GENERATOR REPAIR STEPS

Tools needed: Torx T-15 • 7/16" wrench or ratchet/socket • 1/2" wrench or ratchet/socket • 10 mm
wrench or rachet/socket 3/8" wrench or ratchet/socket • Needle Nose Pliers • Phillips Screwdriver •
Rubber mallet Piece of 2 x 4 wood 12" to 14" long • Fluke 77 or 87 VOM( volt ohm meter) NOTE: If
not using a Fluke 77 or 87VOM the readings described in these steps may differ.
Installation for the New Gen Head Assembly
A- Removal of the old style Gen-Head
Step 1 - Remove the end cover off the gen head Step 4 - Before remove the bearing support, slides a
using a T-20 Torx wrench. 2x4 between the engine and the frame to
support the weight while working on the
gen head.

Step 2 - Once the end cover is removed, disconnect

the wires to the capacitor and the Stator.

Step 5 - Remove the stator.

Step 3 - Remove the grounding lug and the nuts

from the isolators underneath the support
bar on the frame.

1 April 2003
Step 6 - Remove the rotor bolt. Step 7 - Remove the rotor.

B- Installation of the new style Gen-Head For 2500kw - 3500kw generators

Step 1 - Install the new style End Drive Adapter with Step 3 - Install rotor.
the over bolt design

overbolt
design

overbolt
design
Step 4 - Install rotor thru bolt (install short threaded
Step 2 - Install washer, lock washer and bolt using a end of rotor thru bolt in engine shaft until
9/16 socket. The four bolts generators will threads run out), washer and nut, using a ½
be torqued at 204-264 in lbs. socket. Torqued at 120-144 in lbs

April 2003 2
Step 5 - Install stator Step 8 - The ground lug removed from the old bear-
ing support needs to be attached to the
threaded hole in the center of the lower left
tab. With a ½ in wrench torqued the ground
lug at 96-120 in lbs.

grounding
Step 6 - Install bearing support. Larger tabs on the lug
new style bearing support should be locat-
ed at the bottom. The over bolts should be
torqued at 60-70 in lbs. Using a deep well
3/8 socket 3/8's drive.
Step 9 - Reconnect the wires. 2 pink wires to the
capacitor. Connect the remaining wires by
color. Install the end cover.

Step 7 - Remove one isolator and washer and bolt

from the old style bearing support. Install
the washer and isolator in the center of new
style bearing support. Remove the 2x4,
which was supporting the gen head, Line
up the isolator with the hole in the frame
which best centers the gen head and bolt
the isolator to the frame. Torqued at 96-120
in lbs.

3 April 2003
 C- Installation of the new style Gen-Head For 4000kw - 8000kw
An adapter kit is required to install the new gen head on this size generator

Step 1 - Install the new style End Drive Adapter with Step 4 - Install rotor thru bolt (install short threaded
the over bolt design end of rotor thru bolt in engine shaft until
threads run out), washer and nut, using a ½
overbolt socket. Torqued at 120-144 in lbs
design

overbolt
design

Step 2 - Torqued A bolts 204-264 in lbs. Torqued B

bolts 180-220 in lbs. Step 5 - Install stator

A bolts

B bolts

Step 3 - Install rotor.

April 2003 4
Step 6 - Before installing the bearing support. Step 8 - Reconnect the wires. 2 pink wires to the
Remove the vibration isolators off of the old capacitor. Connect the remaining wires by
style bearing support. Install them in the color. Install the end cover.
threaded holes in front of the two lower
tabs. Install the bracket to the lower sup-
port bar on the frame and torqued at 90-
120 in lbs.

Step 9 - The ground lug will need to bolted to a hole

grounding on the support bar to the right of the gen -
lug head. Torqued at 90-120 in lbs.

Step 7 - Install the new style bearing support and

torqued the over bolts at 60-70 in lbs.
Using a deep well 3/8 socket. Remove the
2x4 that is supporting the weight of the gen
head and bolt the vibration isolators to the vibration
bracket. Torqued at 90-120 in lbs. Refer to Isolator
step 9.

grounding
bracket lug

vibration
Isolator

bracket

5 April 2003
1. To make any engine repairs, contact engine manufacturer.
2. Check for proper oil level in engine.
3. Start engine.
4. Use tachometer to check engine speed @ 3750 RPM, without a load, 3600 RPM with a load.
Set if necessary.
5. Use frequency meter to check for proper frequency:
60 to 62.5 Hz.
6. Use VOM (volt/ohm meter) to check genhead for output.

TO RE-EXCITE GENERATOR
1. If no output, rev engine to full throttle for no more than 3 seconds. This will usually re-
excite the genhead if it has lost its residual magnetism.
2. If still no output, shut engine off.
3. Remove end cover screws and end cover from genhead. Remove capacitor leads from capacitor.
NOTE: On the GHC6510 and H650CS remove the two pink capacitor leads from the wire harness
not the capacitor. Attach one capacitor lead to one pole of a 6-volt battery (lantern battery) and strike
the other capacitor lead across the other pole of the battery so as to cause an arc. Reattach capaci-
tor leads to capacitor. Reassemble end cover. Restart engine to check for output.
4. If still no output, shut engine off.

TO CHECK CAPACITOR
(if generator will not re-excite)
1. Remove end cover screws and end cover
from genhead. NOTE: The capacitor on the
GHC6510 and H650CS is located in the panel
assembly, see To Remove Panel Assembly for
this unit and proceed.
a. Remove capacitor leads.
b. Connect VOM to capacitor and watch for
low ohms reading that slowly progresses
to an open circuit. Open circuit from be-
ginning indicates bad capacitor.

TO CHECK STATOR
(if generator will not re-excite and capacitor is
OK)
1. If the capacitor checks okay, check for open
circuits in stator.
2. To check for open circuits in stator,
attach VOM to the following leads:
A. Black- Orange
B. Red- Green
C. Pink capacitor lead- Pink capacitor
lead
Open circuit indicates bad stator.

April 2003 6
3. If open circuits are not found and there is
still a problem, check for circuits grounded
in stator. Attach VOM between:
A. Black- Stator laminations *
B. Red- Stator laminations*
C. Pink capacitor leads- Stator lamina-
tions*
No reading indicates good stator. No read-
ing will be indicated on meter as OL.

4. Attach Vom between black and pink capaci-

tor lead; and red and pink capacitor lead.
Your reading should be infinity or OL. If you
read zero or above, this indicates bad stator.
Most commonly caused by lacings meshed
between windings as shown.

* Varnish on the laminations must be

scraped off to make contact with the
metal surface for correct readings.

TO CHECK ROTOR
(if generator will not re-excite and Stator is OK)

1. If stator checks okay, then check rotor for

open circuits. If the rotor has two diodes,
remove one diode and attach VOM to solder
junction of removed diode to solder junction
of the remaining diode. Open circuit indicates
bad rotor. If the rotor has one diode, remove
the 1/4"-20 nut above the 1/4" female con-
nector and remove from diode bracket.
Attach VOM to female connector and solder
junction on diode. Open circuit indicates bad
rotor.

7 April 2003
TO CHECK ROTOR (if generator will not
re-excite and Stator is OK) (cont'd)
2. If rotor test indicates no open circuit but
double resistance, replace rotor.
3. If open circuits are found, check for short to
laminations. Remove 1/4"-20 nut above 1/4"
female connector and remove from diode
bracket. Attach VOM to female tab and to
rotor laminations*. If reading can be made
then replace rotor.
* Varnish on the laminations must be
scraped off to make contact with the
metal surface for correct readings.

TO CHECK DIODES
1. If all checks okay, then check diode(s).
a. Remove diode from diode bracket.
b. Attach a new AA battery from positive
side to diode in the direction indicate by
an arrow on the diode.
c. Attach VOM to diode for current.
d. If using a Fluke 77 or 87 VOM set to
symbol and listen for a beep from the
meter.
If not using a Fluke 77 or 87 you should
get a reading of 1.5. Turn the battery
around and you should read 0.7 to 0.9.
Any other readings indicates a bad diode.

GS-0082 GS-0081
Used on single and dual diode rotors Used on dual diode rotors in conjuntion with GS-0082
*This symbol is present on all diodes used on DeVilbiss Generators. The arrow indicates the direction of
current flow through the diode. If the arrow points toward the diode bracket, this diode is the GS-0081. If the
arrow points toward the soldered junction, this diode is the GS-0082.

Flow of Electricity

April 2003 8
 RESISTANCE VALUES IN OHMS @ 70° F
Effective 12-01-02, Highlighted models indicate new generator head design. Verify model number when looking for values.

MODEL NUMBERS Main Winding Aux Winding Rotor I/C D/C

Red to Green Pink Capacitor Leads
Black to Orange
CH250 .210 - .240 2.55 - 2.72 1.80 - 1.87 N/A N/A
CH250-1 / D26572 .210 - .240 2.55 - 2.73 1.64 - 1.78 N/A N/A
CDGT3010-3 / D26576 .210 - .240 2.55 - 2.73 1.64 - 1.78 N/A N/A
DTE325-2 / D26576 .210 - .240 2.55 - 2.73 1.64 - 1.78 N/A N/A
DTE325 .210 - .240 2.55 - 2.72 1.80 - 1.87 N/A N/A
DBSI325 .210 - .240 2.55 - 2.72 1.80 - 1.87 N/A N/A
DBSI325-1 / D26576 .210 - .240 2.55 - 2.73 1.64 - 1.78 N/A N/A
CH350CS-2 / D26593 .420 - .480 .110 - .140 1.64 - 1.78 N/A N/A
CH350CS .430 - .470 2.66 - 2.83 1.80 - 1.87 .250 - .280 .110 - .140
CTE300 .260 - .280 2.15 - 2.29 1.82 - 1.90 N/A N/A
CTE300-1 / D26576 .210 - .240 2.55 - 2.73 1.64 - 1.78 N/A N/A
H450CS .370 - .400 2.53 - 2.70 1.80 -1.87 .220 - .250 .110 - .130
T525 .370 - .400 2.50 - 2.65 1.80 -1.87 N/A N/A
T550-W .370 - .400 2.50 - 2.65 1.80 -1.87 N/A N/A
BSI550-W-2 / D26605 .250 - .280 1.42 - 1.55 1.61 - 1.74 N/A N/A
BSI550-W .260 - .280 1.60 - 1.71 1.80 -1.87 N/A N/A
H451CS-W .220 - .250 1.88 - 2.01 1.33 - 1.42 .150 - .176 .071 - .08
BS500 .430 - .470 2.15 - 2.29 1.81 - 1.92 N/A N/A
BS525-W .430 - .470 2.55 - 2.72 1.80 - 1.87 N/A N/A
BSI525-W-1 / D26598 .420 - .480 2.55 - 2.73 1.62 - 1.78 N/A N/A
BSI525 .430 - .470 2.55 - 2.72 1.80 - 1.87 N/A N/A
BS600 .320 - .350 1.50 - 1.60 1.44 - 1.52 N/A N/A
H650CS .180 - .150 1.00 - .935 1.52 - 1.43 .170 - .150 .085 - .055
BSV750-W .130 - .145 .950 - 1.20 1.43 - 1.53 .170 - .210 .082 - .097
BSV800 .160 - .180 1.45 - 1.55 1.43 - 1.52 N/A N/A
H1000 For values on this model, please go to the bottom of this chart
H1000 -1 / H1000IS-W 0.08 - .12 .42 - .46 1.44 - 1.58 .15 - .19 .07 - .11
GBP4000 GBV4600 .3 - .6 1.2 - 1.6 .3 - .8 N/A N/A
GB4000 GB5000 .3 - .6 1.2 - 1.6 .3 - .8 N/A N/A
GB5000-1 GB5000-2 .3 - .6 1.2 - 1.6 .3 - .8 N/A N/A
GB5010 .3 - .6 1.2 - 1.6 .3 - .8 N/A N/A
GBV5000 GBV5000-1 .3 - .6 1.2 - 1.6 .3 - .8 N/A N/A
GBE4010 GHV4500 .3 - .6 1.2 - 1.6 .3 - .8 N/A N/A
GB4000-1 GB4000-2 .3 - .6 1.3 - 1.8 .6 - 1.2 N/A N/A
GB4010 .3 - .6 1.3 - 1.8 .6 - 1.2 N/A N/A
GB4000-3 GBE4010-1 .3 - .6 2.2 - 2.6 2.0 - 2.3 N/A N/A
GB5000-3 GB5000-4 .3 - .6 2.2 - 2.6 2.0 - 2.3 N/A N/A
GT5000 GBP4000-1 .3 - .6 2.2 - 2.6 2.0 - 2.3 N/A N/A
GT5250 GHV4500-3 .3 - .7 1.7 - 2.1 .6 - 1.6 N/A N/A
DGHC6510 .180 - .150 1.00 - .935 1.52 - 1.43 .170 - .150 .085 - .055
GBFE6010 .4 - .7 1.7 - 2.1 1.7 - 2.0 N/A N/A
GBV7000 GBV7000-1 0 - .3 .6 - 1.1 .5 - .9 N/A N/A
GBV7000-2 GBV7010 0 - .3 .6 - 1.1 .5 - .9 N/A N/A
GBV7000-3 0 - .3 .6 - 1.1 .5 - .9 N/A N/A
GBV7000-4 .2 - .6 .6 - 1.3 .9 - 1.7 N/A N/A
CGTP3000-3 / D26576 .210 - .240 2.55 - 2.73 1.64 - 1.78 N/A N/A
CGPT3000 .4 - .7 2.3 - 2.7 1.9 - 2.3 N/A N/A
CGBV4000 .3 - .7 2 2.0 - 2.3 .3 - .6 .3 - .6
GBVE8000 .160 - .180 1.45 - 155 1.43 - 1.52 N/A N/A
3600rpm 120-240v 60 Hz
Stator Rotor Excitation
H1000 R2-160 4.67 0.109 1.3
R2-200 5.23 0.075 1.05

9 April 2003
TO CHECK IDLE CONTROL SWITCH

1. Remove the Panel Assembly. See To Remove

Panel Assembly in the Disassembly Proce-
dures section of this manual.
2. Place idle control switch in the OFF position.
3. Remove the two screws from the front of idle
control switch.
4. Disconnect wire harness from idle control
switch.

Models with Idle Control Switch

H1000 H1000-1 H1000IS
H650CS
H450CS H450CS-1
CGBV4000 PANEL ASSEMBLY
H45ICS-W
CH350CS
CH350IS
BSV750-W

GHC6510 PANEL ASSEMBLY

5. Remove idle control switch and attach the

VOM (volt/ohm meter).
6. Turn idle control switch to the ON position.
A low reading = a good idle control switch
No reading = a bad idle control switch
NOTE: Always place idle control switch to the
OFF position when replacing old or new.

April 2003 10
TO CHECK SOLENOID
(CGBV4000)
1. Unhook wire harness from solenoid.
2. Loosen nut on end of solenoid. DO NOT re-
move.
3. Solenoid will now slide from bracket.
4. Connect VOM (volt/ohm meter) to solenoid
leads. Set VOM (volt/ohm meter) to read

OHMS, the reading should be 150 + or – 10

OHMS. If no reading the solenoid is bad.
5. Reconnect wire harness to solenoid.
6. Start the generator and place the idle control
switch in the ON position. With generator
running and idle control in the ON position the
solenoid should be magnetized, if you place
the solenoid to the frame it should stick. If
solenoid is not magnetic check stator.

(GHC6510 & GH8400CS-W)

solenoid
1. Disconnect the solenoid from the wire har-
ness.
2. Connect the VOM meter to the brass tabs
inside the connector, the VOM meter should
be 26 + or - 1.

wire harness

11 April 2003
CHECK STATOR
(if solenoid is no longer magnetic)
1. Turn the generator off and allow it to cool
before checking stator.
2. To check stator for resistance remove the end
cover. See To Remove End Cover in the
Disassembly section.
3. Attach the VOM (volt/ohm meter) to the two
white leads on the stator. Set VOM (volt/ohm
meter) to read OHMS, the reading should be
.05 OHMS, if no reading the stator is bad.
4. Attach the VOM (volt/ohm meter) to one white
lead on the stator and the stator laminations.
Set VOM (volt/ohm meter) to read OHMS, no
reading indicates a bad stator.
NOTE: If stator is bad, replace and recheck
solenoid for magnetism. If the solenoid is not
magnetized and the stator is good then replace
the circuit board.

* Varnish on the laminations must be scraped

off to make contact with the metal surface for
correct readings.

REPLACE OR REASSEMBLE SOLENOID

(CGBV4000)
Threads flush
1. Thread the back nut all the way up to the so- with nut
lenoid.
2. Slide solenoid into bracket.
3. Thread the front nut only until the end of the
solenoid is flush with the nut.
Thread nut
4. Connect the VOM (volt/ohm meter) to the onto solenoid
120-volt outlet.
5. Start the generator and place the idle control
switch into the ON position. At this time the
magnetism of the solenoid will pull it into
place.

April 2003 12
6. The VOM (volt/ohm meter) should read 60
Hertz.
7. Thread the front nut onto the solenoid until
the VOM (volt/ohm meter) reads 45 Hertz.
8. Using wrenches tighten the back nut tight
against bracket while holding the front nut in
place. MAKE SURE reading remains at 45
Hertz when tightened.
9. Turn the idle control switch to the OFF posi-
tion and the VOM (volt/ohm meter) will return
to 60 Hertz.
(GHC6510)
1. Reconnect solenoid leads to the wire harness.

heatshield

TO REPLACE SOLENOID
(GHC6510 & H650CS)
1. Using a 10 mm socket remove the heatshield.

screw

screw

2. Using Phillips screw driver remove the

screws holding the solenoid in place.

screw

3. Slide arm from the solenoid and remove. solenoid

4. Replace the solenoid in reverse order. screw

screw

arm

13 April 2003
TO SET THE ENGINE IDLE SPEED
(GHC6510)
1. Connect the VOM (volt/ohm meter) to the
120-volt GFCI outlet.

2. Using Phillips screw driver turn the screw on

the carburetor left or right until the VOM
(volt/ohm meter) reaches 45 Hertz. MAKE screw
SURE reading remains at 45 Hertz when
tightened.
3. Turn the idle control switch to the OFF posi-
tion and the VOM (volt/ohm meter) will return
to 60 Hertz.

TO REPLACE THE CIRCUIT BOARD

(CGBV4000)
1. Remove the Panel Assembly. See To Remove
Panel Assembly in the Disassembly Proce-
dures section of this manual.
2. Disconnect circuit board from wire harness
and replace with new.
3. Reassemble the panel assembly in reverse
order of removal. Circuit board

April 2003 14
(GHC6510 & H650CS)
1. Remove the Panel Assembly. See To Remove
Panel Assembly in the Disassembly Proce-
dures section of this manual.
2. Disconnect circuit board from wire harness
and replace with new.
3. Reassemble in reverse order. NOTE: When
reassembling, attach capacitor and bracket,
circuit board, and plug before attaching the
front panel to back panel.

TO CHECK AND REPLACE THE

RECTIFIER (CGBV4000 and GHC6510)
1. To check stator for resistance remove the end
Yellow Lead
cover. See To Remove End Cover in the Dis-
assembly section.
2. Attach the VOM (volt/ohm meter) to the two
yellow leads on the stator. Set VOM (volt/ohm
meter) to read OHMS, the reading should be
.07 OHMS, if no reading the stator is bad.
3. Attach the VOM (volt/ohm meter) to one yel-
low lead on the stator and the stator lamina-
Yellow Lead
tions. Set VOM (volt/ohm meter) to read
OHMS, no reading indicates a bad stator.

* Varnish on the laminations must be scraped

off to make contact with the metal surface for
correct readings.

NOTE: If all readings are OK replace the rectifier.

Rectifier

15 April 2003