– Electrical lift systems
– Radio, etc.
• The conductors must be sized for the electrical load.
• Each separate circuit should have overload protection.

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5. Safety
• It is common for small engines to be used on machines that may
have one or more electrical safety systems.
• These systems are usually designed to stop the engine when
activated.
• The electrical system is used because that is the easiest way to
automate an engine stopping system.
• Safety systems can include:
– Low oil switch
– Seat switch
– Anti after fire solenoid
– Deck switch
– Transmission switch
– Tilt switch

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