Srvm3-20120823 SERVICE MANUAL
Contents
1. ut forvart 101 lt There are two separate coils on each rotor assembly All rotors 2 8kw through 7 5 kw have each coil wound with a single conductor copper wire All rotors 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 should connect to the reverse p olarity diode as shown above on right hand side CAUTION Be very careful when you solder or de solder wires to the diodes 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 24 BOX 120 VOLT ONLY FAR VI 16 GA GREEN CSA GROUND SHROUD ASSEMBLY EAR VIEW2. NOTE PP SERIES WILL DELETE VOLTMETER AND HOUR METER AS SHOWN ABOVE 14 GA RED 12 GA WHITE E PHASE GENERATOR E 120 VOLI ONLY Z 16 GA GREEN EXCITER ROTATING FIELD GEN SET WINDINGS 3 0 KW GROUND TO STATOR THRU BOLT PP 8 GPN SERIES EXCITER ROTATING FIELI 4 0 THRU 7 5 KW PP SERIES 25 NNECTO BLACK BLACI HITE GREEN 4 0 THRU 7 5 KW GPN SERIES GPN PANEL AND BOX 10X14 Q 120 240 VOLT 4 25A 25A 30 H 16 GA GREEN REAR VIEW 14 GA RED EXCITER ROTATING FIELD 12 GA WHITE
3. GROUND THRU E GENERATOR STATOR THRU BOLT 120 240 VOLT 9 THRU 15 KW GPN SERIES 26 gt PN PANEL AND BOX ROTATING EXCITET INDINGS LTAGE REGULATOR N ele lt N LA I E m Sere WINDINGS JVER SPEEI WINDING de SPN PANEL AND BOX 2172 2 ROTATING EXCITER INDING LTAGE REGULATOR i 2 2 FIELI p sl TYPICAL 208 VOLT 3 PHASE WYE CONNECTED WINDING 27 28 BLANK PANEL BDN PANEL AND BOX IRE 12 RIGHT SIDE SEN SE INDING VIEWED OPPOSITE P T O STATOR Al RU STATOR THRU BOLT INGLE PHASE GENERATOF IRE 1 24 OLT AUTOMATI
4. 9000 10500 12500 a najajajajaja nuajajajajaja o 2 2 2 2 8 D D D D1 D1 D1 D1 E E E E E E F F F F G H HH J K L L1 M N O O O P Q Q1 R 5 5 5 U 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 9 GPN SERIES TYPICAL COMPONENTS FOR ALL THREE PHASE BLANK PANEL COVER FOR TYPICAL 39 11 25 THRU 20 0 KVA GPN GPND AND GPNR SERIES 17 RECEPTACLE PANEL 4 5 6 0 KW BDN amp 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 IS SHOWN IN EX PLODED VIEW ONLY TO IDENTIFY COMPONENT PARTS A7 BOX RECEPTACLE PANEL I 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 50
5. FIRE HAZARD Avoid flash fire Do not smoke or allow flame or spark near engine Never try to fill engine fuel tank while the engine is running Safely empty fuel tank before tipping engine to drain oil Always u se a safe portable vented fuel tank that is designed for the purpose of storing or hauling fuel when filling the engine mounted fuel tank Wipe up any fuel spill age before operating engine Never allow children or other u nqualified people around or near this equipment WARNING DANGEROUS FUELS Use extre me caution when handling storing and using fuels All fuels a re explosive in a vapor condition Store all types of fuel in a well ventilated area away from all flames sparks and children Never add fuel to tank while engine is running since spilled fuel may ig nite from ig nition spark or hot engine parts Keep fuel lines in tight and in good condition Don t use rigid fuel lines in place of the original flexible fuel lines Do not operate generator set when fuel spillage fuel leakage or electrical sparks are noticed GASOLINE Always store gasoline in approved red containers that are clearly marked gasoline and having proper venting Don t store gasoline in occupied building WARNING DANGEROUS ACID Avoidallc ontact with battery 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 bat
6. TOUCH PROBES TO CAPACITOI TERMINALS FOR NO MORE THAN ONE ECOND FIGURE 3 STEP 5 Receptacle Panel Wiring Inspect the receptacle panel for worn or loose wires Make sure all wires are secure and tight at the screws of recep tacles Do not allow wires to be pinched kin ked or damaged in any way Inspect for tight connections at circuit breakers capacitors and all receptacles Rep lace any broken component Test any GFCI receptacles by use of its built in test and reset buttons Panel wiring must conform with diagrams as shown on Page 28 through 33 If panel wiring checks good proceed to next repair step 6 STEP 6 Open Shorted or Grounded Stator Main Windings The stator is the outside stationary winding as shown in Figure 1 It consists of copper wire laid in a steel laminated frame To remove stator assembly follow dis assembly instructions part 1 through 5 on page 10 The stator windings form two main poles and have four coils per pole with two lead wire s connected to each pole winding The large black lead wires are numbered 1 and 2 for one field pole and 4 for the other field pole To test the main powe r winding disconnect all lead wires Set ohmmeter to lowest OHM x 1 scale Place one meter test lead on 1 lead of stator winding and the other test lead on 2 lead of stator winding see fig 4 Then record this resistance value Measure resistance values of leads 3 and 4 of the second main pole windin
7. 30 A PUSH BUTTON 270707 CIRCUIT BREAKER 35 A PUSH BUTTON 270704 CIRCUIT BREAKER 40 PUSH BUTTON 270706 CIRCUIT BREAKER 50 A PUSH BUTTON 270715 CIRCUIT BREAKER 20 A 1 POLE MAG 270716 CIRCUIT BREAKER 20 A 2 POLE MAG 270717 CIRCUIT BREAKER 30 A 2 POLE MAG 270718 CIRCUIT BREAKER 35 A 2 POLE MAG 270719 CIRCUIT BREAKER 45 A 2 POLE MAG 270720 CIRCUIT BREAKER 50 A 2 POLE MAG 270311 RECEPT TWIST LOCK NEMA L14 20R 270310 RECEPT TWIST LOCK NEMA L14 30R 270314 RECEPT STRAIGHT BLADE NEMA 14 30R 270308 RECEPT STRAIGHT BLADE NEMA 14 50R 270306 RECEPT TWIST LOCK NEMA L5 30R 270863 440V CAPACITOR BRACKET AND HDWR 3 9 KW 270863 2 440V DUAL CAPACITORS BRACKET AND HDWR 10 5 15 KW 270806 VOLTMETER AND HDWR GPN 270807 HOUR METER AND HDWR GPN 270011 ROCKER START STOP SWITCH OPTIONAL GPNR 241109 KUBOTA START STOP KEY SWITCH GPND 241110 KUBOTA PRE HEAT INDICATOR LIGHT GPND 230300 BLANK PLUG ROCKER SWITCH OPTIONAL GPN 230304 BLANK PLUG CIRCUIT BREAKER 30 211046 RECEPTACLE PANEL BOX PP GPN 211010 RECEPTACLE PANEL BOX GPN 211031 RECEPTACLE PANEL BOX EV 270803 VOLTAGE REGULATOR BOARD AND HDWR 30 270910 FUSE HOLDER 30 270902 FUSE 10 GLASS CARTRIDGE 30 270515 LOAD TERMINAL STRIP 30 260025 PANEL BOX HDWR 260000 RECEPT PANEL BOX HDWR 260027 RECPET PANEL BOX HDWR 210989 UPPER MOUNTING BRACKET
8. consequential or indirect damages caused by manufacturers defects or any delay in repair or replacement of defect e Costs due to trouble shooting with jobsite repair person where no defect is found e Costs for equipment cranes hoist trucks for removal or re installation of gen set e Diesel engine damage due to constant light loads wet stacking e Prime power applications where final gen set is used in place of utility power on a continued basis e Travel expense on any portable generators e Any labor time that is deemed excessive by factory e Metal parts and all other deterioration of parts installed within 25 miles of saltwater contaminants e Overtime labor and overnight freight costs e Failures due but not limited to normal wear misuse negli gence or faulty installations such as in adequate fuel lines or gas pressures e Travel or labor expenses and all other costs incurred while investigating performance complaints unless problem is caused by defective materials or workmanship by Gillette e Warranties of associated equipment not of Gillette manufac ture are subject to the individual manufacturers assigned warranties e Failure to use and exercise gen set for long periods of time e Parts installed from sources other than engine or generator manufacturer e Manufacturer is not responsible for loose connections caused by vibrations during shipment to jobsite All connections must be checked dur
9. 2 LAM STACK 636500 ROTOR 15 0 30 6 1 2 LAM STACK 617750 ROTOR 14 KW 7 3 4 LAM STACK 637750 ROTOR 17 5 30 7 3 4 LAM STACK 261250 ROTOR 3 0 KW BDN 2 1 2 LAM STACK 261387 ROTOR 4 5 KW BDN 3 7 8 LAM STACK 261425 ROTOR 6 0 KW BDN 4 1 4 LAM STACK 261475 ROTOR 7 5 KW BDN 4 3 4 LAM STACK 263475 ROTOR 9 0 KVA BDN 3 4 3 4 LAM STACK 261550 ROTOR 9 0 KW BDN 5 1 2 LAM STACK 263550 ROTOR 11 0 KVA BDN 3 5 1 2 LAM STACK 261650 ROTOR 12 0 KW BDN 6 1 2 LAM STACK 270801 RECTIFIER REVERSE POLARITY w HDWR 270802 RECTIFIER FORWARD POLARITY w HDWR 241000 BALL BEARING SINGLE ROW 241001 BALL BEARING DOUBLE ROW 241001 BALL BEARING DOUBLE ROW FOR BDN 210218 ROTOR THRU BOLT ASSEMBLY 7 3 8 LG 210225 ROTOR THRU BOLT ASSEMBLY 12 LG MODEL GPND 125E 210206 THRU BOLT ASSEMBLY 8 5 8 LG 210207 ROTOR THRU BOLT ASSEMBLY 11 1 2 LG 210208 ROTOR THRU BOLT ASSEMBLY 14 3 8 LG 206006 ROTOR END BEARING RETAINER BOLT ASSMBLY 3 4 LG 712250 STATOR 2 2 3 0 KW 2 1 27 LAM 712255 STATOR 1 8 2 3 KW 50 HZ 2 1 2 LAM 713000 STATOR 3 5 4 0 KW 3 LAM 713005 STATOR 2 8 3 2 KW 50 HZ 3 LAM 713870 STATOR 4 5 5 0 5 5 KW 3 7 8 LAM 713875 STATOR 3 5 4 0 4 5 KW 50 HZ 3 7 8 LAM 714250 STATOR 6 0 KW 4 1 4 LAM 714255 STATOR 5 0 KW 50 HZ 4 1 4 LAM 714750
10. 25 amp diod e capacity resists all spike problems and it is a rare o ccurrence to have these special diodes fail Ho wever the repairman must be familiar with the function and repair ofthese diodes Page 28 shows the diode position and connection A diode can SHORT or OPEN to become defective A shorted diode is the most common defect in competitor s generators but not in this design due to highly over rated diode values However one b oth diodes as well as windings can be destroyed if utility power s allowed to enter the gen set If gen set is used for emergency power with no isolating transfer switch the return of utility power will enter the gen set system 7 If the engine no load speed is norm al 3750 RPM but output voltage is only half the normal volts one of the two diodes may be open It is necessary to determine whether this voltage isa result of an open diode or is due to a defective rotoror stator winding Suspe ct a defe ctive capacitor if both diodes and windings are good Use an ohmmeter in the lowest scale OHMS x 1 position Test the dio de in the forwa rd positive position The ohmmeter should read approximately 15 OHMS or close to zero Reverse the ohmmeter test leads and read over 2000 ohms or close to infinity See Figure 4 Simply put regardle ss of meter polari ty the ohmmeter reading should be zero in one direction and infinity in the opposite direction reversed meter test lea
11. STATOR 6 5 7 5 KW 4 3 4 LAM 714755 STATOR 5 5 6 0 KW 50 HZ 4 3 4 LAM 734750 STATOR 8 0 9 0 30 4 3 47 LAM STACK 734755 STATOR 6 5 7 5 30 50 HZ 4 3 4 LAM STACK 715500 STATOR 9 0 KW 5 1 27 LAM STACK 715505 STATOR 7 5 KW 50 HZ 5 1 2 LAM STACK 735500 STATOR 11 0 KVA 30 5 1 2 LAM STACK 735505 STATOR 9 0 KVA 32 50 HZ 5 1 2 LAM STACK 716000 STATOR 10 5 KW 6 LAM STACK 716005 STATOR 8 0 KW 50 HZ 6 LAM STACK gt gt gt gt gt gt gt xz a a a a a a a a a a 11 BRUSHLESS AND BRUSH TYPE GENERATOR REPAIR PARTS AND LIST PRICE SHEET MAA SIANDBY KW SIZE GPN GPND GPNR PP EV BDN2 K2N 4500 5000 6500 rer PART REPAIR PART DESCRIPTION 5500 7500 6000 J3 736000 STATOR 13 0 30 6 LAM STACK J35 736005 STATOR 10 0 KVA 30 50 HZ 6 LAM STACK J 716500 STATOR 12 0 KW 6 1 2 LAM STACK J5 716505 STATOR 9 0 KW 50 HZ 6 1 2 LAM STACK 736500 STATOR 15 0 KVA 30 6 1 2 LAM STACK 736505 STATOR 12 0 KVA 30 50HZ 6 1 2 LAM STACK 717750 STATOR 14 KW 7 3 4 LAM STACK 717755 ST
12. a voltage re gulator preventing voltage drop when load is applied THE DIODE Two diodes rectifiers form a full wave rectifier ci rcuit to convert the induced A C current to D C current for full rotor field excitation Both diodes are lo cated on a disc heat sink in the cooling air flow and are oversized seven time s required capacity for complete fail proof design LHC BALL BEARING ENGINE CASTING BEARING BRACKET FIGURE 1 4 SCHEDULED MAINTENANCE Scheduled maintenance is preve ntative maintenance Major repairs can be avoided by correcting problems when they are small Always look for signs of potential trouble such as loose electrical connections loose ha rdware or loose mechanical connections Loose screws and bolts bad fuel connections Always test the GFCI receptacles if your gen set has them before each use ITEM OF INSPECTION AND SERVICE Operate in only dry well ventilated areas When running the generator set note any unusual n oises or unusual smells Always follow all safety precautions listed in the front ofthis manual Refer to table on this page for sche duled maintenance ofthe generato r Perform each function at the indicated time interval Refer to engine manual for its individual service requirements BEFORE EACH START EVERY 50 HOURS EVERY 200 HOURS Inspect for broken or dirty receptacles Remove inspection cover and view windings for burned or dirty
13. exciter and main winding will create a certain value of capacitance nullifying standard cap acitance The windi ngs must be cleaned and baked dry as described in item A STATOR ROTOR AND DIODE RESISTANCE MEASUREMENT METHODS FORWARI DIODE J CAPACITOR WINDING IN STAT Z 7 THRU 18 KWZ Y ESPN N Ra STATO 2 HIGH OHMS REVERSE DIODE y NO 1 BLACK NE TATOR LEAD HIGH OHMS NO Black OHMMETE STATOR LEAI TESTING RESISTANCE OF JF TESTING RESISTANCE ONE HALF MAIN WINDIN IN STATOR TESTING RESISTANCE OF THER HALF MAIN WINDING STATOR 2 8 THR 8 KWa STATOR FIGURE 4 CAPACITOR WINDING ROTOR WINDING GENERATOR SIZE AND KW RATING MINIMUM MAXIMUM 2 8 AND 3 0 KW 2 1 2 LAMINATION LENGTH MINIMUM MAXIMUM MINIMUM MAXIMUM 4 0 KW 3 LAMINATION LENGTH 5 0 KW 3 7 8 LAMINATION LENGTH 6 0 KW 4 1 4 LAMINATION LENGTH 6 5 AND 7 5KW 4 3 4 LAMINATION LENGTH 9 0 KW 5 1 2 LAMINATION LENGTH 10 5 KW 6 LAMINATION LENGTH 12 0 KW 6 1 2 LAMINATION LENGTH 15 0 KW 7 3 4 LAMINATION LENGTH 18 0 KW 10 LAMINATION LENGTH CAUTION THESE RESISTANCE VALUES ARE VERY SMALL AND TESTING REQUIRES A GOOD QUALITY LOW RESISTANCE READING METER ALL METER READINGS OF ZERO INDICATE OPEN BAD WINDING ALL METER READINGS FROM WINDING TO METAL FRAME
14. exciter winding is laid directly on top of main winding inside stator assembly It has two coil s per pole and is connected to two re d lead wires Same test procedures as described in ltem 6 a re used to test the exciter winding Disconnect and remove the two red wires from the capacitor Measure resistance across these red wires that lead into stator winding and test for grounded exciter winding Test also for continuity between red wires and all main power winding leads having lead 1 2 and 3 4 If meter shows reading the exciter winding has shorted made connection into the main power winding and stator is defective The red wires should not have any continuity with any of the four black wires and they should not have continuity with a good ground surface Check all resistance values with the resistance chart found on Page 8 If complete st ator winding is not the problem proceed to the next repair step 8 STEP 8 Open Shorted or Grounded Rotor Winding The rotor assembly consists of two separate coils with two diodes mounted on a special heat sink disc For this test it is necessary to remove the bearing bracket and stator so there is room to work on the rotor Prior to testing visually inspect windings for dark streaks shorted check ball b earing by h and rotation If itis rough noisy ordry re place bearing Trya quick resistance test by placing ohmmeter test probes across the solder connection of each diode r
15. 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 Portable and Standby Gen Sets Warranty is void in prime power applications stator only Prime Power Sole power source WARRANTY TIME PERIOD 2 Years or 1000 hours whichever occurs first from date of manufacture Standby First year covers parts and labor Second year covers parts only Portables First year covers parts and labor Second year covers rotor and 1 Y ear or 1000 hours whichever occurs first fro
16. 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 K2N AND BDN Generator kits Warranty is void in prime power applications where O E M generator kit is used as Prime Power replacing utility power WARRANTY TIME PERIOD Original Equipment Manufacturer is responsible to design amp build an end product without endangerment to Gillette generator kits Unsanctioned generator applications are not warranted Sanctioned generator applications 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 e Normal engine wear tune ups service parts including bat teries fuses and engine fluids e Generator kits in trailer mounted use e Original installation or start up costs e Damage due to insect or rodent infestation e Gen sets that are altered from original design e Failures beyond manufacturers control Riots wars theft fire freezing lightening earthquake windstorm flood hurricane and all other external causes and Acts of God e Any incidental
17. rope The generator must turn easily or assembly is wrong STEP 6 Finish reconnection of wires and assemble cover Ref L BRUSHLESS AND BRUSH TYPE GENERATOR REPAIR PARTS AND LIST PRICE SHEET MOT N AN AIZE GPN GPND GPNR PP EV BDN2 K2N 4500 3500 5000 6500 REF PART REPAIR PART DESCRIPTION 4000 a 7500 220007 DRIVE END CASTING BDN 220008 DRIVE END CASTING 220001 ENGINE CASTING 220002 ENGINE CASTING 220010 ENGINE CASTING 5 3 4 PILOT 220011 ENGINE CASTING 6 7 16 PILOT 220012 ENGINE CASTING 7 PILOT 201001 BOLTAND NUT BDN BEARING RETAINER 201002 5 16 BOLT AND WASHER CASTING RETAINER 201003 3 8 BOLT AND WASHER CASTING RETAINER 201004 7 16 BOLT AND WASHER CASTING RETAINER 230017 COOLING FAN WITH SCREWS A FAN 430017 COOLING FAN WITH SCREWS E BORED A PP 28 230018 COOLING FAN WITH SCREWS E C FAN 230019 COOLING FAN WITH SCREWS D 230020 COOLING FAN WITH SCREWS E FAN BDN 230022 COOLING FAN WITH SCREWS E G FAN BDN 230022 COOLING FAN WITH SCREWS 6 FAN 612500 ROTOR 2 2 3 0 KW 613000 ROTOR 3 5 4 0 KW 613870 ROTOR 4 5 5 0 5 5 6 0 KW 614250 ROTOR 6KW 614750 ROTOR 6 5 7 5 KW 634750 ROTOR 8 0 9 0 KVA 30 615500 9 0 KW 635500 ROTOR 11 0 30 5 1 2 LAM STACK 616000 ROTOR 10 5 KW 6 LAM STACK 636000 ROTOR 13 0KVA 30 6 LAM STACK 616500 ROTOR 12 5 KW 6 1
18. tono voltage output will result Always handle or te st the capacitor when the engine is stopped Extremely high voltage is prese nt atthe capacitor terminals while generator is in use and these terminals should not be touched as a potential e lectric shock condition exists Also when engine is stopped the capacitor will still contain high voltage Use extrem caution when handling capacitors A potential shock condition still exists ifsaf e handling procedures are not used Always discharge the capacitor before handling by placing a conductor such as an insulated handle screwdriver across the capa citor terminals while h olding on to insulated handle only This will short out the voltage stored in capacitor thus discharging the capacitor A loud audible noise will result when capacitor is discharged 5 With the engine stop ped remove the protective plasti cover from capacitor lead connections Discon nect both red capacitor winding leads from the capacitor Check the capacitor charge and discharge readings using an ohmmeter on the RX 100 scale See Figure 2 When the ohmmeter lea ds are placed on the capacit or terminals a meter deflection should be seen cha rging followed by a slow return to infinity discharging Reverse the ohmmeter leads and repeat the procedu re for the same results No meter deflection or continuing continuity indicates an open or shorted capacitor All capacitors have an internal built i n circu
19. ATOR 12 KW 50 HZ 7 3 4 LAM STACK 737750 STATOR 18 8 KVA 30 7 3 4 LAM STACK 737755 STATOR 15 0 KVA 30 50 HZ 7 3 4 LAM STACK 210211 STATOR THRU BOLT WITH NUTS 9 3 4 LG 210209 STATOR THRU BOLT WITH NUTS 11 LG 210212 STATOR THRU BOLT WITH NUTS 12 1 2 LG 210213 STATOR THRU BOLT WITH NUTS 14 3 4 LG 210214 STATOR THRU BOLT WITH NUTS 17 3 4 LG 211040 INSPECTION COVER WITH SCREWS 220005 BEARING CASTING 1 PHASE 420005 BEARING CASTING 3 PHASE 241002 BALL BEARING BDN DRIVE END 241003 BALL BEARING BDN DRIVE END 210739 BEARING RETAINER PLATE BDN 210740 BEARING RETAINER PLATE BDN 240800 BRUSHES WITH SCREWS 30 201007 SCREW AND LOCKWASHER 30 230023 BRUSH BRUSH HOLDER ASSEMBLY 30 240101 RETAINER RING BALL BEARING 240102 RETAINER RING BALL BEARING 2 72 2 O n BDN SERIES 3 0 12 KW BRUSHLESS TYPE N AN 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 SP SPD SERIES GPN GPND GPNR 9 0 THRU 15 KW BRUSHLESS TYPE EV 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 ENG
20. C ENGINE IDLE CONTROL is ee HITE RED MATIC COIL 14 GAG GROUND T I 4 IGA GREEN ENGINE BLOCK INLY RRENT TRANSFORME A J SPEEDMATIC CONTROLL arre JGA BLACI TL 113 TL2 INDINGS gt LE PHASE RE 120 24 HITE REI 5 0 THRU 12 5 KW GPNR SERIES WITH SPEED MATIC 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
21. GROUND INDICATE A GROUNDED BAD WINDING ROTOR RESISTANCE IS MEASURED ACROSS EACH SOLDER JOINT 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 No Output Voltage or a small 16 to 24 VAC as measured on two hot positions of 240 VAC receptacle Low Output Voltage High Output Voltage The No Load Voltage Output is at normal reading but drops down as electric load is applied Generator rotor speed is too low Increase engine speed to 3750 RPM 62 hertz 125 volts no load setting Circuit breaker is tripped open Reset breaker Check receptacles for proper operation Open shorted capacitor or red leads disconnected from capacitor Replace capacitor or connected leads Loss of rotor residual magnetism A reading of approximately 16 24 volts AC indicates residual magnetism Restore magnetism by loading generator or flashing rotor fields Defective receptacle panel Inspect all wiring and components on receptacle panel Repair or replace One or both diodes open or shorted see figure 4 Replace both diodes Open or shorted main power windings Replace stator Open or shorted capacitor windings Replace stator Open or shorted rotor winding No load voltage between 8 12 volts at correct operating speed
22. INE CHANNELS ONLY 8900029 BASIC CARRY FRAME _ GPNDL 40E WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 210826 ENGINE CHANNEL 210929 ENGINE TOP BASE 210818 ENGINE CHANNEL 210928 ENGINE BOTTOM BASE 240400 VIBRATION ISOLATOR 8 HDWR ENG END 240402 VIBRATION ISOLATOR 8 HDWR GEN END 210102 VIBRATION ISOLATOR SPACER 201009 ENGINE MOUNTING HDWR 270131 GROUND STRAP AND HDWR 230000 FUEL TANK 4 GAL W HDWR AND FUEL 210913 FUEL TANK HEAT SHEILD 4 GAL 230400 DIESEL FUEL TANK 4 GAL W HDWR AND TANK CAP 210925 DIESEL FUEL TANK HEAT SHIELD 4 GAL 240705 FUEL TANK CAP WITH LEVEL GAUGE 4 GAL 240134M SUCTION RETURN FUEL LINE W BUSHING 4 GAL DIESEL 240207 AIR VENT W BUSHING 4 8 8 GAL 230011 FUEL TANK 8 GAL W HDWR AND FUEL 230411 DIESEL FUEL TANK 8 GAL W HDWR AND FUEL CAP 210988 FUEL TANK HEAT SHIELD 8 GAL 240701 FUEL GAUGE W BUSHING 8 GAL GAS amp DIESEL 240704 FUEL TANK CAP 8 GAL 240134 SUCTION RETURN FUEL LINE W BUSHING 8 GAL 210110 HANDLE AND HDWR DOLLY KIT OPTIONAL 210104 HANDLE AND HDWR DOLLY 210959 PEDESTAL AND HDWR DOLLY 202072 AXLE AND HDWR DOLLY 210745 LEFT HAND AXLE AND HDWR KIT OPTIONAL 210746 RIGHT HAND AXLE AND HDWR KIT OPTIONAL 241103 10 FULL PNUEMATIC TIRE DOLLY 220001 LIFTING DEVICE AND HDWR 210923 LIFTING DEVICE AND HDWR 210958 BATTERY TRAY AND HDWR 240616 BATTERY HOLD DOWN STRAP 270821 S
23. INES GPN GPND GPNR PP EV BDN2 K2N 4500 PART PRICE 2200 5000 6500 REPAIR PART DESCRIPTION EACH 3000 220 7500 211042 PANEL COVER ONLY 911042 PANEL COMPLETE BUILD 211024 PANEL COVER ONLY 911024 PANEL COMPLETE BUILD 211028 PANEL COVER ONLY 911028 RECEPT PANEL COMPLETE BUILD 211038 RECEPT PANEL COVER ONLY GPNDL 60E 911038 RECEPT PANEL COMPLETE BUILD GPNDL 60E 211029 RECEPT PANEL AND BOX ONLY 911029 RECEPT PANEL AND BOX COMPLETE BUILD 211030 RECEPT PANEL AND BOX ONLY 911030 RECEPT PANEL AND BOX COMPLETE BUILD 211030 RECEPT PANEL COVER ONLY 911030 RECEPT PANEL COMPLETE BUILD 211031 RECEPT PANEL AND BOX ONLY 911031 RECEPT PANEL AND BOX COMPLETE BUILD 411031 RECEPT PANEL AND BOX ONLY 411931 RECEPT PANEL AND BOX COMPLETE BUILD 211023 BLANK PANEL COVER ONLY 211003 BLANK PANEL COVER ONLY 911003 BLANK PANEL COMPLETE 930979 ENGINE COVER W METERS 3 5 5 KW 930983 ENGINE COVER W METERS 6 5 7 5 KW 910979 ENGINE COVER 3 5 5 KW 910983 ENGINE COVER 6 5 7 5 KW 910955 ENGINE COVER 9 15 KW 201008 PANEL AND COMPONENT HDWR 270300 DUPLEX RECEPT NEMA 5 15R PP BDN 270313 DUPLEX RECEPT NEMA 5 15R GFCI GPN GPNR 270701 CIRCUIT BREAKER 20 A PUSH BUTTON 270702 CIRCUIT BREAKER 25 A PUSH BUTTON 270703 CIRCUIT BREAKER 30 A PUSH BUTTON 270703 CIRCUIT BREAKER
24. PEED MATIC 12 VDC SOLENOID W BRACKET 270908 SPEED MATIC CONTROL BOARD 270842 SPEED MATIC LOAD SENSING COIL 440175 1 SPEED MATIC THROTTLE LINKAGE W ROLLPIN 440175 2 SPEED MATIC THROTTLE LINKAGE W ROLLPIN 440175 3 SPEED MATIC THROTTLE LINKAGE W ROLLPIN 210721 SPEED MATIC ENGINE MOUNT BRACKET W HDWR 210945 SPEED MATIC ENGINE MOUNT BRACKET W HDWR 9000 10500 12500 lala 1 1 1 1 1 7 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 21 CARRY FRAME BASE 3 0 THRU 7 5 KW GPN GPNR PP SERIES CARRY FRAME BASE 4 08 6 0 KW GPNDL SERIES 22 OPTIONAL TWO WHEEL DOLLY KIT 4 0 THRU 7 5 KW PP GPN GPNR SERIES TWO WHEEL FRAME BASE 9 0 THRU 15 KW GPN GPNR GPNDL SERIES 23 INTERNAL
25. R IS INSTALLED ON MODELS BDN 90 AND BDN 120 a FIG H ONE CAPACITOR IS USED ON MODELS BDN 75 8 BDN 90 FIG TWO CAPACITORS ARE USED ON MODEL BDN 120 18 ENGINE COVER 3 0 THRU 7 5 KW PP GPN GPNR SERIES 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 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 4500 PART 3500 5000 6500 REPAIR PART DESCRIPTION 4000 5500 7500 6000 890001 BASIC CARRY FRAME PP SERIES ONLY WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 890003 BASIC CARRY FRAME PP GPN GPNR WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 890004 BASIC CARRY FRAME WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 890005 BASIC CARRY FRAME PP GPN GPNR WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 690008 BASIC CARRY FRAME GPN GPNR WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 8900011 BASIC CARRY FRAME GPN150EC GPND 90E GPND 125E WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 8900020 BASIC CARRY FRAME PP GPN WITH VIBRATION MTS AND ENGINE CHANNELS ONLY 8900022 BASIC CARRY FRAME GPNDL 60E WITH VIBRATION MTS AND ENG
26. 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 Phone 574 264 9639 FAX 574 262 1840 SRVM3 GIL MAN 933 20120823 TABLE OF CONTENTS SUBJECT Safety Precautions Description of A C Generator Operation Scheduled Maintenance Generator Repair Procedures Generator Dis Assembly and Re Assembly Parts Identification Wiring Diagrams Warranty for K2N amp BDN2 O E M Generators Warranty for Complete Portable Generator Sets PAGE 2 3 5 9 10 11 23 24 28 29 30 SAFETY PRECAUTIONS This service manual describes only the methods of repair concerning the gene rator Always refer to the engine manufacturers repair manual for its o wn repair procedures Read through thism anual Then carefully follo w all recommendations and safety precautions to keep the generator functioning properly and to avoid any serious body injury WARNING A MOVING PARTS Keep hands loose clothing necktie hair or testlead s well a way from all moving items a s serious injury could result from enta nglement Never run generator orengine with guards o r protective covers removed WARNING LETHAL EXHAUST GAS The running engine releases deadly carbon monoxide as part ofthen ormal exhaust gas This poiso nous carbon monoxide gas
27. STATOR WIRING DIAGRAM ROTATING FIELD ROTATING rele jak SINGLE PHASE Sn ere 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 main output windings The capacitor provides the v oltage regulating function for the main 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 points 120 24 0 Volt output Connect main winding leads No 2 and No 3 together 240 Volts is produced at leads No 1 and No 4 120 Volts is roduced at leads No 1 and connection point No 2andNo 3 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
28. aining generator set will drop Itis recommended to block up the generator end to prevent it from falling STEP 5 Removel stator Ref J It may 6 necessary to pry thestato r assembly round housing from machine fit ofengin e casting Ref A Once stator assembly is loose pull stator over rotor assembly and free from generator Be careful not to hitors crape rotor or stator windings when stator is being removed STEP 6 The rotor shaft Ref F has an inner female taper and it has been fitted over the ma tching male taper of engi ne crankshaft The rotor bolt Ref I has already been removed in Step 3 The tight fitofth ese two taper fits will have to be loosened Using a ra whide hammer or a steel hamme and wooden block give the side of the rotor one or two sharp blows then alternate to the oth er side with equal sharp blows Eventually the two tapers will loosen and the rotor can be pulled free from the engine shaft A last resort for rust or corrosion between tapers is to position rotor assem bly straight up The 10 engine will be resting on its recoil starter Pour p enetrating oil straight down the hollow rotor shaft and let it set overnight After 24 hours proceed again to use sharp blows until rotor is free from engine shaft STEP 7 The cooling fan Ref is mountedo engine crankshaft on sizes 2 KW through 7 5 KW The cooling fan is mounted rotor shaft for sizes 9 KW to 15 KW In a
29. ds The same infinity reading in both direction s indicates an open diode A zero reading in both directions indicates a shorted diode Both examples indicate a defective diode and sho uld be replaced When on e diode is defective it is advised to replace both diodes as the rem aining may have been weakened Usea 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 not 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 Depending on meter manufa cturer the red and black leads be reversed in location as sho wn in Figure 4 If diodes test good pro ceed to the next repair step 10 STEP 10 Actual component testing is no w complete Defect or problem should have been found during these repair steps 1 through 9 If problem exists call service department toll free 866 537 4388 and ask for additional repair help MAIN WINDING Many other conditions may happen to cause no voltage output with no apparent reason A If generator has been under water or leftina severe rain the insulation system is soaked and will ground out if used The generator must be taken apart and both stator and rotor must be oven baked at 300 F for 3 hours B If generator windings have been exposed to salt water road salt or sea water a condition b etween
30. ectifier that is mounted on rotor The resulting resistance must compare with rotor resistance as listed on chart as sho wn on Page 8 If resistance does notco mpare further testing is required by removing the diodes from the rotor winding The two copper wires must be removed from the tip of the diodes where they are soldered Remove these wires with the aid ofa solder gun being careful not to brea k any copper wires With copper wires free check each coil with an ohmmeter on its lo west OHM x 1 scale Record this value and compare itwith the rotor resistance chart on Page 8 Also test each coil to ground One meter test lead to coil wire and the other test lead to the metal bracket that holds these coils An ohmmeter reading indicates a grou nded defective rotor and it should be replaced See Figure 4 Always inspect all stator and rotor windings for clea n condition Windings that are covered with mud dirt paint and chemicals may test good but they won t last long unless they are clean ed withan approved electrical cleaner then resealed with an air dry electrical varnish STEP 9 Diode Rectifier The exclusive and unique design of this Power Assist brushless generator is the fail proof diode system Itishig hly unlikely that a diode should ever have to be replaced This is why the diode testing is reserved for the last test Diodes are the number one replacement problem with all other porta ble gen set brands Our 1600 volt
31. esidual 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 voltage 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 STEP 1 Remove two machine screws from cover housing Ref L and remove it from bearing casting Ref N STEP 2 Disconn ect stator wires from flexible conduit wires by cutting apart the butt splice insulated connectors Be car eful to make adr awing orm ark alld isconnected wires so that reconnections are correct STEP 3 Remove a II four stator thru bolts Ref K both flange nuts on mounting feet of casting Ref N and rotor thru bolt Ref I STEP 4 Remove b earing bracket Ref N from the generator It will be necessary to ift the generator end up and off the vibration isolators to remove the casting This bearing bracket casting is a tight fit on the stator flange and the rotor ball bearing this a luminum so a pull ey puller should be used Do not pry casting off with two screw drivers as casting will become distorted and may crack or break Be careful when casting is removed as rem
32. f 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 2921 THORNE DRIVE e ELKHART IN 46514 WARRANTY SERVICE PH 800 777 9639 WARRANTY SERVICE FAX 574 262 1840 WEBSITE www gillettegenerators com 30
33. g Record all values and check them with resistance chart on Page 8 When testing for resistance also test for gro unded field coils One ohmmete r test lead stays on field coil lead while the other test lead is touched to a good g round surface of the metal frame bracket hol ding these coils A reading ofthe ohmmeter indicates a bad condition of a ground field coil and stator assembly should be replaced CAUTION Make sure all leads are disconnected and free The 2 8 3 main field coil leads are intenti onally grounded to form a neutral and will g ive meter 8 false reading Grounded field coils indicate defective stator No reading or resistance values when testing between two lead wires 1 and 2 or 3 and 4 indicate an open stator and it should be replaced Check all met er resistances with chart resistances on Page 8 A quick test for the entire stator winding assembly is to disconnect the two red wires from the capacitor With capacitor out of the circuit conne ct 12 VDC to these two red wires and start the g en set If you measure 30 40 VAC from 240 volt rece ptacle with an AC voltmeter the main winding the rotor a nd the capacitor are good but the exciter winding wound on top of the main winding is bad This requires a complete replacement of stator assembly If stator main windi ng tests good pro ceed to next repair step 7 for further stator tests STEP 7 Open Shorted or Grounded Stator Exciter Winding The
34. ing start up e All shipments are F O B factory consigned to the transit carrier All shipping damage repairs are between carrier and receiver e Any associated costs for replacing components found to be defective e Rental costs of equipment during any warranty procedures e Room and board expense due to overnight service condi 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 WARRANTY SERVICE PH 800 777 9639 WARRANTY SERVICE FAX 574 262 1840 WEBSITE www gillettegenerators com GILLETTE GENERATORS INC 2921 THORNE DRIVE e ELKHART IN 46514 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
35. is particularly dangerous because itisodo rless and colorless Never operate the ge nerator setinside a building unless this exhaust gas is safely piped o utside and the proper amount of free fresh air is allowed to enter ventilate and leave the building Ne ver operate engin e where exhaust gas may travel insid e occupied building Avoid breathing fumes when working on or near generator set Use extreme ca ution when ope rating gen set with LPG PROPANE or NATURAL GAS fuel Always consult your local gas fire departm ent before operation is begun to confirm sa fe installation and operating conditions 2 WARNING BURN HAZARD All engine parts and muffler will get extremely hot while running Complete engine should be allowed to cool down before set is worked on and repaired WARNING A HIGH VOLTAGE The job function of the genera tor is to produce electricity and wh enever this en ergy is present there is the pot ential of ele ctrical shock and death by electro cution Noone e xcept trained and qualified repairmen should be allowed to work o n the generator Keep everyone especially children a way from unguarded or running set Wirin g should be inspected frequently Replace any leads 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 WARNING
36. ism may be 6 lost Asthe generator is brushless the field cann ot be flashed in the normal way The residual magnetism can sometimes be restored by connecting a full electric load to the receptacles and then manually increase engine speed to approximately 4500 RPM fortwo se conds This all ows the com pounding system to assist the full load circuit witha resulting increase in the effective residual voltage This is the quick method and sometimes it does not work If residu al magnetism of 4 6 volts is not resto red proceed to actua flashing of the rotor winding The generator set should be run at normal no load speed 12 VDC battery should then be instanta neously flashed touched for only one second across the capacitor terminals Pola rity is of no con cern The red leads should remain connected tothe cap acitor The output voltage should then build up to normal levels See Figure 3 Caution Flashing the field has resto red voltage output but when set is stopped and restarted with resulting no voltage output then check engine speed as it is too low A potential shock hazard exists when handling battery and battery jumper leads Never wear jewelry or use tools or metal items that may make cont act across battery terminals Revie w safety rules at the begin ning of this manual If residual magnetism was not the problem pro ceed to next step 5 INSULATEL MPEI BATTERY LEADS DC BATTEI
37. it breaker If capacitor becomes shorted this internal circuit breaker trips open and causes the entire top portion where terminals are located to become extremely convexed or to push outward When this happ ens the capacitor is bad and must be replaced CAUTION Inspect connection of red wires to capacitor terminals They must be sold ered rigidly tight Repair or replace any loose or poor connections Iftherei s no method to check the cap acitor check the Yellow Page s and call any electric motor repair shop They have the equipment to testcap acitors If the capaci tor is determined not to be the cause pro ceed to the next repair step 4 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 in the rotor system roto r windings and diodes are good and engine speed is correct an A C voltage of 8 12 volts on 120 VAC and 16 24 volts can be measured at the 240 VAC load lin es of stato r power outp ut leads Wit h no voltage present or one half or less of above designated voltage it can be presum ed that residual voltage is lost and the rotor winding must be re energized or flashed If the rotor has been removed or the generator has been stored for over six months the rotor s magnet
38. lation of explosive gases WARNING HIGH VOLTAGE The capacitor contains high voltage Use extreme wh en handling the capacit or as electrical shock can result Always di scharge capacitor before handling by placing an insulated handle screwdriver across capacitor terminals WARNING A ELECTRICAL SHOCK When flashing the generator by applying 12 volts DC battery voltage to ca pacitor terminals be carefulto avoid touching anyb are and exposed battery and cap acitor terminals as dan gerous electric shock is present WARNING DANGER OF ELECTROCUTION Some of the test procedures require that the generator set be running while tests are performed Extreme caution must be used when making these tests as potential electric shock is present This manual and the manufacturer cannot possibly anticipate every possible happening that might involve a hazard The listings warnings and cautions in this man ual and on tags and decals affixed to the equipment are therefore NOT ALL INCLUSIVE If a certain procedure work method test method and operating procedure that are not recommended by this manual and by this manufacturer is used you must assume all responsibility that it is safe for y ou and for all others You must also be sure thatthe generator will not be harmed or damaged or made unsafe by the procedure work or method you have chosen If you modify or change this equipment in any way from the origin al design yo
39. ll c ases loosen two fan hub set screws and pull fan free STEP 8 Remove four bolts from engine casting Ref A Use soft hammer and tap casting off engine pilot flange RE ASSEMBLY This is basically a reversal of disassembly The following is a brief recap with some emphasizing of important points STEP 1 Install engine casting on engine pilot flange and secure with four bolts Casting must be even with pilot with no distorted or uneven assembly fit STEP 2 Re install cooling fan on engine shaft or rotor shaft STEP 3 Install rotor ontoe ngine taper but first inspect female taper and engine shaft for clean surfaces Push the rotor on the e ngine shaft and check for a snug fit There should be no looseness or sloppy fit Install rotor bolt Ref I and tighten STEP 4 Slide stator over rotor and push into place as far as possible STEP Install bearing casting Ref N b y lightly tapping its b earing bore over and onto the rotor ball bearing Be very careful to start this casting on straight Keep lig htly tapping until casting is on the ball bearing but not fitting into inside diameter of stator sleeve ends Install four stator thru bolts Ref K and matching flange nuts Tighten nuts using X pattern and lightly tap casting so it draws up evenly Continue this until casting pilots are all the way into stator sleeve Tap around casting bore to ensure pressure is relieved Test by pulling on engine starting
40. m date of manufacture THIS WARRANTY SHALL NOT APPLY TO AND NOT LIMITED TO THE FOLLOWING e Normal engine wear tune ups service parts including bat teries fuses and engine fluids e Generators in trailer mounted use e Original installation or start up costs e Damage due to insect or rodent infestation e Gen sets that are altered from original design e Radiators replaced rather than repaired e Failures beyond manufacturers control Riots wars theft fire freezing lightening earthquake windstorm hail flood hurricane and all other external causes and Acts of God e Any incidental consequential or indirect damages caused by manufacturers defects or any delay in repair or replacement of defect e Costs due to trouble shooting with jobsite repair person where no defect is found e Costs for equipment cranes hoist trucks for removal or re installation of gen set e Adjustments to fuel systems or governor systems at time of start up or anytime thereafter e Excess mileage costs are not permitted Authorized service provider is limited to 200 mile round trip e Diesel engine damage due to constant light loads wet stacking e Travel expense on any portable generators e Any labor time that is deemed excessive by factory e Overtime labor and overnight freight costs e Steel enclosures and all other deterioration of parts installed within 25 miles of saltwater contaminants e Failures due but no
41. on 120 VAC Replace rotor One diode is open capacitor is defective or exciter winding is bad Engine speed slightly below operating speed but enough to collapse all output Increase engine speed to 3750 RPM 62hertz 125 volts no load setting Rotor winding wire broken off at diode solder joint Re solder copper wire to diode Rotor slipping and free wheeling on engine crankshaft 1 Tighten rotor thru bolt 2 Possible broken engine crankshaft Rotor winding partially shorted Generator rotor speed too high Test rotor winding Replace rotor Reduce engine speed to 3750 RPM 62 hertz 125 volts no load setting Higher micro farad size capacitor is used Some generators have multiple copper wires in field coil One or more of these individual wires may break off the connecting lead wire Check capacitor size It should be 50 mfd 440 volts Test resistance measurements replace stator Rotor diodes have a partial loss of blocking characteristics but still tests good Replace diodes Engine is in need of repair Carboned cylinder head bad fuel or defective engine governor will reduce effective horse power Have authorized repair station test engine The connected electric load has an unacceptable power factor below 7 lagging inductive load Correct the power factor to be between 9 and 1 0 If diode has shorted to conduction of both directions the r
42. r 2600 RPM atn ormal speed of3150RP M 50 hertz below required speed Thi s design feature eliminates the problem of low voltage output at low speeds which is a common problem with competitor s generators and which may result in damage to the plugged in electric load Proper speed setting can also be id entified by no load voltage output of 122 125 volts or no load frequen cy output of 62 hertz If speed setting is prop er and not the cause of no voltage out put proceed to the next repai r step 2 STEP 2 Open Circuit Breaker The A C mainline circuit breaker acts to protect the main power wi nding It will trip open immediately upon short circuit and trip open within 30 seconds at approximately 15 overload To restore A C output close circuit brea ker Reduce the amount of electric load if breaker continues to trip open If generator has no electric load applied and breaker continues to trip replace defective breaker If you are operating the gen set when ambient temperatures are higher than 105 F the thermal brea kers will automatically trip as a normal function Do not operate generator in these hot con ditions If the circuit breaker is determined not to be the cause proceed to the next repair step 3 STEP 3 Open or Shorted Capacitor Our voltage regulating capacitors are of one common size 50 mfdat4 40 volts T hey can be used ina ny size generator for complete interchangeability If this capacitor is openor shorted near
43. t limited to normal wear misuse negli gence or faulty installations such as in adequate fuel lines or gas pressures e Travel or labor expenses and all other costs incurred while investigating performance complaints unless problem is caused by defective materials or workmanship by Gillette e Warranties of associated equipment not of Gillette manufac ture auto transfer switches engines generators are subject to the individual manufacturers assigned warranties e Failure to use and exercise gen set for long periods of time e Parts installed from sources other than engine or generator manufacturer e Manufacturer is not responsible for loose connections caused by vibrations during shipment to jobsite All connections must be checked during start up e All shipments are F O B factory consigned to the transit carrier All shipping damage repairs are between carrier and receiver e Any associated costs for replacing components found to be defective e Rental costs of equipment during any warranty procedures e Room and board expense due to overnight service condi 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 o
44. t will tend to preve nt the main winding voltage from falling therefore acting asa capacitor regulator This innovative voltage stabilizing effect is calle d Power Assist and is an exclusive design with these products GENERATOR CONSTRUCTION Each generator component is described in detail Figure 1 THE ROTOR The engine end of rotor inner shaft is tapered and is connected directly to the male taper of engine crankshaft This end is supported by theen gine crankshaft ball bearing The opposite end of rotor is supported by ball bearing in the bearin g bracket There are two in dividual coils wound on the rotor These two windings create a permanent magnetic field for the main stato r power winding When the gen set is working with the cap acitor removed this rotor winding will generate approximately 8 12 VAC at 120 VAC normal output and 16 24 VAC at 240 VAC normal output in main winding due to what is called Residual Magnetism THE STATOR The stator is a cylinder and the inside diameter is slotted lengthwise The win dings ofboth main power and capacitor coils called exciter windings are placed in these stator slots The mai n power windings are connected directly to the output re ceptacles The exciter winding will produce power for the rotor field are co nnected directly to the capacitor See THE CAPACITOR This device is connected in series with the exciter winding and its only purpo se is to act as
45. teries If battery electrolyte is splashed in the eye s or on skin immediately flush area for 30 minutes with large quantities of clean fresh water Seek immediate medical aid in event of eye contact Never add battery acid to a battery that is in service as it may result in dangerous splattering of electrolyte WARNING ELECTRICAL SHOCK A battery can cause electrical burns and shocks Use e xtreme care when working on batteries to avoid elect rical connections through tools wristwatches rings or any other type of jewelry Always use factory supplied original parts Substitution parts often cause m ore failures resulting in eq uipment down time due to lower values of look alike components You can rely on 24 hour shipment of common rep air parts of these brushless generators Call us and ask for our parts manag er to obtain a ny part you may require WARRANTY CLAIM Notif y factory before any attempt is made to repair a Gen Set D efective parts must be sent to us for inspection before warranty claim is approved WARNING EXPLOSIVE BATTERY GASES battery under charge can emit highly explosive gases Do not smoke or permit flame or sp ark near battery especially when it is being charged Avoid contacting b attery terminals with tools to prevent burns o r sparks that could cause an explosion Remove all jewelry befo re handling battery to avoid burns Battery compa rtments should be well ventilated to prevent accumu
46. u mustassume all responsibility for its safe operation 3 DESCRIPTION OF A C GENERATOR OPERATION A C GENERATOR The A C generator converts the mechanical energy from the engineto electrical power The re are fou r major components involved in the bru shless Power Assist generator set The construction of each m ajor part is described in detail POWER GENERATION The rotor windings are initially charged with a D C voltage and permanently retains a residual magnetic flux During start up an initial flow of electric current is induced in the winding of the capa citor coils located in the stator The lines of magnetic flux from the charged rotor are cut by the stator field coil windin gs This induced flow of current and voltage is very low As the engine increases in speed the voltage induced in the capacitor windings rises An alternating curren t flows in these windings The rising and falling magnetic field from this current is cut by the field coils inthe rotor inducing an excitation voltage dio de rectifier in the rotor field winding rectifies the current from A C to D C The D C current inthe rotor field generates its own magnetic field which sweeps past main power windings in the stator This swe eping magnetic field induces the rated voltage in the main winding as long as the rotor is turning at the correct speed When the el ectric load is con nected to the main power winding the cap acitor coil circui
47. windings Tighten all stator thru bolts rotor thru bolts Inspect wiring for frayed or damaged insulation Tighten all screws on all receptacles Inspect connections to capacitor They must be tight Remove all ground wires clean wire terminals and ground location Re assemble ground wire GENERATOR REPAIR PROCEDURES GENERAL When repairing the generato r always con sider the simplest possible causes first Narrow the problem down to a specific function al system Fora generator to work properly all internal and external parts must be clean All electrical connections must be tight Ifthe generato r produces no electrical power check the following possible causes int he exact sequence of 10 repai steps beginning with the most frequent problem before the gen set is dis assembled STEP 1 Engine Speed Improper low engine speed setting is ve ry common and re sults in being the main problem in a no voltage condition This should be the first item to check Determin e the engine speed at no load applied to generator with a tachometer or other qu alified speed indicator The en gine must be running at 3750 RPM 60 RPM or inthe case of a special 50 cycle winding the running speed mustbe at 3150 RPM 50 RPM for proper voltage output The brushless Power Assist winding is de signed to produce no voltage output if engine speed is reduced 15 or more 3 100 RPM at normal speed of 3750 RPM 60 hertz o
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