SERVICE MANUAL

FOR
BRUSHLESS GENERATORS
2.2 KW THROUGH 15 KW

Gillette Generators, Inc.

2921 Thorne Drive • Elkhart, IN 46514
Web Site - http://www.gillettegenerators.com
E-mail - sales@gillettegenerators.com
Technical Support (800) 777-9639
SRVM3 Phone - (574) 264-9639
GIL-MAN-933-20120823 FAX - (574) 262-1840
 TABLE OF CONTENTS
SUBJECT PAGE
Safety Precautions 2-3
Description of A-C Generator Operation 4
Scheduled Maintenance 5
Generator Repair Procedures 5-9
Generator Dis-Assembly and Re-Assembly 10
Parts Identification 11-23
Wiring Diagrams 24-28
Warranty for K2N & BDN2, O.E.M Generators 29
Warranty for Complete Portable Generator Sets 30

SAFETY PRECAUTIONS
This service manual describes only the methods of repai r WARNING!
concerning the gene rator. Always refer to the engine
manufacturer's repair manual for its o
procedures.
wn repair !
Read through this m anual. Then carefully follo w all BURN HAZARD! All e ngine parts and muffler wil l get
recommendations and safety precautions to keep the extremely hot while running. Complete engine should be
generator functioning properly and to avoid any serious allowed to cool down before set is worked on and
body injury. repaired.
WARNING!
WARNING!
!
!
HIGH VOLTAGE! The job function of the genera tor is
MOVING PARTS! Keep hands, loose clothing, necktie, to produce electricity, and wh enever this en ergy is
hair or test lead s well a way from all moving items a s present, there is the pot ential of ele ctrical shock and
serious injury could result from enta nglement. Never run death by electro cution. No one, e xcept trained and
generator or engine with guards o r protective covers qualified repairmen, should be allowe d to work o n the
removed. generator. Keep everyone, especially children, a way
from unguarded or running set. Wirin g should be
WARNING! inspected frequently. Rep lace any lea ds that are fra yed
or in poor condition. Be sure that generator and plugged
! in equipment are pro perly grounded. Do not operate
electrical equipment when standing in water, wet ground
or when your hands are wet.
LETHAL EXHAUST GAS! The running engine
releases deadly carbon monoxide as part of the n ormal WARNING!
exhaust gas. This poiso nous carbon monoxide gas is
particularly dangerous because it is odo rless and
colorless. Never operate the ge nerator set i nside a
!
building unless this exhaust gas is safely piped o utside
and the proper amount of free fresh air is allowed to enter, FIRE HAZARD! Avoid flash fire. Do not smoke or allow
ventilate, and leave the building. Ne ver operate engin e flame or spa rk near en gine. Never try to fill engine fuel
where exhaust gas may travel insid e occupied building. tank while the engine is running. Safely empty fuel tank
Avoid breathing fumes when working on or near generator before tipping engine to drain oil. Always u se a safe,
set. Use extreme ca ution when ope rating gen-set with portable, vented fuel tank that is designed for the purpose
LPG, PROPANE, or NATURAL GAS fuel. Always consult of storing or hauling fuel when filling the en gine mounted
your local gas co mpany and fire departm ent before fuel tank. Wipe up any fuel spill age before operating
operation is begun to confirm sa fe installation and engine. Never allow chil dren or other u nqualified people
operating conditions. around or near this equipment.
(2)
 WARNING! WARNING!

! !
DANGEROUS FUELS! Use extre me caution when EXPLOSIVE BATTERY GASES! A battery under
handling, storing and using fuels. All fuels a re explosive charge can emit highly explosive gases. Do not smoke or
in a vapor condition. Store all types of fuel in a well permit flame or sp ark near battery, esp ecially when it is
ventilated area away from all flames, sparks, and being charged. Avoid contacting b attery terminals with
children. Ne ver add fuel t o tank while engine is run ning tools to prevent burns o r sparks that could cause an
since spilled fuel may ig nite from ig nition spark or hot explosion. Remove all jewelry befo re handling battery to
engine parts. Keep fuel lines in tight and in good avoid burns. Battery compa rtments should be well
condition. Don't use rigid fuel lines in place of the original ventilated to prevent accumulation of explosive gases.
flexible fuel lines. Do not operate generator set when fuel
spillage, fuel leakage or electrical sparks are noticed.
WARNING!
GASOLINE - Always store gasoline in approved red
containers that are clearly marked "gasoline" and having
proper venting. Don't store gasoline in occupied building.
!
HIGH VOLTAGE! The capacitor contains high voltage.
Use extreme caution wh en handling the capacit or as
WARNING!
electrical shock can result. Always di scharge capacitor
before handling by placing an insulated handle screwdriver
! across capacitor terminals.

DANGEROUS ACID! Avoid all c ontact with battery WARNING!

electrolyte. It contains a dang erous acid which can burn
skin, burn holes in clothing, and cause permanent damage
to eyes. Al ways wear protective safety goggles when
!
working around batteries. If battery electrolyte is splashed
in the eye s or on skin, i mmediately flush area for 30 ELECTRICAL SHOCK! When "flashing" the generator
minutes with large qua ntities of clean fresh water. Seek by applying 12 volts DC battery voltage to ca pacitor
immediate medical aid in event of eye contact. Never add terminals, be careful to avoid touching any b are and
battery acid to a battery that is in service as it may result in exposed battery and cap acitor terminals as dan gerous
dangerous splattering of electrolyte. electric shock is present.

WARNING!
WARNING!

! !
DANGER OF ELECTROCUTION! Some of the test
ELECTRICAL SHOCK! A battery can cause electrical procedures require that the generator set be running while
burns and shocks. Use e xtreme care when working on tests are performed. Extreme caution must be used when
batteries to avoid elect rical connections through tools, making these tests as potential electric shock is present.
wristwatches, rings, or any other type of jewelry.

Always use factory supplied, original parts. Substitution parts This manual and the manufacturer cannot possibly anticipate
often cause m ore failures resulting in eq uipment down-time, every possible happening that might i nvolve a hazard. T he
due to lower values of look-alike components. listings, warnings, and ca utions in this man ual and on tags
and decals affixed to the equipment are, therefore, NOT ALL
You can rel y on 24-hour shipment of common rep air parts of INCLUSIVE. If a certain procedure, work method, test method
these “brushless” generators. and operating procedure that are n ot recommended by this
manual and by this manufacture r is used, you must assu me
Call us a nd ask for our parts manag er to obtain a ny part you all responsibility that it is safe for y ou and for all others. You
may require. must also b e sure that the generator will not be harmed or
damaged or made unsafe by the procedure, work, or method
WARRANTY CLAIM: Notif y factory before any attempt is you have chosen. If y ou modify or change this equipment in
made to repair a Gen-Set. D efective parts must be se nt to us any way from the origin al design, you must assume all
for inspection before warranty claim is approved. responsibility for its safe operation.

(3)
 DESCRIPTION OF A-C GENERATOR OPERATION

A-C GENERATOR GENERATOR CONSTRUCTION

The A-C ge nerator converts the mecha nical energy from Each generator component is d escribed in detail. (See
the engine t o electrical power. The re are fou r major Figure 1)
components involved in the bru shless "Power-Assist"
THE ROTOR
generator set. The construction of each m ajor part is
The engine end of rotor inner shaft is tapered and is
described in detail.
connected directly to the male taper of engine crankshaft.
This end is supported by the en gine crankshaft ball
bearing. The opposite end of rotor is supported by a ball
POWER GENERATION bearing in the bearin g bracket. There are two in dividual
The rotor windings are initially cha rged with a D-C v oltage coils wound on the roto r. These two windings create a
and permanently retains a residual magnetic flux. Duri ng permanent magnetic field for the main stato r power
start-up, an initial flow of electric current is induced in the winding. Wh en the gen-set is working with the cap acitor
winding of the capa citor coils (l ocated in the stator). The removed, this rotor winding will generate approximately 8 -
lines of m agnetic flux, fro m the ch arged rotor, are cut by 12 VAC at 120 VAC normal output and 16 - 24 VAC at 240
the stator field coil windin gs. This induced flow of current VAC normal output in mai n winding, due to what is called
and voltage is very low. “Residual Magnetism”.
As the engin e increases in spe ed, the voltage indu ced in THE STATOR
the capacitor windings rises. An alternating curren t flows The stator is a cylinder and the inside diameter is sl otted
in these windings. The rising and falling magnetic field lengthwise. The win dings of both main power and
from this cu rrent is cut by the field coils in the rotor, capacitor coils (called exciter windings) are placed in these
inducing an excitation voltage. A dio de (rectifier) in the stator slots. The mai n power windings are connected
rotor field winding rectifies the current from A- C to D-C. directly to the output re ceptacles. The exciter winding will
The D-C current in the rotor field generates its own produce power for the rotor field and are co nnected
magnetic field which sweeps past the main power directly to the capacitor.
windings in the stator. This swe eping magnetic field
induces the rated voltage in the main winding as long as THE CAPACITOR
the rotor is turning at the correct speed. This device is connected in series with the exciter winding,
and its only purpo se is to act as a voltage re gulator,
When the el ectric load is con nected to the main power preventing voltage drop when load is applied.
winding, the cap acitor coil circuit will tend to preve nt the
main winding voltage from falling; therefore, acting as a THE DIODE
capacitor regulator. Two diodes (rectifiers) form a full wave rectifier ci rcuit to
convert the induced A-C current to D-C current for full rotor
This innovative voltage stabilizin g effect is calle d "Power- field excitation. Both diodes are lo cated on a disc heat-
Assist" and is an exclusive design with these products. sink in the cooling air flow and are oversized seven time s
required capacity for complete fail-proof design.

FIGURE 1

(4)
 SCHEDULED MAINTENANCE
Scheduled maintenance is "preve ntative maintenance". When running the generator set, note any unusual n oises
Major repairs can be avoided by correcting problems when or unusual smells. Alwa ys follow all safety precautions
they are small. Always look for signs of potential trouble, listed in the front of thi s manual. Refer to tabl e on this
such as loose electrical connections, loose ha rdware or page for sche duled maintenance of the generato r.
loose mechanical connections. Loose screws and bolts, Perform each function at the indicated time interval. Refer
bad fuel connections. Always test the GFCI receptacles (if to engine manual for its individual service requirements.
your gen-set has them) before each use.

ITEM OF INSPECTION AND SERVICE BEFORE EVERY 50 EVERY 200

EACH START HOURS HOURS
Operate in only dry, well ventilated areas. x
Inspect for broken or dirty receptacles. x
Remove inspection cover and view windings
x
for burned or dirty windings.
Tighten all stator thru-bolts, rotor thru-bolts. x
Inspect wiring for frayed or damaged insulation.
Tighten all screws on all receptacles. Inspect connections to x
capacitor. They must be tight.
Remove all ground wires, clean wire terminals and ground
x
location. Re-assemble ground wire.

GENERATOR REPAIR PROCEDURES

GENERAL STEP 2. Open Circuit Breaker: The A-C mainline
When repairing the generato r, always con sider the circuit breaker acts to protect the main power wi nding. It
simplest possible causes first. Narrow the problem down will trip open immediately upon short circuit and trip open
to a specific function al system. For a generator to work within 30 seconds at approximately 15% overload. To
properly, all internal and external parts must be clean. All restore A-C output, close circuit brea ker. Reduce the
electrical connections must be tight. If the generato r amount of electric load if breaker continues to trip open. If
produces no electrical power, check the following possible generator has no electric load applied and breaker
causes in t he exact sequence of (10) repai r steps, continues to trip, replace defective breaker.
beginning with the most frequent problem, before the gen-
set is dis-assembled. If you are operating the gen -set when ambient
temperatures are higher th an 105 F, the thermal brea kers
STEP 1. Engine Speed: Improper low engine speed will automatically trip as a normal function. Do not operate
setting is ve ry common and re sults in being the main generator in these hot con ditions. If the circuit breaker is
problem in a no voltage condition. This should be the first determined not to be the cause, pro ceed to the next repair
item to check. Determin e the engine speed at no load step, #3.
applied to generato r with a tachometer or other qu alified
speed indicator. The en gine must be running at 3750 STEP 3. Open or Shorted Capacitor:
RPM (± 60 RPM) or in t he case of a special 50 cycle Our voltage regulating capacitors are of one common size,
winding, the running speed must b e at 3150 RPM (± 50 50 mfd at 4 40 volts. T hey can be used in a ny size
RPM) for proper voltage output. generator for complete interchangeability. If this capacitor
is open or shorted near to no voltage output will result.
The brushless "Power-Assist" winding is de signed to Always handle or te st the capacitor when the engine is
produce no voltage output if engine speed is reduced 15% stopped. Extremely high voltage is prese nt at the
or more (3 100 RPM at normal speed of 3750 RPM 60 capacitor terminals while generator is in use and these
hertz or 2600 RPM at n ormal speed of 3150 RP M 50 terminals should not be touched as a potential e lectric
hertz) below required speed. Thi s design feature shock condition exists. Al so, when engine is stopped, the
eliminates the problem of low voltage output at low speeds capacitor will still contain high voltage. Use extrem e
which is a co mmon problem with comp etitor's generators caution when handling capacitors. A potential shock
and which may result in d amage to the plugged-in electric condition still exists if saf e handling procedures are not
load. used. Always discharge the capacitor before handling by
Proper speed setting can also be id entified by n o load placing a conductor, such as an insulated handle
voltage output of 122 - 125 volts or no load frequen cy screwdriver, across the capa citor terminals while h olding
output of 62 hertz. If speed setting is prop er and not the on to insulated handle only. This will short out the voltage
cause of no voltage out put, proceed to the next repai r stored in capacitor, thus discharging the capacitor. A loud
step, #2. audible noise will result when capacitor is discharged.
(5)
With the engine stop ped, remove the protective plasti c lost. As the generator is brushless, the field cann ot be
cover from capacitor lead connections. Discon nect both "flashed" in the normal way.
red capacitor winding leads from the capacitor. Check the
capacitor "charge and discharge" readings using an The residual magnetism can sometimes be restored by
ohmmeter on the RX-100 scale. (See Figure 2) connecting a full electric l oad to the re ceptacles and then
manually increase engine speed to approximately 4500
When the ohmmeter lea ds are pla ced on the capacit or RPM for two se conds. This all ows the com pounding
terminals, a meter deflection should be seen (cha rging) system to assist the full load circuit with a resulting
followed by a slow return to infinity (discharging). Reverse increase in the effective residual voltage. This is the quick
the ohmmeter leads and repeat the procedu re for the method and sometimes it does not work. If residu al
same results. No meter deflection or continuing continuity magnetism of 4-6 volts is not resto red, proceed to actua l
indicates an open or shorted capacitor. "flashing" of the rotor winding.

All capacitors have an internal, built-i n circuit brea ker. If The generator set should be run at normal no-load speed,
capacitor becomes "shorted", this internal circuit breaker A 12 VDC battery should then be instanta neously
trips open and causes the entire top portion (where "flashed" ("touched" for only one second) across the
terminals are located) to become extremely convexed or to capacitor terminals. Pola rity is of no con cern. Th e red
push outward. When this happ ens, the cap acitor is bad leads should remain connected to the cap acitor. The
and must be replaced. output voltage should then build up to normal levels. (See
Figure 3.)
CAUTION: Inspect connection of red wires to capacitor
terminals. They must be sold ered rigidly tight. Repair or Caution: Flashi ng the field has resto red voltage o utput;
replace any loose or poor connections. If there i s no but when set is stopped and restarted with resultin g no
method to check the cap acitor, check the Yellow Page s voltage output, then check engine speed as it is too low.
and call any electric motor repair shop. They have the
equipment to test cap acitors. If the capaci tor is A potential shock hazard exists when handling battery and
determined not to be the cause, pro ceed to the next repair battery jumper leads. Never wear jewelry, or use tools, or
step #4. metal items that may make cont act across battery
terminals. Revie w safety rules at the begin ning of this
manual.

If residual m agnetism was not the problem, pro ceed to

next step, #5.

FIGURE 2

STEP 4. Loss of Rotor Residual Magnetism-Flashing

Field: The rotor windings have b een "charged" with a
powerful D-C current, and it will hold a residual magnetism
within its metal lamination stack. When every component FIGURE 3
in the rotor system (roto r windings and diodes) are good STEP 5. Receptacle Panel Wiring: Inspect the
and engine speed is correct, an A-C vo ltage of 8 -12 volts receptacle panel for worn or loose wires. Make sure all
on 120 VAC and 16 - 24 volts can be measured at the 240 wires are se cure and tight at the screws of recep tacles.
VAC load lin es of stato r power outp ut leads. Wit h no Do not allow wires to be pinched, kin ked or damag ed in
voltage present, or o ne-half or le ss of above designated any way. Inspect for tight connections at circuit bre akers,
voltage, it can be presum ed that resid ual voltage is lost, capacitors, and all receptacles. Rep lace any broken
and the rotor winding must be re-energized or "flashed". component. Test any GFCI receptacles by use of its built-
in test and reset buttons. Panel wiring must conform with
If the rotor h as been removed or the generator has been diagrams as shown on Page 28 through 33. If panel wiring
stored for over six months, the rotor's magnetism may be checks good, proceed to next repair step, #6.
(6)
STEP 6. Open, Shorted, or Grounded Stator Main with any of the four black wires, and they should not have
Windings: The stator is the outside stationary winding as continuity with a good ground surface.
shown in Figure 1. It consists of copper wire laid in a steel
laminated frame. To remove stator assembly, follow dis- Check all resistance values with the resistance chart found
assembly instructions, part #1 through #5, on page 10. on Page 8. If complete st ator winding is not the pro blem,
proceed to the next repair step, #8.
The stator windings form two main poles and have four
coils per pole with two lead wire s connected to each pole STEP 8. Open, Shorted or Grounded Rotor Winding:
winding. The large black lead wires are numbered #1 and The rotor assembly consists of two separate coils with two
#2 for one field pole; #3 and #4 for the other field pole . To diodes mounted on a special heat-sink disc. For thi s test,
test the main powe r winding, disconnect all lead wires. it is necessary to remove the bearing bracket and stator so
Set ohmmeter to lowest O HM x 1 scale . Place one meter there is room to work on the rotor.
test lead on #1 lead of stator winding and the other test
lead on #2 lead of stator winding. (see fig. 4) Then record Prior to te sting, visually i nspect windings for dark streaks
this resistance value. Measu re resistance values of leads (shorted), check ball b earing by h and rotation. If it is
#3 and #4 of the second main pole winding. Record all rough, noisy or dry, re place bearing. Try a quick
values and check them with resistance chart on Page 8. resistance test by placing ohmmeter t est probes across
the solder connection of each diode (rectifier) that is
When testing for resi stance, also test for gro unded field mounted on rotor. The resulting resistance must compare
coils. One ohmmete r test lead stays on field coil lead with rotor resistance as listed on chart as sho wn on Page
while the other test lea d is touched to a good "g round" 8. If resistance does not co mpare, further testing is
surface of the metal frame bracket hol ding these coils. A required by removing the diodes from the rotor winding.
reading of th e ohmmeter indicates a bad condition of a
ground field coil and stator assembly should be replaced. The two copper wires must be removed from the tip of the
diodes where they are soldered. Remove these wires with
CAUTION: Make sure all leads are disconnected and the aid of a solder gun being careful not to brea k any
free. The #2 & #3 main field coil leads are intenti onally copper wires. With copper wires free, check each coil with
grounded to form a neutral and will g ive meter a false an ohmmeter on its lo west OHM x 1 scale. Record this
reading. value and compare it with the roto r resistance chart on
Page 8.
Grounded field coils indicate defective stator.
Also test each coil to ground: One meter test lead to coil
No reading or resistance values when testing between two wire and the other test lead to the metal bracket that holds
lead wires (#1 and #2 or #3 an d #4) indicate an open these coils. An ohmmeter reading indicates a grou nded
stator, and it should be replaced. defective rotor, and it should be replaced. (See Figure 4)

Check all met er resistances with chart resistances on Always inspect all stator and rotor windings for clea n
Page 8. A quick test for the entire stator winding assembly condition. Windings that are covered with mud, dirt, paint,
is to disconnect the two red wires from the capacitor. With and chemicals may test good; but they won't last long
capacitor out of the circuit, conne ct 12 VDC to the se two unless they are clean ed with an approved electrical
red wires an d start the g en-set. If you measure 30-40 cleaner then resealed with an air dry electrical varnish.
VAC from 240 volt rece ptacle with an AC voltmeter, the
main winding, the rotor, a nd the capa citor are goo d; but STEP 9. Diode (Rectifier): The ex clusive and unique
the exciter winding (wound on top of the main winding) is design of this "Power-Assist" brushless generator is the fail
bad. This requires a complete replacement of stator -proof diode system. It is hig hly unlikely that a diode
assembly. If stator main windi ng tests good, pro ceed to should ever have to be replaced. Thi s is why the diode
next repair step, #7, for further stator tests. testing is reserved for the last test. Diodes are the number
one replacement problem with all other porta ble gen-set
STEP 7. Open, Shorted, or Grounded Stator Exciter brands. Ou r 1600 volt, 25 amp diod e capacity resists all
Winding: The exciter windi ng is laid directly on top of spike problems, and it is a rare o ccurrence to have these
main winding inside stator assembly. It has two coil s per special diodes fail. Ho wever, the repairman must be
pole and is conne cted to two re d lead wires. Same test familiar with the function and repair of these diodes. Page
procedures as described in Item 6 a re used to test the 28 shows the diode position and connection.
exciter winding. Disconnect and remove the two red wires
from the capacitor. Measure resistance across these red A diode can “SHORT” or “OPEN” to become defective. A
wires that lead into stator winding an d test for grounded shorted diode is the most common defect in competitor’s
exciter winding. generators, but not in this design, due to highly over-rated
diode values. Howeve r, one or b oth diodes, as well as
Test also for continuity between red wires and all main windings, can be destroyed if utility power i s allowed to
power winding leads, having lead #1 - #2 and # 3 - #4. If enter the gen-set. If gen-set is used for emergency power,
meter shows reading, the exciter winding has shorted with no isolating transfer switch, the return of utility power
(made connection) into the main power winding, and stator will enter the gen-set system.
is defective. The red wires should not have any continuity
(7)
If the engine no load speed is norm al 3750 RPM but Many other conditions may happe n to cau se no voltage
output voltage is only half the normal volts, one of the two output with no apparent reason:
diodes may be open, It is necessary to determine whether
this voltage is a result of an o pen diode or is due to a A) If generat or has be en under water or left in a severe
defective rotor or stator winding. Suspe ct a defe ctive rain, the insulation system is soaked and will ground out if
capacitor if both diodes and windings are good. used. The generator must be taken apart and both stator
and rotor must be oven baked at 300ºF for 3 hours.
Use an ohmmeter in the lowest scale OHMS x 1 position.
Test the dio de in the forwa rd (positive) position. The B) If generator windings have been exposed to salt water
ohmmeter should read approximately 15 OHMS (or close (road salt or sea water), a condition b etween exciter and
to zero). Reverse the ohmmeter test leads and read over main winding will create a certain val ue of capacitance,
2000 ohms (or close to infinity). (See Figure 4.) nullifying standard cap acitance. The windi ngs must be
cleaned and baked dry, as described in item (A).
Simply put, regardle ss of meter polari ty, the ohmmeter STATOR, ROTOR, AND
reading should be zero in one direction and infinity in the DIODE RESISTANCE
opposite direction (reversed meter test leads). The same MEASUREMENT
infinity reading in both direction s indicates an open d iode. METHODS
A zero reading in both directions indicates a shorted diode.
Both examples indi cate a defective diode and sho uld be
replaced. When on e diode is defe ctive, it is advised to
replace both diodes as the rem aining may have been
weakened. Use a sol dering iron to soften solde r and
remove the copper conductor wires from the diode. When
re-soldering copper wires to new diode, be careful n ot to
damage, crack, or break the copper wires. Do not allow
heat of sold ering iron to remain on diode for over ten
seconds or diode damage may result.

NOTE: Dep ending on meter manufa cturer, the red and

black leads may be reversed in location as sho wn in
Figure 4. If diodes test good, pro ceed to the next r epair
step, #10.

STEP 10. Actual component testing is no w complete.

Defect or pro blem should have been found during these
repair steps #1 through #9. If probl em exists, call service
department toll-free (866) 537-4388 and ask for additional
repair help. FIGURE 4

GENERATOR SIZE MAIN WINDING CAPACITOR WINDING ROTOR WINDING

AND KW RATING MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM
2.8 AND 3.0 KW, 2 1/2
LAMINATION LENGTH .905 .915 1.625 1.635 .850 .870
4.0 KW, 3”
LAMINATION LENGTH .568 .563 1.942 1.947 .905 .875
5.0 KW, 3 7/8”
LAMINATION LENGTH .365 .370 1.455 1.460 .710 .730
6.0 KW, 4 1/4
LAMINATION LENGTH .343 .348 1.227 1.232 .735 .755
6.5 AND 7.5KW, 4 3/4
LAMINATION LENGTH .247 .252 1.446 1.451 .832 .852
9.0 KW, 5 1/2”
LAMINATION LENGTH .169 .174 1.218 1.223 .515 .535
10.5 KW, 6”
LAMINATION LENGTH .130 .135 .563 .568 .555 .575
12.0 KW, 6 1/2”
LAMINATION LENGTH .119 .124 .562 .567 .587 .607
15.0 KW 7 3/4”
LAMINATION LENGTH .092 .097 .449 .454 .655 .675
18.0 KW 10”
LAMINATION LENGTH N/A N/A N/A N/A N/A N/A
CAUTION: THESE RESISTANCE VALUES ARE VERY SMALL AND TESTING REQUIRES A GOOD QUALITY LOW RESISTANCE READING METER. ALL METER
READINGS OF ZERO INDICATE AN OPEN(BAD) W INDING. ALL METER READINGS FROM WINDING TO METAL FRAME(GROUND), INDICATE A GROUNDED
(BAD) WINDING. ROTOR RESISTANCE IS MEASURED ACROSS EACH SOLDER JO INT OF THE TWO DIODES, WHICH ARE CONNECTED IN PARRALLEL WITH
ROTOR COILS. TO DETERMINE RESISTANCE OF EACH SINGLE POLE, MULTIPLY CHART RESISTANCE X 4, THEN ÷ BY 2.
(8)
 QUICK REFERENCE GENERATOR FAULT GUIDE
SYMPTOM POSSIBLE CAUSE REMEDY
Increase engine speed to 3750 RPM,
Generator rotor speed is too low.
62 hertz, 125 volts, no load setting.
Reset breaker, Check GFCI receptacles
Circuit breaker is tripped open.
for proper operation

Open, shorted capacitor or red leads

Replace capacitor or connected leads.
disconnected from capacitor.

Loss of rotor residual magnetism.

Restore magnetism by loading generator
No Output Voltage, (A reading of approximately 16 - 24 volts
or flashing rotor fields.
or a small, 16 to 24 VAC, AC, indicates residual magnetism)
as measured on two hot
Inspect all wiring and components on
positions of 240 VAC receptacle Defective receptacle panel.
receptacle panel. Repair or replace
One or both diodes open or shorted.
Replace both diodes
(see figure 4)
Open or shorted main power windings. Replace stator.
Open or shorted capacitor windings. Replace stator.

Open or shorted rotor winding. Replace rotor.

No load voltage between 8 - 12 volts at One diode is open . capacitor is defective

correct operating speed, on 120 VAC or exciter winding is bad.
Engine speed slightly below operating Increase engine speed to 3750 RPM,
speed but enough to collapse all output. 62hertz, 125 volts, no load setting.
Low Output Voltage Rotor winding wire broken off at diode
Re-solder copper wire to diode.
solder joint.
Rotor slipping and free wheeling on engine (1) Tighten rotor thru-bolt.
crankshaft. (2) Possible broken engine crankshaft.
Rotor winding partially shorted. Test rotor winding. Replace rotor.
Reduce engine speed to 3750 RPM,
Generator rotor speed too high.
62 hertz, 125 volts, no load setting.
High Output Voltage
Check capacitor size. It should be 50 mfd.,
Higher micro-farad size capacitor is used.
440 volts.

Some generators have multiple copper

wires in field coil. One or more of these Test resistance measurements - replace
individual wires may break off the stator.
connecting lead wire.

Rotor diodes have a partial loss of blocking

The No Load Voltage Output Replace diodes.
characteristics but still tests good.
is at normal reading but drops
down as electric load is applied. Engine is in need of repair. Carboned
cylinder head, bad fuel, or defective engine Have authorized repair station test engine.
governor will reduce effective horse power.
The connected electric load has an
Correct the power factor to be between .9
unacceptable power factor, below .7
and 1.0.
lagging inductive load.

If diode has shorted to conduction of both directions, the residual magnetism of rotor field may have been destroyed
and it may be necessary to “flash” the exciter winding.

The generator set may be limited by the horsepower rating of the engine. As a guide, the engine has to supply (2)
horsepower for each 1000 watts of power.

Rotation can be in either direction. There is no volta ge output when engine speed drops 20% below normal 3750 rpm
62 hertz duty or 3150 rpm 52 hertz duty.
(9)
 DIS-ASSEMBLY AND RE-ASSEMBLY INSTRUCTIONS
FOR 2 -POLE GENERATOR KITS, 2.8KW - 18KW
DIS-ASSEMBLY engine will be resting on its r ecoil starter. Pour p enetrating oil
STEP 1: Remove two machine screws from cover housing (Ref. straight down the hollow rotor shaft and let it set overnight. After
L) and remove it from bearing casting (Ref. N). 24 hours, proceed again to use sharp blows until rotor is free
from engine shaft.
STEP 2: Disconn ect stator wires from flexible conduit wires by STEP 7: The cooling fan (Ref. D) is mounted o n engine
cutting apart the b utt-splice insulated connectors. Be car eful to crankshaft on sizes 2 KW through 7.5 KW . The cooling fan is
make a dr awing or m ark all d isconnected wires so that mounted on rotor shaft for si zes 9 KW to 1 5 KW. In all c ases,
reconnections are correct. loosen two fan hub set screws and pull fan free.

STEP 3: Remove a ll four stator thru-bolts (Ref. K), both flange STEP 8: Remove four bolt s from engine casting (Ref. A). Use
nuts on mounting feet of casting (Ref. N), and rotor thru-bolt (Ref. soft hammer and tap casting off engine pilot flange.
I).
RE-ASSEMBLY
STEP 4: Remove b earing bracket (Ref. N) from the generator. This is basical ly a reversa l of disassembl y. The following is a
It will be necessary to l ift the ge nerator end u p and off the brief recap with some emphasizing of important points.
vibration isolators to remove the casting. This bearing bracket
casting is a tight fit on the sta tor flange and the rotor ball bearing STEP 1: Install engine casting on engine pilot flange and secure
so a pull ey puller should be used. Do not pry this a luminum with four bolts. Casting must be even with pilot with no distorted
casting off with or un e ven
two screw- assembly fit.
drivers as
casting will STEP 2: Re-install
b e c o m e cooling fan on
distorted and engine shaft or
may crack or rotor shaft.
break. Be
careful when STEP 3: Install
casting is rotor onto e ngine
removed as taper; but first
remaining inspect female
generator set taper and engine
will drop. It is shaft for clean
recommended surfaces. Push the
to block up the rotor on the e ngine
generator end shaft and c heck for
to prevent it a snug fit. There
from falling. should be no
looseness or sloppy
STEP 5: fit. Install rotor bolt
R e m o v e (Ref. I) and tighten.
stator (Ref. J).
It may be STEP 4: Slide
necessary to stator over rotor
pry the stato r and push into place
assembly as far as possible.
round housing
from machine STEP 5: Install
fit of engin e bearing casting
casting (Ref. (Ref. N) b y lightly
A). Once tapping its b earing
stator assembly is loose, pull stator over rotor assembly and free bore over and onto the rotor ball b earing. Be very careful to start
from generator. Be careful not to hit or s crape rotor or stator this casting o n straight. Keep lig htly tapping until casti ng is on
windings when stator is being removed. the ball bearing but not fitting into inside diameter of stator sleeve
ends. Instal l four stator thru- bolts (Ref. K) and matching flange
STEP 6: The rotor shaft (Ref. F) has an inner female taper , and nuts. T ighten nuts usi ng X-pattern and lightly tap c asting so it
it has been fitted over the ma tching male taper of engi ne draws up evenly. Continue this until casting pilots are all the way
crankshaft. The rotor bolt (Ref. I) has already been removed in into stator sleeve. Tap around casting bore to ensure pressure is
Step 3). The tight fit of th ese two taper fits will have to be relieved. Test by pulling on engine starting rope. T he generator
loosened. Using a ra whide hammer or a steel hamme r and must turn easily or assembly is wrong.
wooden block, give the side o f the rotor one or t wo sharp blows,
then alternate to the oth er side with equal sharp blows.
Eventually, the two tapers will loosen, and the rotor can be pull ed STEP 6: F inish reconnection of wires and assemble cover (Ref.
free from the engine shaft. A last resort (for rust or corrosion L).
between tapers) is to position rotor assem bly straight up. The

(10)
BRUSHLESS AND BRUSH TYPE GENERATOR
MAXIMUM (STANDBY) KW SIZE
REPAIR PARTS AND LIST PRICE SHEET
GPN-GPND-GPNR-PP-EV-BDN2-K2N NET- 4500
PRICE 2200 3500 5000 6500 14000
9000 10500 12500
REF. PART# REPAIR PART DESCRIPTION EACH 3000 4000 5500 7500 15000
ITEM 6000
A 220007 DRIVE END CASTING, BDN $ 81 1 1
A 220008 DRIVE END CASTING, BDN 88 1 1 1
A 220001 ENGINE CASTING 56 1 1
A 220002 ENGINE CASTING 56 1 1
A 220010 ENGINE CASTING, 5 3/4” PILOT 75 1 1 1 1
A 220011 ENGINE CASTING, 6 7/16” PILOT 90 1 1 1 1
A 220012 ENGINE CASTING, 7” PILOT 90 1 1 1 1
B 201001 BOLT AND NUT, BDN BEARING RETAINER 3 2 2 2 2 2
B 201002 5/16” BOLT AND WASHER, CASTING RETAINER 3 4 4
B 201003 3/8” BOLT AND WASHER, CASTING RETAINER 3 4 4
B 201004 7/16” BOLT AND WASHER, CASTING RETAINER 3 4 4 4 4
DE 230017 COOLING FAN WITH SCREWS (E) A - FAN 30 1 1
DE 430017 COOLING FAN WITH SCREWS (E) BORED -A (PP-28) 30 1
DE 230018 COOLING FAN WITH SCREWS (E) C - FAN 30 1 1
DE 230019 COOLING FAN WITH SCREWS (E) D - FAN 30 1 1
DE 230020 COOLING FAN WITH SCREWS (E) E - FAN (BDN) 30 1 1
DE 230022 COOLING FAN WITH SCREWS (E) G - FAN (BDN) 33 1 1 1
DE 230022 COOLING FAN WITH SCREWS (E) G - FAN 33 1 1 1 1
FGH 612500 ROTOR, 2.2, 3.0 KW (2 1/2” LAM STACK) 253 1
FGH 613000 ROTOR, 3.5, 4.0 KW (3” LAM STACK) 268 1
FGH 613870 ROTOR, 4.5, 5.0, 5.5, 6.0 KW (3 7/8” LAM STACK) 291 1
FGH 614250 ROTOR, 6 KW (4 1/4” LAM STACK) 305 1
FGH 614750 ROTOR, 6.5, 7.5 KW (4 3/4” LAM STACK) 347 1
FH3 634750 ROTOR, 8.0, 9.0 KVA 3Ø (4 3/4” LAM STACK) 395 1
FGH 615500 ROTOR, 9.0 KW (5 1/2” LAM STACK) 390 1
FH3 635500 ROTOR, 11.0 KVA 3Ø (5 1/2” LAM STACK) 475 1
FGH 616000 ROTOR, 10.5 KW (6” LAM STACK) 437 1
FH3 636000 ROTOR, 13.0 KVA 3Ø (6” LAM STACK) 484 1
FGH 616500 ROTOR, 12.5 KW (6 1/2” LAM STACK) 460 1
FH3 636500 ROTOR, 15.0 KVA 3Ø (6 1/2” LAM STACK) 507 1
FGH 617750 ROTOR, 14 KW (7 3/4” LAM STACK) 502 1
FH3 637750 ROTOR, 17.5 KVA 3Ø (7 3/4” LAM STACK) 578 1
FGH 261250 ROTOR, 3.0 KW (BDN) (2 1/2” LAM STACK) 252 1
FGH 261387 ROTOR, 4.5 KW (BDN) (3 7/8” LAM STACK) 282 1
FGH 261425 ROTOR, 6.0 KW (BDN) (4 1/4” LAM STACK) 333 1
FGH 261475 ROTOR, 7.5 KW (BDN) (4 3/4” LAM STACK) 366 1
FH3 263475 ROTOR, 9.0 KVA (BDN-3Ø) (4 3/4” LAM STACK) 414 1
FGH 261550 ROTOR, 9.0 KW (BDN) (5 1/2” LAM STACK) 446 1
FH3 263550 ROTOR, 11.0 KVA (BDN-3Ø) (5 1/2” LAM STACK) 522 1
FGH 261650 ROTOR, 12.0 KW (BDN) (6 1/2” LAM STACK) 478 1
G1 270801 RECTIFIER, REVERSE POLARITY w/ HDWR 25 1 1 1 1 1 1 1 1
G2 270802 RECTIFIER, FORWARD POLARITY w/ HDWR 25 1 1 1 1 1 1 1 1
H 241000 BALL BEARING, SINGLE ROW 9 1 1 1 1 1 1 1
H 241001 BALL BEARING, DOUBLE ROW 26 1
H 241001 BALL BEARING, DOUBLE ROW FOR BDN 26 1 1 1 1 1
I 210218 ROTOR THRU-BOLT ASSEMBLY, 7 3/8” LG. 7 1 1 1
I 210225 ROTOR THRU-BOLT ASSEMBLY, 12” LG. (MODEL GPND-125E) 7 1
I 210206 ROTOR THRU-BOLT ASSEMBLY, 8 5/8” LG. 7 1
I 210207 ROTOR THRU-BOLT ASSEMBLY, 11 1/2” LG 7 1 1 1
I 210208 ROTOR THRU-BOLT ASSEMBLY, 14 3/8” LG 7 1
I 206006 ROTOR END, BEARING RETAINER BOLT, ASSMBLY 3/4”LG 5 1 1 1 1
J 712250 STATOR, 2.2, 3.0 KW (2 1/2” LAM 232 1
J5 712255 STATOR, 1.8 - 2.3 KW (50 HZ) (2 1/2” LAM 240 1
J 713000 STATOR, 3.5, 4.0 KW (3” LAM 244 1
J5 713005 STATOR, 2.8, 3.2 KW (50 HZ) (3” LAM 254 1
J 713870 STATOR, 4.5, 5.0, 5.5, KW (3 7/8” LAM 282 1
J5 713875 STATOR, 3.5, 4.0, 4.5, KW (50 HZ) (3 7/8” LAM 291 1
J 714250 STATOR, 6.0 KW (4 1/4” LAM 329 1
J5 714255 STATOR, 5.0 KW (50 HZ) (4 1/4” LAM 339 1
J 714750 STATOR, 6.5, 7.5 KW (4 3/4” LAM 371 1
J5 714755 STATOR, 5.5, 6.0 KW (50 HZ) (4 3/4” LAM 381 1
J3 734750 STATOR, 8.0, 9.0 KVA 3Ø (4 3/4” LAM STACK) 398 1
J35 734755 STATOR, 6.5, 7.5 KVA 3Ø (50 HZ) (4 3/4” LAM STACK) 407 1
J 715500 STATOR, 9.0 KW (5 1/2” LAM STACK) 407 1
J5 715505 STATOR, 7.5 KW (50 HZ) (5 1/2” LAM STACK) 419 1
J3 735500 STATOR, 11.0 KVA, 3Ø (5 1/2” LAM STACK) 436 1
J35 735505 STATOR, 9.0 KVA, 3Ø (50 HZ) (5 1/2” LAM STACK) 446 1
J 716000 STATOR, 10.5 KW (6” LAM STACK) 432 1
J5 716005 STATOR, 8.0 KW (50 HZ) (6” LAM STACK) 442 1
(11)
BRUSHLESS AND BRUSH TYPE GENERATOR
MAXIMUM (STANDBY) KW SIZE
REPAIR PARTS AND LIST PRICE SHEET
GPN-GPND-GPNR-PP-EV-BDN2-K2N NET 4500
PRICE 2200 5000 6500 14000
PART 4000 9000 10500 12500
REF. REPAIR PART DESCRIPTION EACH 3000 5500 7500 15000
# ITEM 6000
J3 736000 STATOR, 13.0 KVA, 3Ø (6” LAM STACK) $ 460 1
J35 736005 STATOR, 10.0 KVA, 3Ø (50 HZ) (6” LAM STACK) 473 1
J 716500 STATOR, 12.0 KW (6 1/2” LAM STACK) 456 1
J5 716505 STATOR, 9.0 KW (50 HZ) (6 1/2” LAM STACK) 465 1
J3 736500 STATOR, 15.0 KVA, 3Ø (6 1/2” LAM STACK) 484 1
J35 736505 STATOR, 12.0 KVA, 3Ø (50HZ) (6 1/2” LAM STACK) 492 1
J 717750 STATOR, 14 KW (7 3/4” LAM STACK) 502 1
J5 717755 STATOR, 12 KW (50 HZ) (7 3/4” LAM STACK) 512 1
J3 737750 STATOR, 18.8 KVA, 3Ø (7 3/4” LAM STACK) 530 1
J35 737755 STATOR, 15.0 KVA, 3Ø (50 HZ) (7 3/4” LAM STACK) 540 1
K 210211 STATOR THRU-BOLT WITH NUTS, 9 3/4” LG. 6 4 4
K 210209 STATOR THRU-BOLT WITH NUTS, 11” LG. 6 4
K 210212 STATOR THRU-BOLT WITH NUTS, 12 1/2” LG. 6 4
K 210213 STATOR THRU-BOLT WITH NUTS, 14 3/4” LG. 8 4 4 4
K 210214 STATOR THRU-BOLT WITH NUTS, 17 3/4” LG. 11 4
LM 211040 INSPECTION COVER WITH SCREWS 17 1 1 1 1 1 1 1 1
N 220005 BEARING CASTING, 1 PHASE 71 1 1 1 1 1 1 1 1
N 420005 BEARING CASTING, 3 PHASE 77 1 1 1 1 1
O 241002 BALL BEARING, BDN DRIVE END 47 1 1
O 241003 BALL BEARING, BDN DRIVE END 64 1 1 1
P 210739 BEARING RETAINER PLATE, BDN 8 1 1
P 210740 BEARING RETAINER PLATE, BDN 9 1 1
Q 240800 BRUSHES WITH SCREWS, 3Ø 11 2 2 2 2 2
R 201007 SCREW AND LOCKWASHER, 3Ø 2 1 1 1 1 1
SS 230023 BRUSH-BRUSH HOLDER ASSEMBLY, 3Ø 43 1 1 1 1 1
Y 240101 RETAINER RING, BALL BEARING 8 2 2
Y 240102 RETAINER RING, BALL BEARING 8 2 2 2

BDN SERIES
3.0 - 12 KW
BRUSHLESS TYPE

(12)
GPN-PP-EV SERIES
2.2 THRU 4.0 KW
BRUSHLESS TYPE

GPN-GPND-PP-EV
SERIES
4.5 THRU 7.5 KW
BRUSHLESS TYPE

(13)
 GPN - GPND - GPNR -
EV - SP - SPD SERIES
9.0 THRU 15 KW
BRUSHLESS TYPE

TYPICAL (3) PHASE

WINDING MODIFICATION
FROM 6 THRU 17.5 KVA

(14)
RECEPTACLE PANEL / ENGINE COVER MAXIMUM (STANDBY) KW SIZE
REPAIR PARTS AND LIST PRICE SHEET AIR COOLED ENGINES
GPN-GPND-GPNR-PP-EV-BDN2-K2N NET 4500
PRICE 2200 3500 5000 6500 14000
PART 9000 10500 12500
REF. REPAIR PART DESCRIPTION EACH 3000 4000 5500 7500 15000
# ITEM 6000
A 211042 RECEPT. PANEL COVER ONLY (PP) $ 19 1
AA 911042 RECEPT. PANEL - COMPLETE - BUILD (PP) 47 1
A1 211024 RECEPT. PANEL COVER ONLY (PP) 34 1 1 1
AA1 911024 RECEPT PANEL - COMPLETE - BUILD (PP) 97 1 1 1
A2 211028 RECEPT. PANEL COVER ONLY (GPN) 32 1 1 1
AA2 911028 RECEPT PANEL - COMPLETE - BUILD (GPN) 144 1 1 1
A3 211038 RECEPT. PANEL COVER ONLY (GPNDL-60E) (GPN) 49 1 1 1 1 1
AA3 911038 RECEPT PANEL - COMPLETE - BUILD (GPNDL-60E) (GPN) 232 1 1 1 1 1
A4 211029 RECEPT. PANEL AND BOX ONLY (BDN) 29 1
AA4 911029 RECEPT. PANEL AND BOX COMPLETE - BUILD (BDN) 142 1
A5 211030 RECEPT. PANEL AND BOX ONLY (BDN) 42 1
AA5 911030 RECEPT. PANEL AND BOX COMPLETE - BUILD (BDN) 144 1
A6 211030 RECEPT. PANEL COVER ONLY (EV) 48 1
AA6 911030 RECEPT. PANEL - COMPLETE - BUILD (EV) 170 1
A7 211031 RECEPT. PANEL AND BOX ONLY (BDN) 46 1
AA7 911031 RECEPT. PANEL AND BOX COMPLETE - BUILD (BDN) 185 1
A8 411031 RECEPT. PANEL AND BOX ONLY (BDN) 47 1 1
AA8 411931 RECEPT. PANEL AND BOX COMPLETE - BUILD (BDN) 196 1 1
A9 211023 BLANK PANEL COVER ONLY (3Ø) 26 1
A10 211003 BLANK PANEL COVER ONLY (3Ø) 39 1 1 1 1
AA10 911003 BLANK PANEL - COMPLETE (3Ø) 131 1 1 1 1
A11 930979 ENGINE COVER W/ METERS 3 - 5.5 KW (GPN) 169 1 1
A12 930983 ENGINE COVER W/ METERS 6.5 - 7.5 KW (GPN) 178 1
A13 910979 ENGINE COVER 3 - 5.5 KW (PP) 39 1 1
A14 910983 ENGINE COVER 6.5 - 7.5 KW (PP) 47 1
A15 910955 ENGINE COVER 9 - 15 KW (GPN) 104 1 1 1 1
B 201008 PANEL AND COMPONENT HDWR 4 4 6 6 6 8 8 8 8
C 270300 DUPLEX RECEPT., NEMA 5-15R (PP - BDN) 11 2 2 2 2 2 2
C 270313 DUPLEX RECEPT., NEMA 5-15R, GFCI (GPN - GPNR) 28 2 2 2 2 2 2 2
D 270701 CIRCUIT BREAKER, 20 A., PUSH BUTTON 41 1 2 2
D 270702 CIRCUIT BREAKER, 25 A., PUSH BUTTON 41 2 2 2 2 2
D 270703 CIRCUIT BREAKER, 30 A., PUSH BUTTON (GPN) 46 1 1 1 1 1
D1 270703 CIRCUIT BREAKER, 30 A., PUSH BUTTON (BDN) 46 2
D1 270707 CIRCUIT BREAKER, 35 A., PUSH BUTTON (BDN) 46 2
D1 270704 CIRCUIT BREAKER, 40 A., PUSH BUTTON (BDN) 46 2
D1 270706 CIRCUIT BREAKER, 50 A., PUSH BUTTON (BDN) 58 2
E 270715 CIRCUIT BREAKER, 20 A., 1 POLE MAG. (GPN) 26 1
E 270716 CIRCUIT BREAKER, 20 A., 2 POLE MAG. (GPN - GPNR) 47 1 1
E 270717 CIRCUIT BREAKER, 30 A., 2 POLE MAG. (GPN - GPNR) 52 1
E 270718 CIRCUIT BREAKER, 35 A., 2 POLE MAG. (GPN - GPNR) 56 1
E 270719 CIRCUIT BREAKER, 45 A., 2 POLE MAG. (GPN - GPNR) 60 1 1
E 270720 CIRCUIT BREAKER, 50 A., 2 POLE MAG. (GPN - GPNR) 65 1
F 270311 RECEPT. TWIST-LOCK NEMA L14-20R 36 1
F 270310 RECEPT. TWIST-LOCK NEMA L14-30R 41 1
F 270314 RECEPT. STRAIGHT BLADE NEMA 14-30R 43 1
F 270308 RECEPT. STRAIGHT BLADE NEMA 14-50R 45 1 1 1 1
G 270306 RECEPT. TWIST-LOCK NEMA L5-30R 39 1 1 1 1 1
H 270863 440V CAPACITOR, BRACKET, AND HDWR 3 - 9 KW 60 1 1 1 1 1
HH 270863-2 440V DUAL CAPACITORS, BRACKET, AND HDWR 10.5 - 15 KW 120 1 1 1
I 270806 VOLTMETER AND HDWR (GPN) 43 1 1 1 1 1 1 1
J 270807 HOUR METER AND HDWR (GPN) 37 1 1 1 1 1 1 1
K 270011 ROCKER START-STOP SWITCH (OPTIONAL) (GPNR) 11 1 1 1 1 1 1
L 241109 KUBOTA START-STOP KEY SWITCH (GPND) 54 1 1 1
L1 241110 KUBOTA PRE-HEAT INDICATOR LIGHT (GPND) 16 1 1 1
M 230300 BLANK PLUG, ROCKER SWITCH (OPTIONAL) (GPN) 4 1 1 1 1 1 1
N 230304 BLANK PLUG, CIRCUIT BREAKER (3Ø) 3 2 5 5 5 5 5
O 211046 RECEPTACLE PANEL BOX (PP - GPN) 39 1 1 1
O 211010 RECEPTACLE PANEL BOX (GPN) 39 1 1 1 1 1
O 211031 RECEPTACLE PANEL BOX (EV) 39 1 1
P 270803 VOLTAGE REGULATOR BOARD AND HDWR (3Ø) 342 1 1 1 1 1
Q 270910 FUSE HOLDER (3Ø) 11 1 1 1 1 1
Q1 270902 FUSE, 10 A. GLASS CARTRIDGE (3Ø) 5 2 2 2 2 2
R 270515 LOAD TERMINAL STRIP (3Ø) 32 1 1 1 1 1
S 260025 RECEPT. PANEL / BOX HDWR 4 2
S 260000 RECEPT. PANEL / BOX HDWR 4 6 6 6
S 260027 RECPET. PANEL / BOX HDWR 4 4 4 4 4
U 210989 UPPER MOUNTING BRACKET (GPN) 24 1 1 1 1 1 1
(15)
 RECEPTACLE PANEL
3.0, 4.0, 5.0, 6.5, AND
7.5 KW
GPN AND GPNR SERIES

RECEPTACLE PANEL
4.0, 5.0, 6.0, 7.5, 9.0,
10.5, 12.5, 15.0 KW
GPN, GPND,
GPNR SERIES

*FIG. H: ONE CAPACITOR IS USED ON MODELS

4.0 THRU 9.0 KW.

*FIG. HH: TWO CAPACITORS ARE USED ON

MODELS 10.5 THRU 15.0 KW.

(16)
 CONTROL PANEL
TYPICAL COMPONENTS
FOR ALL THREE PHASE
9 KVA
GPN SERIES

BLANK PANEL COVER

FOR TYPICAL 3Ø
11.25 THRU 20.0 KVA
GPN, GPND, AND
GPNR SERIES

(17)
 RECEPTACLE PANEL
4.5, 6.0 KW
BDN & EV SERIES

NOTE: CONTROL BOX IS ONE ASSEMBLY.

IT IS SHOWN IN EXPLODED VIEW ONLY TO
IDENTIFY COMPONENT PARTS.

NOTE: CONTROL BOX IS ONE ASSEMBLY. IT IS SHOWN IN EX-

PLODED VIEW ONLY TO IDENTIFY COMPONENT PARTS. A7 BOX
RECEPTACLE PANEL IS USED ON BDN-75. A8 IS USED ON BDN-90 AND BDN-120.
7.5, 9.0, 12 KW *FIG. F: NEMA L14-30R IS INSTALLED ON MODEL BDN-75. NEMA
BDN SERIES 14-50R IS INSTALLED ON MODELS BDN-90 AND BDN-120.
*FIG. H: ONE CAPACITOR IS USED ON MODELS BDN-75 & BDN-90.
*FIG. HH : TWO CAPACITORS ARE USED ON MODEL BDN-120.

(18)
 ENGINE COVER
3.0 THRU 7.5 KW
PP, GPN, GPNR SERIES

GE
WIT

KL
H

N−
EE
N−
POPR
O
WE
RO
R

BY
GI
LL
ET
TE

ENGINE COVER WITH INSTRUMENTS, FOR

ENGINE COVER WITH NO INSTRUMENTS, GPN, GPNR SERIES 3—7.5 KW GEN-SETS.
FOR PP SERIES GEN-SETS.

ENGINE COVER
9.0 THRU 15 KW
GPN - GPNR SERIES

GE
WIT
H
KL N−
EE
PR
N −P
OW
O ER OR
BY
GI
LL
E TT
E

ENGINE COVER WITH NO INSTRUMENTS, FOR

GPN, GPNR SERIES 9 - 15 KW GEN-SETS

(19)
CARRY FRAME AND STATIONARY BASE MAXIMUM (STANDBY) KW SIZE
REPAIR PARTS AND LIST PRICE SHEET AIR COOLED ENGINES
GPN-GPND-GPNR-PP-EV-BDN2-K2N NET 4500
PRICE 2200 3500 5000 6500 14000
PART 9000 10500 12500
REF. REPAIR PART DESCRIPTION EACH 3000 4000 5500 7500 15000
# ITEM 6000
A 890001 BASIC CARRY FRAME - ( PP SERIES ONLY) $ 96 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 890003 BASIC CARRY FRAME- ( PP - GPN-GPNR) 138 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 890004 BASIC CARRY FRAME - ( GPN - GPNR) 187 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 890005 BASIC CARRY FRAME - ( PP - GPN - GPNR) 137 1 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 890008 BASIC CARRY FRAME- ( GPN - GPNR) 214 1 1 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 8900011 BASIC CARRY FRAME- ( GPN150EC, GPND-90E, GPND-125E ) 214 1 1 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 8900020 BASIC CARRY FRAME- ( PP - GPN) 154 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 8900022 BASIC CARRY FRAME- ( GPNDL-60E ) 197 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
A 8900029 BASIC CARRY FRAME- ( GPNDL-40E ) 197 1
( WITH VIBRATION MTS. AND ENGINE CHANNELS ONLY )
B 210826 ENGINE CHANNEL 15 1 1 1 1
B 210929 ENGINE TOP BASE 18 1 1 1 1
B 210818 ENGINE CHANNEL 21 1 1 1
B1 210928 ENGINE BOTTOM BASE 18 1 1 1 1
C 240400 VIBRATION ISOLATOR & HDWR (ENG. END) 19 4 4 4 4 2 2 2 2
C1 240402 VIBRATION ISOLATOR & HDWR (GEN. END) 24 2 2 2 2
C2 210102 VIBRATION ISOLATOR SPACER 13 1 1 1 1
D 201009 ENGINE MOUNTING HDWR 6 2 2 2 2 2 2 2 2
E 270131 GROUND STRAP AND HDWR 11 1 1 1 1 1 1 1 1
F 230000 FUEL TANK (4 GAL.) W/ HDWR AND FUEL CAP 101 1 1 1
F1 210913 FUEL TANK HEAT SHEILD (4 GAL.) 41 1 1 1
F2 230400 DIESEL FUEL TANK (4 GAL.) W/ HDWR AND TANK CAP 112 1 1
F3 210925 DIESEL FUEL TANK HEAT SHIELD (4 GAL.) 37 1 1
F4 240705 FUEL TANK CAP WITH LEVEL GAUGE (4 GAL.) 28 1 1 1
F5 240134M SUCTION/RETURN FUEL LINE W/ BUSHING (4 GAL. DIESEL) 11 1
F6 240207 AIR VENT W/ BUSHING (4 & 8 GAL.) 13 1 1 1 1 1 1 1 1
G 230011 FUEL TANK (8 GAL.) W/ HDWR AND FUEL CAP 128 1 1 1 1
G1 230411 DIESEL FUEL TANK (8 GAL.) W/ HDWR AND FUEL CAP 138 1
G2 210988 FUEL TANK HEAT SHIELD (8 GAL.) 29 1 1 1 1
G3 240701 FUEL GAUGE W/ BUSHING (8 GAL. GAS & DIESEL) 48 1 1 1 1
G4 240704 FUEL TANK CAP (8 GAL.) 16 1 1 1 1
G5 240134 SUCTION/RETURN FUEL LINE W/ BUSHING (8 GAL.) 11 1 1 1 1
I 210110 HANDLE AND HDWR, DOLLY KIT (OPTIONAL) 18 2 2 2
I 210104 HANDLE AND HDWR, DOLLY 22 1 1 1 1
J 210959 PEDESTAL AND HDWR, DOLLY 18 1 1 1 1
K 202072 AXLE AND HDWR, DOLLY 28 2 2 2 2
KL 210745 LEFT HAND AXLE AND HDWR KIT (OPTIONAL) 22 1 1 1
KR 210746 RIGHT HAND AXLE AND HDWR KIT (OPTIONAL) 22 1 1 1
L 241103 10” FULL PNUEMATIC TIRE, DOLLY 31 2 2 2 2 2 2 2
M 220001 LIFTING DEVICE AND HDWR 18 1 1 1
M 210923 LIFTING DEVICE AND HDWR 21 1 1 1 1
N 210958 BATTERY TRAY AND HDWR 25 1 1
Q 240616 BATTERY HOLD DOWN STRAP 5 1 1 1 1 1 1
R 270821 “SPEED-MATIC” 12 VDC SOLENOID W/ BRACKET 88 1 1 1 1
S 270908 “SPEED-MATIC” CONTROL BOARD 77 1 1 1 1
T 270842 “SPEED-MATIC” LOAD SENSING COIL 55 1 1 1 1
U 440175-1 “SPEED-MATIC” THROTTLE LINKAGE W/ ROLLPIN 5 1
U1 440175-2 “SPEED-MATIC” THROTTLE LINKAGE W/ ROLLPIN 5 1
U2 440175-3 “SPEED-MATIC” THROTTLE LINKAGE W/ ROLLPIN 5 1 1
V 210721 “SPEED-MATIC” ENGINE MOUNT BRACKET W/ HDWR 24 1 1
V1 210945 “SPEED-MATIC” ENGINE MOUNT BRACKET W/ HDWR 31 1 1
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 SPEED-MATIC
ASSEMBLIES FOR
ALL GPNR SERIES

*FIG. V: THIS “SPEED-MATIC” ENGINE MOUNT BRACKET IS USED

ON GPNR GEN-SETS, 4.0 THRU 7.5 KW, WITH HONDA ENGINES.

*FIG. V1: THIS “SPEED-MATIC” ENGINE MOUNT BRACKET IS USED

ON GPNR GEN-SETS, 9.0 THRU 15.0 KW, WITH VANGUARD ENGINES.

CARRY FRAME BASE

2.2 KW
PP SERIES

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 CARRY FRAME BASE
3.0, THRU 7.5 KW F4
GPN, GPNR, PP SERIES F6

F
Q

C
F

E
N

C
B D C

F1
D
C
C C
C

CARRY FRAME BASE

4.0 & 6.0 KW
GPNDL SERIES F5

F6

F5

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 OPTIONAL
TWO WHEEL DOLLY KIT
4.0 THRU 7.5 KW
PP, GPN, GPNR SERIES

I L I

KL
I
KR

I I
KR

TWO WHEEL FRAME

BASE
9.0 THRU 15 KW
GPN, GPNR, GPNDL
SERIES

(23)
 INTERNAL STATOR WIRING DIAGRAM

FIGURE A FIGURE B

Brushless Generators are of two pole construction and must operate at 3750 RPM, no load speed setting, to maintain
61.5 Hertz. Auxiliary capacitor winding (exciter winding) serves to provide rotor excitation and is placed on top of, and 90
electrical degrees from m ain output windings. The capacitor provides the v oltage regulating function for the mai n
windings. Main winding connections: (A) 120 Volt output only: Connect main winding leads No. 1 and No. 3 together for
“HOT” line. Connect main winding leads No. 2 and No. 4 together for grounded neutral line. 120 Volts will be produced
from these two poi nts. (B) 120/24 0 Volt output: Conne ct main winding leads No. 2 and No. 3 together. 240 Volts is
produced at lead s No. 1 a nd No. 4. 120 Volts is p roduced at leads No. 1 an d connection point No. 2 and No. 3. A
second circuit of 120 Volts is produ ced at lead No. 4 and connection point of leads No. 2 and No. 3. NOTE: 10 KW and
larger sizes have (2) regulating capacitors.

ROTOR DIODE CONNECTION DIAGRAM

There are two sep arate coils on each rotor assembly. All rotors, 2.8kw throu gh 7.5 kw h ave each coil wound with a
single conductor copper wire. All roto rs 9.0 kw and larger, have each coil wound with (2) conductor copper wires.
Locate these conductor wires and determine how they come off and away from these two coils. The conductor wires
coming off the very top of each coil (top view) should connect to the forward polarity diode as shown above. The
conductors coming off the very bottom of each coil (bottom view) shoul d connect to the reverse p olarity diode as
shown above on right hand side.
CAUTION: Be very ca reful when you solder or de-solder wires to the di odes. Always use 60/40, 18 gauge rosin
core solder. The repair person must replace original diode with one of the same polarity and having the same original
rotor wires attached and soldered to the same diode connection points.

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 3.0 KW
PP & GPN SERIES

4.0 THRU 7.5 KW

PP SERIES
(25)
 4.0 THRU 7.5 KW
GPN SERIES

9 THRU 15 KW
GPN SERIES
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TYPICAL 240 VOLT, 3 PHASE
DELTA CONNECTED WINDING

TYPICAL 208 VOLT, 3 PHASE

WYE CONNECTED WINDING
(27)
 4.5 THRU 12 KW
BDN SERIES

AUTOMATIC ENGINE IDLE CONTROL

(SPEEDMATIC)

LOAD
5.0 THRU 12.5 KW
GPNR SERIES WITH SPEED-MATIC
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 GILLETTE LIMITED WARRANTY
FOR K2N SERIES AND BDN SERIES GENERATOR KITS, THAT ARE INSTALLED BY
ORIGNAL EQUIPMENT MANUFACTURERS (O.E.M.) ON THEIR EQUIPMENT
The Gillette Generator is designed around the latest technology, manufactured and quality inspected by carefully trained and
experienced craftspersons. Gillette warrants to the original O.E.M., for the time periods as shown below, that each generator
finished product is free from defects in materials and workmanship. Gillette, at it’s option, will repair, replace, or offer appropri-
ate adjustments, for any generator part that, upon examination and testing by Gillette’s factory engineers or by a Gillette author-
ized service dealer, is found to be defective, when generator set is properly installed, operated and maintained, according to Gil-
lette’s instructions. All transportation costs for parts returned to the factory, and new parts sent back to end user, are to be borne
and paid by the O.E.M. This warranty is not transferable and does not apply to malfunctions caused by damages, unreasonable
use, misuse, unauthorized repair persons, or normal wear and tear. All warranty cost allowances must be within limits as shown
in “Gillette Warranty Policies”, procedures and flat rate manual.

GILLETTE PRODUCT WARRANTY TIME PERIOD

K2N AND BDN Generator kits………………………… Original Equipment Manufacturer, is responsible to design & build an
(Warranty is void in prime power applications end product, without endangerment to Gillette generator kits. Unsanctioned
where O.E.M. generator kit is used as Prime generator applications are not warranted. Sanctioned generator applications
Power, replacing utility power.) carry a (1) year limited warranty , which consist of (6) months full parts and
labor coverage, (6) months parts only coverage.

THIS WARRANTY SHALL NOT APPLY TO (AND NOT LIMITED TO) THE FOLLOWING:
● Normal engine wear, tune-ups, service parts, including bat- ● Overtime labor and overnight freight costs.
teries, fuses, and engine fluids. ● Failures due, but not limited to, normal wear, misuse, negli-
● Generator kits in trailer mounted use. gence, or faulty installations, such as in-adequate fuel lines
● Original installation or start-up costs. or gas pressures.
● Damage due to insect or rodent infestation. ● Travel or labor expenses and all other costs, incurred while
● Gen-sets that are altered from original design. investigating performance complaints, unless problem is
● Failures beyond manufacturers control: Riots, wars, theft, caused by defective materials or workmanship by Gillette.
fire, freezing, lightening, earthquake, windstorm, hail, ● Warranties of associated equipment, not of Gillette manufac-
flood, hurricane, and all other external causes and Acts of ture are subject to the individual manufacturers assigned
God. warranties.
● Any incidental, consequential, or indirect damages, caused ● Failure to use and exercise gen-set for long periods of time.
by manufacturers defects, or any delay in repair or ● Parts installed from sources other than engine or generator
replacement of defect. manufacturer.
● Costs due to trouble shooting with jobsite repair person, ● Manufacturer is not responsible for loose connections caused
where no defect is found. by vibrations during shipment to jobsite. All connections
● Costs for equipment (cranes, hoist, trucks) for removal or re must be checked during start-up.
-installation of gen-set. ● All shipments are F.O.B. factory, consigned to the transit
● Diesel engine damage due to constant light loads (wet carrier. All shipping damage repairs, are between carrier
stacking). and receiver.
● Prime power applications, where final gen-set is used in ● Any associated costs for replacing components, found to be
place of utility power, on a continued basis. defective.
● Travel expense on any portable generators. ● Rental costs of equipment during any warranty procedures.
● Any labor time that is deemed excessive, by factory. ● Room and board expense due to overnight service condi-
● Metal parts, and all other deterioration of parts, installed tions.
within 25 miles of saltwater contaminants.

Any implied or statutory warranty, including any other warranty as to the merchant ability or fitness for a particular purpose or
use, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty
may last, or the exclusion or limitation of incidental or consequential damages, so the above listing of limitations or exclusions,
may not apply to you.
This is our written limited warranty and we make no other expressed warranty. No other identity is authorized to make any dif-
ferent or additional warranties on Gillette’s behalf. This Gillette warranty gives you specific rights. You may have additional
rights that may vary from state to state.
WARRANTY SERVICE PH: 800-777-9639
GILLETTE GENERATORS, INC. WARRANTY SERVICE FAX: 574-262-1840
2921 THORNE DRIVE ● ELKHART, IN 46514 WEBSITE: www.gillettegenerators.com

(29)
 GILLETTE LIMITED WARRANTY
FOR STATIONARY STANDBY EMERGENCY POWER SYSTEMS,
STATIONARY PRIME POWER SYSTEMS OR PORTABLE POWER SYSTEMS
The Gillette Generator is designed around the latest technology, manufactured and quality inspected by carefully trained and ex-
perienced craftspersons. Gillette warrants to the original end user, for the time periods as shown below, that each generator fin-
ished product is free from defects in materials and workmanship. Gillette, at it’s option, will repair, replace, or offer appropriate
adjustments, for any generator part that, upon examination and testing by Gillette’s factory engineers or by a Gillette authorized
service dealer, is found to be defective, when generator set is properly installed, operated and maintained, according to Gillette’s
instructions. All transportation costs for parts returned to the factory, and new parts sent back to end user, are to be borne and
paid by the end user. This warranty is not transferable and does not apply to malfunctions caused by damages, unreasonable use,
misuse, unauthorized repair persons, or normal wear and tear. All warranty cost allowances must be within limits as shown in
“Gillette Warranty Policies”, procedures and flat rate manual.
GILLETTE PRODUCT WARRANTY TIME PERIOD
Portable and Standby Gen-Sets………………....(2) Years or 1000 hours (whichever occurs first), from date of manufacture.
(Warranty is void in prime power applications) Standby: First year covers parts and labor. Second year covers parts only.
Portables: First year covers parts and labor. Second year covers rotor and
stator only.
Prime Power (Sole power source)………………...(1) Year or 1000 hours (whichever occurs first), from date of manufacture.

THIS WARRANTY SHALL NOT APPLY TO (AND NOT LIMITED TO) THE FOLLOWING:
● Normal engine wear, tune-ups, service parts, including bat- ● Overtime labor and overnight freight costs.
teries, fuses, and engine fluids. ● Steel enclosures, and all other deterioration of parts, installed
● Generators in trailer mounted use. within 25 miles of saltwater contaminants.
● Original installation or start-up costs. ● Failures due, but not limited to, normal wear, misuse, negli-
● Damage due to insect or rodent infestation. gence, or faulty installations, such as in-adequate fuel lines
● Gen-sets that are altered from original design. or gas pressures.
● Radiators replaced rather than repaired. ● Travel or labor expenses and all other costs, incurred while
● Failures beyond manufacturers control: Riots, wars, theft, investigating performance complaints, unless problem is
fire, freezing, lightening, earthquake, windstorm, hail, caused by defective materials or workmanship by Gillette.
flood, hurricane, and all other external causes and Acts of ● Warranties of associated equipment, not of Gillette manufac-
God. ture (auto transfer switches, engines, generators) are subject
● Any incidental, consequential, or indirect damages, caused to the individual manufacturers assigned warranties.
by manufacturers defects, or any delay in repair or ● Failure to use and exercise gen-set for long periods of time.
replacement of defect. ● Parts installed from sources other than engine or generator
● Costs due to trouble shooting with jobsite repair person, manufacturer.
where no defect is found. ● Manufacturer is not responsible for loose connections caused
● Costs for equipment (cranes, hoist, trucks) for removal or re by vibrations during shipment to jobsite. All connections
-installation of gen-set. must be checked during start-up.
● Adjustments to fuel systems or governor systems at time of ● All shipments are F.O.B. factory, consigned to the transit
start-up, or anytime thereafter. carrier. All shipping damage repairs, are between carrier and
● Excess mileage costs are not permitted. Authorized service receiver.
provider is limited to 200 mile round trip. ● Any associated costs for replacing components, found to be
● Diesel engine damage due to constant light loads (wet defective.
stacking). ● Rental costs of equipment during any warranty procedures.
● Travel expense on any portable generators. ● Room and board expense due to overnight service condi-
● Any labor time that is deemed excessive, by factory. tions.

Any implied or statutory warranty, including any other warranty as to the merchant ability or fitness for a particular purpose or
use, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty
may last, or the exclusion or limitation of incidental or consequential damages, so the above listing of limitations or exclusions,
may not apply to you.
This is our written limited warranty and we make no other expressed warranty. No other identity is authorized to make any dif-
ferent or additional warranties on Gillette’s behalf. This Gillette warranty gives you specific rights. You may have additional
rights that may vary from state to state.

GILLETTE GENERATORS, INC. WARRANTY SERVICE PH: 800-777-9639

2921 THORNE DRIVE ● ELKHART, IN 46514 WARRANTY SERVICE FAX: 574-262-1840
WEBSITE: www.gillettegenerators.com

(30)