Bringing another military diesel generator back to life

In this video, I bring another MEP-004a military surplus diesel generator back to life. This one posed its own challenges, including a faulty switch, leaky injector lines, and more.
24:24 and 29:14 are both interesting points in the video...I figure if I don't post links to them here, somebody else will!

[@MattVerley]

I have found that it is easy to repair individual components on these sets. The electrical parts are very standardized and easy to find suitable replacements, at the component level. The major parts of the engines (injection pump, injectors, thermostats, starters, alternators, etc.) are all rebuildable by a good shop. If you need complete assemblies, surplus dealers are the only way to go.

[@viscache1]

Exciting stuff! I got aa perfectly good running 5 kWh with a 5 ton truck and missile trailer that i bought for logging. Has under 200 hours but I haven’t had time to fiddle with it for two years. I like your methodical approach and will rewatch this as i get mine up to snuff to power all my farm out buildings. Our local power utility fades in and out like a wildflower during a drought! I need reliable power for my shop! I used these overseas in the Army and came to appreciate how bulletproof they are

[@billjenkins687]

Matt, I truly appreciate your attention to detail and your obviously high level of skill and experience. I may hire you as a consultant on a future project. Thanks for a great video!

[@mainlawcafewv7681]

very smart, logical, step by step approach.

[@tigerelectronics5966]

These videos are super enjoyable! keep up the good work!

[@MattVerley]

Thanks!

[@towrecker]

Great , I now have an idea of what to look for , and where , yeah , I need to do some major exploration of this unit , and get to know it , as my plan is to yank it off the trailer , pour a pad , and set it out back of the house for winter power outages , so I need to know this thing well enough to work on it , that's a fact ! You have no idea how much help your answering my questions is worth to me , your great , Thanks Again for being there and helping me out !

[@MattVerley]

Yep; I run into this often. The "no fuel" warning light is set off by a float switch in the stainless day tank, not the main fuel tank. Most likely cause is that the screens for both fuel pumps are clogged up, and/or the plungers are stuck. Twist the caps off of the ends of the two pumps and clean them out; before you go to re-start the set, leave the start switch in "run" and battleshort switch on for about a minute before starting to allow the pumps to re-fill the day tank.

[@outdoorlifeinsc3583]

I just won and picked up my first, a MEP803A. All it needed was batteries and it fired off on the third crank. Im amazed at how quiet it is. Ill be doing a load test withing the next two weeks.

[@iamthetarget52]

24:24 Priceless !!!! 24:52 Is even BETTER !!! It taught me something new, so thank you.

[@binarybox.binarybox]

Well done. Many points to correct and fit missing parts. The inductive prob sounded like the back emf..glad you were ok !

[@Robertalcine]

this was a great video Matt I enjoyed it

[@rustblade5021]

quite the exciting video, you got lit up and an arc flash too!

[@phooesnax]

awesome job.

[@3cl1]

Nice work on the generator.

[@MattVerley]

The price depends on the time of year and how many other units are available at the same auction. I typically don't bid on anything once it hits $1000, unless its REALLY nice.

[@Gordonseries385]

Nice Job!

[@diosdadohassan2725]

I recently purchased a MEP803A and was wondering if you could help me with information on 2 issues I and concerned with.

[@mikeransom1168]

You mentioned leaks at both ends of the radiator hose. I noticed what appeared to be a flattening of the upper hose connection area. that may restrict coolant flow. you might want to keep a close eye on the temperature.

[@femespwa7179]

I have the PU794/G 20kw 4 cylinder which is a modified MEP004, generator run when i connect the positive battery lead to the fuel injector and push the start button, but the panel does not work. I noticed that the battle short light is missing and circuit bracker light is missing as well. Generator does not produce current when tested.

[@princessbremner9255]

hi i have a 60 kw military generator that would start up wonderful but would not out put no voltage could you give me some advise on what i could check

[@Cdubp01]

Thnx for the reply. Dang those things are heavy, haha. Guess Im going to need to get a 5ton from auction before I get a MEP. haha

[@jasonmartin2133]

I Just picked up a MEP 004-A tactical (1982) in very good shape. While looking it over I noticed that the Tac or Speed Control Unit was not connected to the engine block. The wire harness was still there, and I found the speed control unit in a small box in the immediate vicinity. I think that I might be missing an adapter between the engine block and the unit. Can you please show how that unit is supposed to mount to the engine block. I want to verify that I have all the pieces and parts and put back together correctly. The Tech manuals are not that clear. Thanks

[@ashforkdan]

I love the videos keep them up.I started buying the gen sets and found that its close to impossible to get parts for them.Do you have a place or are you just using parts from a donator gen sets?Please don't stop making these videos because it really does help.Thanks

[@sky1hawk988]

Question: When operating these three phase gen sets in single phase ONLY, to avoid damage, is it necessary to "balance" the generator head to address the effect of the unused winding for the third phase? If balancing is needed in your single phase installation, how is that achieved?

[@MattVerley]

If the wires are for the ether system, they don't connect to anything... Can you tell me what number is stencilled on them (you may have to trace them back for a little while to find the stencil)

[@XER239]

what surge power is it capable of?

[@colbyhowerton4213]

Matt Verley- I have a 1986 MEP 005A.... It will crank just fine and it will turn over with ether.... Seems the engine is not getting fuel... I am getting fuel to the injector pump but no luck with start up. I am doing as much research as I can but I am not finding much.... Any help? I am in Texas.

[@donaldsmith3048]

Do they make a generator that uses the multi fuel engine like is in the M35A2 truck. If there is one can you give me the number for it?

[@cesarduque5992]

Hi, I bought an generator just like this one. Mine is missing the fuse on the alternator, the one you show at 15:45. Can you tell me what amp capacity fuse is required. BTW thanks a lot for loading this videos. Thank you

[@MattVerley]

The trailer date and gen date will be different; I have never seen one where the dates matched. I don't know of any way to date the machine beyond the label plates that should be riveted to the outside of the generator enclosure. If they aren't there, then I'm not sure if there is a way to tell...

[@genefredrick8842]

I have a MEP003A, it's locked up, what's the best way to get marvel mystery oil into the cylinders? Where is the best place to find manuals?

[@MattVerley]

Day tank is a small stainless tank (maybe 2 gallons?) located on the vertical support in between the 2 compartments on the left side of the generator. Best access is through the panel where all of the filters (fuel and oil) are located. The pumps are directly below that; from my memory, they are roughly 3" in diameter and maybe 5" tall, and they are bolted side by side. If you follow the fuel lines back from the fuel filters, you should be able to figure out how the fuel system works.

[@nafivesa1]

Great video's. Looking forward to doing the single phase conversion. I have a MEP-005a that ran great until last week. The fault breaker starting tripping. All lights are working, but none are on during or after the fault. Only trips after 20 seconds when I switch in the main load contactor. Using a pair of 120 volt light bulbs across in series L2 and L3 for indication of power out. Any help would be appreciated. Thank you.

[@tyebratvold2456]

Hi there, I am looking at picking up a MEP-005 35KW genset that isn't running to use for my M934 5 ton. I don't know a whole lot about them and was wondering if you would be willing to work on it to get in running? Thank you.

[@robertstephenson8089]

Ok, I see these on gov plant from time to time. This is an auction site and so is iron planet. I was wondering if it would be worth it to bid on a 15kw generator to power my house? Could you reply to this e-mail?

[@SASPOWER1]

Would love to know if you had a spare engine harness for one of these. Have an MEP005A that had a harness stripped off.

[@MattVerley]

The terminals likely went to the ether injection system. Rare to see one of those intact; seems the military removed most of them. Most likely have air in your fuel lines, or restriction somewhere in the supply to the injection pump. The fuel just gravity feeds from the day tank into the pump. Make sure you have a good flow of fuel at the inlet to the inj. pump.

[@towrecker]

I think I have the pumps cleared up , just have to install them , and to a real time test to make sure , also are there any sources online for the factory connections to the voltage re connection board ? this thing was surplus from what used to be civil defense , it has a nice set up mounted to it a total of 24 120v outlets , and 2 240v outlets , I don't know how they did it , best to see what they did , and see if it is what you do in your rewire ,I checked a 120v , it tested right but...

[@MrShawn305]

Ohh ok, I thought I heard Ft. Bliss! What do these units usually go for? I would love to get hold of an MEP003 to work on.

[@towrecker]

possible easy question for you , if you don't know that's ok , the one I just got done something that seems odd , like you I found it with no fluids , it did however have a small amount of fuel , I added about 4 gallons , started it , it started right up , ran for about 10 min , and shut down with no fuel light on , my gauge also reads full , I know better , are there 2 sensors for fuel , a level sender , and say a flow sensor or something ? I flipped the battle short , and ran it for another 10

[@440dross]

You don't happen to have the wireing diagram for the engine of an AO84? really like to get it running and charging on it's own. There is genertor, just the engine. Thanks. dave

[@MattVerley]

It depends on the model, hours, accessories, and how much I am into the generator for...a set like the one in this video goes for around $2500 to $3000.

[@MattVerley]

I'm not familiar with an AO84; is that an aircraft engine? At any rate, I don't have any info on it...sorry!

[@tobyzahn9943]

Matt on my 804A can you tell me about the 2 mystery wires from the genhead labeled F1 and F2. Kinda begging at this point.

[@MattVerley]

You are hearing them rapidly click, correct? Hearing them come almost to a stop is a good sign; that means they are building pressure. I have never seen a bad one (just dirty ones that needed cleaning) so I suspect they are still good. They are hard plumbed into a solenoid valve that feeds the day tank; are you trying to get fuel after that solenoid valve? Perhaps it is stuck closed, or the float switch in the day tank that controls that valve is defective...

[@jimflynn7551]

how many kw is this gen set

[@towrecker]

you are a great help , and I really appreciate it , I really do , being that it is producing power , and the engine sounds great , a few little issues is just a blessing , their could be rods hanging out of the block lol ...also is there anywhere on the unit that will help me place a date of manufacture for it , the engine is sand color unlike the rest of it , the engine is dated 1985 , I can not seem to find another single date on the machine ... it's trailer is dated 1/65 , would that be it ?

[@MattVerley]

Probably does have air in the injection pump/lines. Easiest way to purge the air is to crack the lines at the injectors (don't remove) them. Turn the switch to run and let the lift pumps run for several minutes. Then crank the engine over in 15 second intervals until you get clear fuel coming from the lines. Re-tighten, and then try to start it again. Feel free to message me if you need any more help

[@juliocesaraburtotellez8365]

Matt tengo un problema con mi generador militar no está arrancando y no trabajan las 2 bomba eléctricas de diésel tu crees que sea el máster swuich

[@8tyman8]

love the vids keep them up

[@Troyisbig]

could you give me some advice on a mep-002a - it ran great for about 10-15 seconds and then slowly lowered in rpm. I think it has air in it, as it spit air/fuel out the drain cock on the second filter. I could only find one fuel filter in my town. Any trouble shooting advice? Thanks

[@Cdubp01]

Without the enclosure, how much does one of these genies weigh? IE-how hard to transport if I purchased one from auction? thnx

[@Robertalcine]

hey Matt have you done any work. on mep 804a that will not stay runing Woodward gov shuts down over speed

[@THOMAS01ify]

One thing is for sure it has no blow by sometime when they get old the oil pan will pressurise and shot the dip stick out and spray oil all over the place the only way to prevent this is just to leave the dip stick hanging out on start up and cracking the fill port

[@joesphkoellner3954]

I'm not getting power to my fuel pump but if I jump out the fuel pump and hold the start button and stop position to stay running soon as I Let Go it shuts down this is on a mep-004a I noticed this the fuses what could it be

[@MattVerley]

+joesph koellner I don't think I fully understand your question; but, the lift pumps (the ones that make a clicking noise) should not turn on unless: 1. The generator is running and up to speed -or- 2. The start switch is in run and the battleshort switch is in battleshort. If the day tank (the small stainless tank mounted on the frame slightly above and behind the fuel filters) is empty, then it needs to be filled by placing the start switch in start and the battleshort switch in battleshort. It should take the lift pumps about a minute to fill it if it is completely empty. When it is full, the "clicking" noise from the pumps will slow down to about 1 per second. If you're talking about something else, let me know...

[@MattVerley]

I've never run JP8 in any of the MEP generators, so I don't have any firsthand experience with it. I have run centrifuged waste oil through them, and they seemed to run just fine on it...

[@radboy28]

how much would you sell one of these sets for?

[@nsaquatics1]

Do you sell these generators or just use them for yourself? I'm looking at buying one to power my Fish Store. I've seen allot of the mep004a on auction sites.

[@towrecker]

I can look to see if they moved what you show , but I am afraid they could have moved other wires , so I kind of need to know where they all are supposed to be in original configuration ...yes all the plates that should be on or in this generator are you guessed it missing ;(

[@MattVerley]

I'm not really in the business of selling them; when I can get my hands on projects like the one in the video, I do go through them and then re-sell them. I haven't been able to purchase any for the last year or so, so I don't currently have any for sale.

[@nyyrusty]

They always leave those cross over cables on the batteries when they're pulled, lol. Stay away from the tan ones, sand fucks everything up.

[@minionmaster8805]

Have been enjoying your videos and posts on SSs. I've started my restoration of a MEO-004A and have been successful with it up till now. I can't get fuel out to injectors. Fuel going to IP is nice and clean. However that is because I finally had it flowing from day tank after replacing transfer pump. I believe by looks inside top of pump, initially there was no fuel in IP and it had rust in on steel parts. Meter valve was stuck and after I freed it up, I was expecting all well. But no luck. How far do you think I should go with IP and is there a manual on it specifically. Also is there any publication showing the fault indicator assy. Not working as well. Thanks

[@matthewverley1433]

The -34p tech manual covers the disassembly, inspection, some adjustments, and reassembly of the injection pump (starting on page 101). If you can't find a copy, I can email it to you. Just send me a message with your email address. Honestly, I've never tried to repair an injection pump. They are a pretty common stanadyne pump, a relatively inexpensive to have rebuilt (it has been a number of years since I had one done though). Any good injection pump shop should be able to rebuild it. As far as the alarm circuit, I would use the schematics at the end of the -12 TM, and possibly the test procedures in the -34p. Does nothing light up when the test/reset button is operated?

[@MattVerley]

The -34p tech manual covers the disassembly, inspection, some adjustments, and reassembly of the injection pump (starting on page 101). If you can't find a copy, I can email it to you. Just send me a message with your email address. Honestly, I've never tried to repair an injection pump. They are a pretty common stanadyne pump, a relatively inexpensive to have rebuilt (it has been a number of years since I had one done though). Any good injection pump shop should be able to rebuild it. As far as the alarm circuit, I would use the schematics at the end of the -12 TM, and possibly the test procedures in the -34p. Does nothing light up when the test/reset button is operated?

[@minionmaster8805]

sewerzuk Just found it and downloaded and was looking when you replied. Thanks.

[@pulesjet]

I've operated the vary same type generated while in the USAF. Maintained that along with a 2000Ah 48v battery back up for Communications facilities. Get your self a block heater if you plan on operating them in sub zero temps. The DON'T Play well in the cold !

[@MattVerley]

Not sure of any online sources for the voltage reconnection board; but I can email the manual to you that has original schematics and drawings of the board. If you can read the schematics, all of the info is in there...

[@GAButcher56]

Where are you located, very informative video. Just purchased an MB*18 with a generator problem. Would be willing to have it repaired. Would you be interested? Thank You

[@72chargerse72]

Shocks..I once got a zap that sent me across the boat by being wet and touching the 12 v battery. If you are sweaty you can get a rude awakening.

[@towrecker]

I removed the pumps completely , inlet and outlet lines disconnected , inlet line placed in a jar of diesel it would not pump it , just fast clicking , took caps off both pumps filled with diesel , them placed inlet in the jar again , after a few min the clicking came to a stop , outlet wide open , all it ever did was dribble a small bit , the only bit of promise i seen was if you cut power , it would squirt one squirt like an oil can , restore power nothing , same thing over and over ...

[@jeremywells87]

Do you now how to covert m1032 pto gen to 240volt

[@MattVerley]

Sounds like something is wrong inside of the pumps...never actually seen one go bad though! The plungers are easily removed once you pull the cap off of the end. Maybe fully disassemble and clean them?

[@paulharriscuzican2591]

Can any one help me..trying to find were to get parts for my army generator

[@towrecker]

I found the day tank , and the pumps , wound up removing the pumps for access , what a pain that was , day tank empty , pumps not pumping , cleaned screens , pressed plungers , they were not stuck , I tried everything to get them to pump , they make noise , I later filled them with diesel , and tried to pump from a jar and the outlet into thin air , the clicking came to an almost stop , nothing more than a dribble from them , bad pumps , or am I missing something here ;)

[@apjdad]

Just a suggestion for while you are discussing what you are doing. Use a small flashlight that will focus a narrow beam so you can light up what you are talking about. Sometimes the lighting inside the enclosure is not good and just appears as a dark area in the picture.

[@christopherthumm4348]

Is it better to have something plugged into the generator while starting, giving the generator a load, or is this unnecessary

[@MattVerley]

It is best to have nothing plugged in during startup and shutdown

[@MattVerley]

Those go to an optional block heater. I've never seen one of those installed...your set likely does not have one.

[@towrecker]

I know this will sound very stupid but , I know where the tank is that is in the "bottom of the unit" where are the actual pumps , and the day tank located , I am sure I have looked right at them , and just not known it sadly , if you can please tell me in in this stupid way , from the switch panel , which side and what door , and top or bottom , and maybe a land mark piece I will know what is , I am very mechanical minded , just never messed with one of these , and THANK YOU !! you are great !

[@towrecker]

I also have been thinking , the pumps were dry and dirty when I took the caps off of them to clean them ...they are full now , maybe soaking so to speak till fix them up , there is not much inside those things , if they were not 24v , I would have just replaced them and been done with them , but thats not so easy ...

[@enterBJ40]

White diesel engine? How old is this genset?

[@XGalaxy4U]

Ouch, sounds like he got in some 120v. It hurts but you can pull away from it. If you have good boots on. That 480 3 phase shit I stay away from. I mean I've worked on it. It's very dangerous.

[@soniadamasdamas5427]

Buen comentario sobre la mecánica es mi trabajo grasias

[@WogChilli]

Flywheel effect due to Lenz's law of electromagnetics

[@MattVerley]

The -004a without ASK weighs 2450lbs. The -005a without ASK weighs about 2850. The ASK adds quite a bit of weight; guessing nearly 1000lbs.

[@cliffcollins4124]

In a lot of generators the Frequency is held by a capacitor you may have just got a tingle from that

[@uploadJ]

What!?

[@MattVerley]

Steel Soldiers in the Auxiliary Equipment forum, or Smokstak in the military generators forum. Once I have your email address I will send the tech manuals...

[@MattVerley]

Ft. Lewis; WA. I actually live in OR.

[@MrShawn305]

You said fort bliss... are you here in El Paso??

[@MrShawn305]

What effects, if any, have you seen on these units from running them on JP8? A guy around here is parting out a 5 ton and gave me about 100-120 gallons of it to get it out of the truck, I was thinking about adding some 2 cycle oil and cetane boost to it and running it in my kubota generator.

[@wtftolate3782]

That hurt!!!0

[@anonanonme2463]

Flash may have been a spider web burning up.

[@DevoldoinHD]

He said at the end of the video what the arc was from... And spider webs are not conductive...

[@philstreeter9703]

Grest video.

[@MattVerley]

I have run into this before; the main breaker requires a constant power once it is closed to stay closed. Any loose contact in the leads running to the breaker will cause it to spontaneously trip. Too difficult to describe how to troubleshoot this here; there are lots of plugs, relays, and switches. You'll need to study the schematic on page 345 of the -12 tech manual. If you don't have this, send me a message with your email address and I will send it to you.

[@THOMAS01ify]

710 hours my foot looks like over 20k I was stationed at lewis looks like from the fast attack tank brigade I bet its idles for weeks on end . I bet some stupid private scavenge parts off for another generator when that one was new .

[@440dross]

A084 engine pulled a generator to start jet/ gas turbine engines, thanks for the comment.

[@jeffreymaynard5367]

old sparky hahahaha

[@revolution3797]

Do you know where and what size fuel pick cock I can find? My erythreader says it's M12X1.25 n I can't find those.

[@williamsantiago7303]

Could someone tell me how much I would have to pay for one of these at the government auction. I see alot of these videos with these government gens that a individual bought and I ask them how much they cost them and they refuse to say. I don't understand that about people. This is a great video and very informative, thanks.

[@MattVerley]

It has been several years since I bought one of these so things may be a little different now. A good low hour one would run around $1200. A high hour one or one that was missing parts would go for around $600. An -004a like the one in this video would sell for around $1500 if it was in good condition. Prices varied quite a bit though; if there were a lot of these for sale at the same time, prices would be a little lower.

[@williamsantiago7303]

@@MattVerley Matt, thank you for your fast response and for your honesty. Good look with your gen and your videos. Take care bud.

[@towrecker]

you are so great , I will send you my email address in a private message here on youtube , also what is the forum your part of , I think I need to be part of it for learning , other peoples issues now , might be mine next week so to speak ...

[@nibotkram7743]

Generator is mad at you

[@MCBatty80]

Suspected that shock was going to happen. have had it happen to me once.

[@tucoremirezful]

I Hope you had it for free !!!!!!

[@Alexthebro265]

fort lewis my dad works their.