TROUBLESHOOTING AND SERVICE

INFORMATIONFOR MECC ALTE

PORTABLE GENERATORS
All troubleshooting and service information is offered
for the use by authorized Mecc Alte service centers.
Repairing Generators is NOT a "DO IT YOURSELF" task.
Exposed electrical wires and rotating parts present a
danger for personal injury or death. Always wear safety
glasses when servicing the generator and or battery.
Only qualified electricians and/or authorized service
centers are authorized to service these units.

Please refer to the Mecc Alte web site in order to

download the correct instruction manual for the model
of generator you will be servicing.

www.meccalte.com
Direct link below

Mecc Alte Manual Downoads Link

OR
www.meccalte.com/index.php?s=52

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 SUGGESTED REPAIR PROCEDURES FOR S15W, S16W, S20W, S16F, S20F AND S20FS
SERIES GENERATORS

1. Check engine speed (3720 RPM no load) and frequency 62 hertz no load.
2. Open end cover with receptacles exposed if equipped. See figure 1. Check lead wires 1,2,3 &
4 according to the resistance chart in the installation manual as follows:
Lead wires 1 (black) to lead 2 (white)
Lead wires 3 (white) to lead 4 (black)
Orange to orange (exciter) Disconnect the red wires to the capacitor before checking
the resistance in the wires.

Important on some models, lead wire 2 (white) and 3 (white) are connected together. See figure 2.
To test the stator lead wires and leads 1, 2, 3 and 4 must not be connected together. See figure3.
When checking lead wires, leads 2 and 3 are connected together at the factory on some models.
You must disconnect these leads when testing resistance of the various coils or you will get
incorrect readings.

Figure 1 Figure 2

Figure 3 Figure 4

In addition to checking each coil, test each coil to the ground terminal on the aluminum end
bracket to see if any winding has gone to ground. If any lead wire indicates positive continuity to
the ground, replace the stator.

3. Check the capacitor for the proper microfarad reading with a capacitor tester. If a capacitor
tester is not available, use an ohmmeter set at 10k and touch both terminals at the same time.
See figure 4. The meter should bounce up with a reading and immediately drop off. If the
meter does not indicate anything or remains holding a reading, the capacitor is defective and
must be replaced.

4. For a unit that has been out of service for a period of time, flashing the field is recommended.
See attached instructions.

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 5. If the first four steps show no failures, remove the stator from the generators. With the stator
removed, the diodes must be checked. To test each diode without disconnecting it from the
circuit, use a 12-volt battery and a 45-watt light bulb (automotive type) as shown in illustration
950204. The light should turn on in one direction, as shown. If you cannot test the diodes as
previously indicated, you must disconnect the copper wires from one end of the diode. You
must also disconnect the varister (surge suppressor) from the diode. With the wire removed
use an ohmmeter set to 10K and touch both terminals of the diode. Diodes pass current in
one direction only. If you do not get a reading, reverse the terminals of the meter. If you do
not get any readings or if you get readings in both directions, the diode is defective. Be sure to
check both diodes. If you have only one defective diode, it is strongly recommended to
replace both diodes. If the positions of the diodes are reversed, you will block the current flow
and get no output form the generator. Pay careful attention to the marking to the current
direction of each diode.

6. To check the winding on the rotor you must remove one end the diodes and varister. With an
ohmmeter check the readings for each coil. The rotor coils are identical. See chart for the
various ohm readings. Prior to testing resistance in each coil, be sure to zero out your ohm
meter. All readings must be within 25% or less of the published ohms and be consistent
(either at slightly higher or slightly lower, not some higher and some lower).

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 Out of Use for a Long Period
If the generator set has not been used in over 6 months and the generator worked properly when
last used, it is very likely that the capacitor is discharged. The capacitor needs to be "flashed" or
reenergized.

On S15W, S16W, S20W units, open the end cover where the receptacles are located if equipped.
See picture #1. The capacitor is connected to the aluminum casting and has 2 red or orange
wires from the generator exciter windings. Partially slide the 2 plastic wire covers back exposing
the metal contacts on the capacitor. Caution! Exposed generator wires present a danger and
great care must be taken to not touch any exposed wires of the generator or electrical shock may
occur. Be certain the ground surface is dry. Start the engine with no load and apply 12 volt DC
from a car battery to both terminals. There is no polarity issue so it does not matter which
terminals you touch. Danger!-once you touch the capacitor terminals voltage will start and you
will have live wires exposed. There will be a small arcing when you touch the capacitor and you
will hear a grunt sound from the generator. Stop the engine. Carefully slide the 2 plastic wire
covers completely back on the capacitor. Replace the end cover on the generator. Be sure the
wires are away from the bearing and rotor through bolt area in the center of the casting and
retighten the cover screws. Start the engine again and check the voltage from each receptacle
for proper voltage (120/240 volts for 60 Hz and 110/220 for 50 Hz). Note- If, the generator does
not produce voltage a day or two after flashing/reenergizing the capacitor, you must replace the
capacitor.

S16F, S20F AND S20FS Models

These units have the capacitor in the top terminal cover of the generator. See figure #2.

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 TROUBLE SHOOTING
FOR S15W, S16W, S20W, S16F, S20F AND S20FS SERIES

PROBLEM CAUSES REMEDIES

No Voltage 1. Low speed 1. Check RPM of engine 3720 RPM
2. Faulty capacitor 2. Check and replace

3. Faulty windings 3. Check winding resistance

4. Out of Service
4. Flash capacitor (See page 4)
many months
5. Faulty Circuit
5. Check and replace.
Breaker

High/no load Voltage 1. Speed too high 1. Check and adjust to 3720 RPM
2. Capacitor with high 2. Check and replace
capacity

Low no load Voltage 1. Speed to low 1. Check and adjust to 3720 RPM
2. Faulty diodes 2. Check & replace diodes
3. Winding breakdown 3. Check winding resistance
4. Capacitor with low 4. Check and replace
capacity

Voltage on 120 volt 1. One defective diode 1. Replace both diodes and varister
Side is 60-90 volts

Circuit breaker trips 1. Overload on circuit 1. Reduce electric load

2. Shorted electric load 2. Repair short in device
3. Defective breaker 3. Replace breaker

Proper no load Voltage1. Low loaded speed 1. Check & adjust engine RPM
But Low loaded 2. Load too heavy 2. Check & reduce load
Voltage 3. Diodes shorted 3. Check & replace
4. Engine governor 4. Adjust or repair governor

Proper no load but

1. Excessive RPM 1. Check & adjust
High loaded voltage
1. Check connections at receptacles and
Unstable voltage 1. Loose contacts
circuit breakers
2. Uneven rotation 2. Check engine RPM

3. Loose rotor 3. Tighten rotor through bolt

Noisy Generator 1. Bearing 1. Replace
2. Poor coupling 2. Check & repair

3. Broken fan 3. Replace

Ground Fault 1. Receptacle too 1. Replace
Receptacle trips sensitive
2. Extension Cord 2. Replace extension cord

Voltage for a few 1. Cracked windings 1. Replace rotor or stator

Minutes then no
Voltage

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 DIODE DIRECTION

FOR ALL S15W, S16W, S20W, S16F, S20F AND S20FS DIODE
REPLACEMENTS

While looking at the rotor in this position, the numbers and letters on all diodes are readable as shown
above. The numbers and letters may be different but all face the same direction in this position.

With the stator removed, cut the diode wire half way between the diode and it connection and re-solder
the new diode to the half that remained. Note the direction of the wording on the original diode. Replace
the varister and diode with this same process. Do not keep solder gun on new diode leads for more than
a few seconds or damage to the diode may occur.

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 CAPACITOR TESTING
1. The generator should NOT be running. Disconnect the two exciter lead wires to the capacitor.
With a capacitor tester connect to the capacitor read the MFD indicated which should be exactly what is
marked MF or UF on the capacitor. There are no polarity concerns when testing a capacitor.

2. If no capacitor tester is available, use a multi-meter set in the resistance (Ohms) position at 1K
or 10K, connect the lead wires as noted in the drawings below. A good capacitor should make the meter
have a momentary reading and then drop off to zero. A defective capacitor will either cause the meter to
hold a reading or have no reading at all. You can only do this test a couple of times as you will be
discharging the capacitor. Replace defective capacitors with like size MFD 450 volt capacitors.

MULTI-METER IN OHMS POSITION

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 FIGURE 950204

DIODE TEST WITHOUT REMOVING THE DIODE FROM THE ROTOR

Connect a 12 volt DC battery and a 45 watt (automobile type) bulb as shown below. The light will turn on
in one direction only as shown.

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 WWW.MECCALTE.COM

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Via Roma, 20 - 36051 Creazzo (VI) MECC ALTE INDIA PVT LTD
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FAR EAST TEL. +91 2137 619600 - FAX +91 2137 619699
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19 KIAN TECK DRIVE
SINGAPORE 628836 DEUTSCHLAND
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ECONOMIC DEVELOPMENT AREA
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TEL: 86 513-82325758 Mecc Alte Inc.
FAX: 86 513-82325768 1229 Adams Drive
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