Generac Power Systems 0595-0 User Manual

OWNER'S MANUAL
IM-52, IM-66 AND IM-72
AIR-COOLED
Manual No. 98699
INDUSTRIAL MOBILE GENERATORS
Model Nos.0595-0, 0860-0, 0861-0
CORPORATION
Printed in U.S.A.

GENERAL SAFETY RULES

THE MANUFACTURER SUGGESTS THAT THESE "RULES” FOR SAFE OPERATION BE COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE GENERATOR. SAFETY
A
SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT.
Study these SAFETY RULES carefully before operat ing or servicing applicable equipment. Become familiar with this Owner's Manual and with your generator.
Safe, efficient and reiiable operation can only be achieved if generator is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.
The manufacturer suggests that these GENERAL SAFETY RULES be copied and posted in potential hazard areas of the generator. Safety should be stressed to all operators and potential operators of equipment.
The manufacturer cannot possibly anticipate every cir cumstance that might involve a hazard. The \warnings in this Manual and on tags and decals affixed to the
unit are, therefore, not all-inclusive. If you use a proce
dure, work method or operating technique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure the procedure, work method or operat ing technique that you chose does not render the gen erator to be unsafe.
For fire safety, the industrial mobile generator must be
A
properly installed and maintained. Installation must
always remain in compliance with applicable codes and standards. In addition, the generator must be installed in conformance to the manufacturer's detailed installa tion instructions. Following installation, nothing must be done that might render the generator in noncompliance with such codes, standards and instructions.
The INDUSTRIAL MOBILE generator produces
A
extremely high and dangerous electrical voltages and can cause dangerous, and possibly fatal, electrical shock. Avoid contact with bare wires, terminals, etc. while the unit is running. If you must work around an operating generator, stand on an insulated, dry surface to reduce shock hazard.
Never work on this equipment or handle any electrical device while standing in water, while barefoot, or while hands or feet are wet. Dangerous electrical shock will result.
Have the generator properly grounded (bonded) during installation onto the vehicle, either by solid mounting to
the vehicle frame or chassis or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped. DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine mainte nance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 AWG cop per wire minimum.
In case of accident caused by electric shock, shut down the source of electrical power down at once. If
this cannot be done, free victim from live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a dry board, dry rope, or other non-conducting imple ment to free the victim from live conductor.
Inspect fuel system frequently for leaks or damage. Repair or replace any damaged or leaking component
immediately. Never attempt to change, alter or modify the generator fuel system in any way that might affect safety or compliance with applicable codes and standards.
The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dan gerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must have been properly installed, in strict compliance with applicable codes and standards. Following installation, you must do nothing that might render the system unsafe or in non-compliance with such codes and standards. The generator compart ment must be completely vapor sealed from vehicle interior. There must be no possibility of exhaust fumes entering the vehicle interior. Never operate this equip ment with a leaking or defective exhaust system.
Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts and
may result in dangerous, fuel leakage, oil leakage, etc. Do not smoke around the generator. Wipe up any fuel,
and oil immediately. Never leave oily or fuel soaked rags in the generator compartment or on the generator itself. Keep the area around the generator clean and free of debris.
Adequate ventilation is required to expel toxic fumes and gasoline vapors from the generator compartment. Do not alter the installation of this equipment in any manner that might obstruct air and ventilation open ings. Such openings must be kept clear and unob structed.
Keep hands, feet, clothing, etc., away from drive belts, fans and other moving parts of this equipment. Never remove any drive belt or fan guards while the unit is operating.
Inspect the generator periodically. Repair or replace all damaged or defective parts immediately
These generators can be converted to use LP gas (propane) as a fuel. Liquid Propane gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion.
Before performing any maintenance on- the generator
set, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (-) first. Reconnect that cable last.
IDENTIFICATION RECORD
Please record the following information from the generator DATA PLATE or information decal.
1.Model Number 2.Serial Number
3.kW Ratina 4. Rated Voltage
5. Phase 6. Hertz
GENERATOR RPM [
FOR SERVICE CENTER LOCATION CALL
800-333-1322 24 HOURS A DAY
GENERAC CORPORATION
WAUKESHA, Wise.
1

TABLE OF CONTENTS

GENERAL SAFETY RULES
IDENTIFICATION RECORD....'
...........
inside cover
......................
READ THIS MANUAL THOROUGHLY
Operation and Maintenance
How to Obtain Service.................................................. 3
.........................................
GENERATOR FAMILIARIZATION
■ Generator Applicability
Installation.....................................................................4
Safety
...........................................................................
Generator AC Connection System
..................................................
...............................
OPERATING INSTRUCTIONS
Operating Precautions.................................................. 5
Generator Control Panel
Fuel Primer....................................................................5
Start/Stop Switch...........................................................5
Fuse..............................................................................5
Main Breaker.................................................................5
Remote Start/Stop Switch Automatic Choke Before Starting the Engine
Installation.....................................................................6
Engine Lubrication
Fuel Supply...................................................................6
Cooling and Ventilation Air Engine Exhaust Gas
Starting the Generator................................................. 6
Stopping the Generator................................................ 6
25 Hour Break-In Period................................................6
25 Hour Check-up Period..............................................7
Attention Required After Submersion
Effects of Moisture and Dirt...........................................7
Automatic Low Oil Pressure Shutdown
High Oil Temperature Shutdown Field Boost
Over Voltage Protection
Engine Governed Speed...............................................8
Fuel Requirements........................................................8
Optional LP Gas Fuel System
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SPECIFICATIONS
Engine Oil Requirements
1
3
4
4 4
5
5
5
5
Engine Specifications,...................................................9
Generator Specifications...............................................9
MAINTENANCE
Checking Engine Oil Level Change Engine Oil Change oil filter Engine Air Cleaner
Clean Air Intake Screen..............................................11
Engine Spark Plugs....................................................11
Fuel Filter....................................................................11
Spark Arrestor Muffler
Cleaning the Generator...............................................12
Battery.........................................................................12
Major Service Manual
Drive Belts...................................................................12
Exercising the Generator Out of Service Protection Return the Unit to Service after Storage
...........................................................
TROUBLESHOOTING ELECTRICAL DATA
6
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13
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9
10 10 10
11
11
12
12 12 13
14
REPAIR PARTS.....................................15 to 23
6
6
7
7 7 7 7
8
CAL. EMISSIONS WARRANTY
WARRANTY
.......................................
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back page
24 - 25
2

READ THIS MANUAL THOROUGHLY

If you don't understand any portion of this manual, contact Generac for a demonstration of actuai start ing, operating and sen/icing procedures.
Throughout this publication and on tags and decals affixed to the generator, DANGER and CAUTION blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety warnings cannot eliminate the hazards that they indicate. Strict compliance with the special instructions while performing the service plus "com mon sense" are major measures to prevent acci dents.
The foliowing definitions apply to DANGER, CAU TION and NOTE blocks found throughout the manual.
[ DANGER: AFTER THIS HEADING YOU CAN READ
A HANDLING, INSTALLING, OPERATING OR SERVIC-
' ING INSTRUCTIONS THAT, IF NOT STRICTLY COM
PLIED WITH, MAY RESULT IN PERSONAL INJURY.
CAUTION: After this heading you can read instruc tions for handling, installing, operating or servicing the generator that, if not strictly complied with, may result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory
statements that require special emphasis. These symbois indicate the following:
■ Points out important safety information and, if not followed, could endanger personal safety and/or property of yourself and others.
Potential explosion hazard
Potential fire hazard
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The operator (driver) is responsible for proper and safe use of the vehicle, equipment on the vehicle, and the safety of all vehicle occupants. We strongly rec ommend that the operator read this Owner's Manual and thoroughly understand all instructions before
using this equipment. We aiso strongly recommend
instructing other occupants in the vehicie to properiy start and operate the generator. This prepares them if they need to operate the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibiiity to perform all safety checks; to make sure that all maintenance for safe operation is performed promptly; and to have the
equipment checked by an Authorized Dealer periodi cally. Normal maintenance service and replacement of parts are the responsibility of the Owner/Operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty.
Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your industrial
mobile generator assures a minimum number of prob
lems and keeps your operating expenses at a mini
mum. See your authorized Deaier/Distributor for ser vice aids and accessories.

HOW TO OBTAIN SERVICE

When your industrial mobile generator set requires
servicing or repairs, simply contact an Authorized
Service Facility for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.
When contacting an Authorized Service Facility or the factory about parts and service, always supply the complete model number and serial number of your
unit as given on its data decal. The warranty on your generator is included in this
Owner's Manual, as well as listings for repair parts.
Potential electrical shock hazard
A
3-

GENERATOR FAMILIARIZATION

GENERATOR APPLICABILITY

These generators have been designed and manufac tured for supplying electrical power for Industrial mobile vehicles. You should not modify the generator or use it for any application other than for what it was designed.
If there are questions pertaining to its application, write or call the factory. Do not use the unit until you have been advised by a competent authority.
DANGER; FOR FIRE SAFETY, THE GENERATOR MUST HAVE BEEN PROPERLY INSTALLED IN COM
A
PLIANCE WITH INDUSTRY STANDARDS. THE GEN
ERATOR ALSO MUST HAVE BEEN INSTALLED IN STRICT COMPLIANCE WITH THE MANUFACTUR ER’S DETAILED INSTALLATION INSTRUCTIONS. AFTER INSTALLATION, DO NOTHING THAT MIGHT RENDER THE UNIT IN NON-COMPLIANCE WITH SUCH CODES, STANDARDS AND INSTRUCTIONS.
You can use this generator to supply electrical power for operating 120/240 volts, single phase, 60 Hertz, a-c electrical loads requiring the following:
Industrial
Generator (wattage) 120 Volts 240 Volts
IM-52 IM-66 IM-72 7200 60 30
Power
5200 43.3 21.6 6600 55
Amps at Amps at
27.5

SAFETY

Before using the generator set, carefully read GENER AL SAFETY RULES inside the cover. Comply with these RULES to prevent accidents and damage to equipment and/or property. Generac suggests copying and posting the GENERAL SAFETY RULES in poten tial hazard areas of the generator. Safety should be stressed to all operators of this equipment.
GENERATOR AC CONNECTION
SYSTEM
This generator set is equipped with dual Stator a-c power windings. These two stator windings supply electrical power to customer electrical loads by means of a dual 2-wire connection system. Note, however, that neutral is grounded.
The generator may have been installed so that units power 120/240 volts AC loads (Figure 1); or you can wire them to connect only 120 volts AC electrical loads
(Figure 2). Be sure to install jumper wire between the circuit breakers (C.B. in Figure 2) when reconnecting for 120 volts.
Figure 1 —Connections for 120/Z40 Volts
CAUTION: Do not overload the generator. Some installations may require that electrical loads be alternated to avoid overloading. Applying exces
sively high electrical loads may damage the genera tor and may shorten its life. Add up the rated watts of all electrical lighting, appliance, tool and motor
loads the generator will power at one time. This
total should not be greater than the wattage capaci ty of the generator. If an electrical device nameplate gives only volts and amps, multiply volts times amps to obtain watts (volts x amps = watts). Some electric motors require more watts of power (or amps of current) for starting than for continuous operation.

INSTALLATION

This Owner’s Manual has been prepared under the assumption that a competent, qualified technician installed the generator into an industrial vehicle. We also assume the installer complied with all applicable codes, standards and regulations pertaining to installa tion.
Owners/Operators should make sure nothing is done during installation that might render the unit unsafe or in noncompliance with,applicable codes, standards and instructions. They should be sure the unit has been installed to allow adequate ventilation for cooling and exhaust air.
Figure!—Connections for 120 Volts
GROUNDED
. NEUTIRAL
4
OPERATING INSTRUCTIONS

OPERATING PRECAUTIONS

WARNING: NEVER OPERATE THE GENERATOR SET WHILE THE VEHICLE IS PARKED OVER DRY
LEAVES, DRY GRASS OR ANY OTHER COM
FUSE
Protects the engine DC control circuit against electrical overload. If the fuse element has melted open due to overloading, the engine cannot be cranked. If you must replace it, use only an identical replacement fuse.
BUSTIBLE SUBSTANCE. THE GENERATORS EXHAUST SYSTEM BECOMES EXTREMELY HOT AND CAN CAUSE FIRE IF IT IS TOO CLOSE TO COMBUSTIBLE MATERIALS.
WARNING: THE GENERATORS EXHAUST SYSTEM
GIVES OFF DEADLY CARBON MONOXIDE GAS.
THIS DANGEROUS GAS, IF BREATHED IN SUFFI
CIENT CONCENTRATIONS CAN CAUSE UNCON SCIOUSNESS AND EVEN DEATH. NEVER OPER ATE THE GENERATOR SET WITH THE VEHICLE INSIDE ANY GARAGE OR OTHER ENCLOSED AREA. NEVER OPERATE THE GENERATOR WITH A LEAKING EXHAUST SYSTEM. CLOSE WINDOWS IN
MAIN BREAKER
Protects generators AC output circuit against overload and provides a method of turning OFF the generators 120/240 volts a-c output to vehicle circuits. The IM-52 units have 25 amp breakers while the IM-66 and IM-72 generators are equipped with 30 amp circuit breakers (Figure 4).
NOTE: Refer to THE GENERATOR A-C CONNEC
TION SYSTEM on page 4. Individual installations will differ. If an overload occurs, the dual breaker will open the hot stator leads (11 and 44), When the generator has been connected for 120 volts only, either of the dual circuit breakers will open stator a-c output leads
No. 11 and No. 33.
THE VICINITY OF THE GENERATOR EXHAUST OUT LET AND TAKE ANY OTHER STEPS THAT MAY BE
Figure 4—25 Amp Dual Circuit Breaker
NECESSARY TO PREVENT EXHAUST GASES FROM ENTERING ROOMS OR AREAS OCCUPIED BY PEO PLE OR ANIMALS.
LINE
BREAKERS

GENERATOR CONTROL PANEL

Mounted on the generator control panel.(Figure 3) are
the following features:
Figure 3 —Generator Control Panel
FUSE MAIN
START 15A BREAKER
STOP FUEL
PRIMER
FUEL PRIMER
Before starting a cold engine (it has not been started in more than two weeks), you must press this switch to bring fuel from the tank to the fuel pump. This rocker type switch springs back into its original position when you release it. •
START/STOP SWITCH
To crank and start the engine, hold this switch at its START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in its STOP position until the engine shuts off. The switch center position is the RUN position.
5-
cm

REMOTE START/STOP PANEL

A remote mounted Start/Stop Panel is available, which allows you to start and stop the generator engine con veniently from inside the vehicle.

AUTOMATIC CHOKE

The engine is equipped with an automatic choke. During engine cranking (Start/Stop switch at START),
a solid state choke module signals the choke solenoid to acuate a cyclic rate dependent on ambient tempera ture. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is crank ing. When you start it and release the start/stop switch, choke action stops. As the engine warms, the carburetor choke valve then opens gradually.

BEFORE STARTING THE ENGINE

IMPORTANT: INSTRUCTIONS AND INFORMATION
IN THIS MANUAL ASSUME THE GENERATOR HAS BEEN PROPERLY INSTALLED, CONNECTED, SER VICED, TESTED AND ADJUSTED BY A QUALIFIED INSTALLATION TECHNICIAN OF INSTALLATION CONTRACTOR.
INSTALLATION
Generator installation must have been properly com pleted so it complies with all applicable codes, stan dards and regulations and with the manufacturer's rec ommendations.
ENGINE LUBRIG\TION
Have engine crankcase properly serviced with recom mended oil before starting. Refer to "Maintenance" and "Specifications" sections for oil servicing procedures and recommendations.
CAUTION: Any attempt to crank or start the engine before you have properly serviced it with the recom
mended oil may result in engine failure.
FUEL SUPPLY
The engine must have adequate supply of proper fuel to operate. Before starting, check that sufficient fuel is available.
NOTE;
been provided with its own fuei tank. On other installa tions, the generator may “share” with the vehicle’s fuel tank. When the vehicle’s tank is shared, some installers may have installed a generator fuel pick up tube in the shared tank that is shared tank that is short er than the vehicle’s pick up tube. When a shorter generator fuel pick up tube is installed in the tank, the generator will run out of gas while sufficient fuel remains in the tank for vehicle engine operation.
On some installations, the generator may have

STARTING THE GENERATOR

To start the generator from either the generator control panel or from the optional Remote Panel, proceed as follows:
1. Turn OFF electrical loads, using whatever means provided in your vehicle (such as a main line circuit breaker or trans fer switch.
NOTE;
loads by setting the generators main circuit breaker to “OFF” or “OPEN”. If starting from a Remote Panel, turn OFF loads using whatever means is provided in the vehicle (such as a main circuit breaker).
2. If you have not started the engine in more that two weeks,
3. To crank and start the engine, hold the start/stop switch at
4. Let the engine run at no-load for a few minutes to stabilize
5. Turn ON electrical loads, using whatever means provided
If starting from the generator panel, turn OFF
press the Fuel Pump Primer switch and hold it for about 30
seconds to activate the automatic shut-off function. However, if the engine is warm, skip step 2.
START. Release the switch when the engine starts.
CAUTION: If the engine does not start after it has been cranking for 15 seconds, release the start/stop
A
switch and try again. Holding the switch for longer than 15 seconds can damage the starter motor.
and warm up the engine.
(such as a main circuit breaker or transfer switch).
■ COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compart
ment must be open and unobstructed for continued
proper operation. Without sufficient cooling and venti
lating air flow, the engine-generator quickly overheats, which causes it to quickly shutdown. Overheating could also damage the unit or your vehicle.
ENGINE EXHAUST GAS
Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the vehicle interior and endangering people or animals. Close windows, doors and other openings in the vehi cle that, if open, might permit exhaust gases to enter the vehicle.
DANGER: THE GENERATOR ENGINE GIVES OFF DEADLY CARBON MONOXIDE GAS THROUGH ITS EXHAUST SYSTEM. THIS DANGEROUS GAS, IF BREATHED IN SUFFICIENT CONCENTRATIONS,
CAN CAUSE UNCONSCIOUSNESS OR EVEN
DEATH. DO NOT OPERATE THE GENERATOR IF ITS EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (A) INABILITY TO THINK COHER ENTLY, (B) VOMITING, (C) TWITCHING MUSCLES, (D) THROBBING TEMPLES, (E) DIZZINESS, (F) HEADACHE, (G) WEAKNESS AND SLEEPINESS. IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP. .

STOPPING THE GENERATOR

1. Turn OFF all electrical loads, using whatever means pro vided (such a main circuit breaker or transfer switch).
2. Place start/stop switch in its STOP position.

25 HOUR BREAK-IN PERIOD

The first 25 hours of operation is the break-in period for the generator. Properly breaking in the generator is essential to reducing oil consumption and enhancing engine performance. During the break-in period, observe the following rules:
• For the first 25 hours, run the generator at varying electri cal loads, to help set the engine piston rings properly.
• Following the initial 25 hour break-in period, avoid light electrical loads tor the next 75 hours of operation. The unit should be loaded at 50% (or more) of its capacity during those 75 hours. Repeated light loads during break-in peri od may improperly seat the piston rings, resulting in blow­by and high oil consumption.
• Check oil level frequently during the break-ln period. Add oil if needed. It Is natural for the generator engine to con sume more oil than is normal until the piston rings have seated properly.
• When the 25 hour break-in period is done, complete the tasks recommended under 25 HOUR CHECK-UP PERIOD.
6

25 HOUR CHECK-UP PERIOD

After the first 25 hours of operation have been com
pleted, contact an Authorized Service Facility for the
following maintenance. The Owner/Operator is
responsible for any changes.
• Change engine crankcase oil and oil filler.
• Check all cooling system ventilation openings on the vehicle.
• Check engine carburetor adjustments.
• Check engine ignition system.
• Inspect the entire electrical system.
• Inspect the engine exhaust system.
ATTENTION REQUIRED AFTER
SUBMERSION
If the generator has been submerged in water, it must
NOT be started or operated. Following any submersion in water, have an authorized Generac Service Facility thoroughly clean and dry the generator.

EFFECTS OF MOISTURE AND DIRT

Keep the generator set as clean,and dry as possible.
Protect unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.
When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation. This causes a reduced
insulation resistance and will eventually cause prob
lems. Dirt will make the problem worse, since dirt tends to hold moisture in contact with windings. Salt (as from
sea air) will also worsen the problem since it tends to
absorb moisture from the air. Salt and moisture, when
combined, form a good electrical conductor.
AUTOMATIC LOW OIL PRESSURE
SHUTDOWN
The engine is equipped with a normally-closed (N.C.)
oil pressure switch (Figure 5). Engine oil pressure
holds the switch open during cranking and operation.
Should oil pressure drop below about 8-10 psi, the
switch contacts close and the engine automatically
shuts down.
HIGH OIL TEMPERATURE
SHUTDOWN
An oil temperature switch (Figure 5) with normally­open (N.O.) contacts is mounted on the engine. Should engine oil temperature exceed about 284°F (140°C), the switch contacts close and the engine shuts down.

FIELD BOOST

The controller Circuit Board houses a field boost diode­and resistor. These two components are part of a “field- boost” circuit (Figure 6).
Figure 6 — Field Boost Circuit,
During engine cranking only, a positive DC (battery) voltage is delivered through the diode, resistor, brush es and slip rings, and to the generator rotor. Application of this voltage to the rotor “flashes the field” whenever it is started. Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce the
required “pick up" voltage in the stator windings.

OVER VOLTAGE PROTECTION

A solid state voltage regulator (Figure 7) controls the generators AC output voltage. This regulator supplies an excitation current to the rotor. By regulating the
rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When the AC frequency is 60 Hz, voltage is regulated at 120 volts
(voltage-to-frequency ratio is 2-to-1).
Figure 7 — Solid State Voltage Regulator
Figure 5 — Oil Pressure and Temperature Switches
O—TO ROTOR
The voltage regulator also incorporates a “voltage surge protection circuit." This circuit prevents trouble some surges in the generator AC output voltage. Voltage surge is a common cause of damage to elec tronic equipment.
7
j (O'^eCT CURnÇNT)
FROM STATOR
eXCn'ATIONWINOINQ
{ALTERHATINO CURRENT)
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