Military surplus generator repair, and first start after years of sitting

[@aserta]

Methodical, clean, competent work. It's a joy to behold someone who ISN'T stumbling around and has factual knowledge on the machine they work on. Great video.

[@tamphan6828]

This is just what is needed for partial rv backup. Operates the ac and stuff perfectly. kzbin.infoUgkxOTeIs0vv4_9B5hsmnLsk9r930uDQLu_Y is quieter than my rv generator. Only suggestion is that it needs a fuel shutoff valve. So it is easier to store.

[@bte52]

Don’t ask me why because I don’t know the next thing about generators but I found this video very interesting. You’re manner of delivering your message is very, very good. Thank you.

[@MattVerley]

I was actually in the Navy for 9 years as a Nuclear Electronics Technician; I didn't work with generators at all, but did work with military electronics. I think that the military (any branch) provides people with valuable experience, training, and self confidence not offered in most other occupations. Yes, there is likely a good market for a good generator technician. And, serving your country in the armed forces has value beyond a civilian job...

[@TzzX78]

Thank you for sharing your military history. I happened to be familiar with these generator. It was part of the TO&E equipment for our Dental Field Unit at Ft Campbell. I had 4 of the 15KW back in 1993. The 666th Med Det. 86th CSH. Those where the days of glory

[@gertraba4484]

so they deploy these in the field, right? who maintians them there?

[@abergethirty]

Brings back memories. We had these for the Radar System on a Hawk Missile system. We would run two of them 24/7 one up, one down for months. If it's in an active unit these things end up having a lot of hours on them.

[@dilbertbob5420]

Wow! I'm getting flashbacks. I was a power generation mechanic in the Army for fifteen years, ten of which I was a generator repair instructor in an Army schoolhouse. Good Stuff!

[@gertraba4484]

POWER_FUL:L JOB TRAINING!!!!!!!!!!!!!!!

[@frankdalla]

I once knew a man who purchased enormous ammounts of government surplus. Being fortunate enough to go to a government sale, I noticed many items which were brand new. Upon asking about this, the answer was that the new stuff was discarded so as to make room for their replacement with identical new items. Not spending enough would lead to getting a budgets cut, so the new was, and probably still is, scrapped to be replaced with a newer same item. Its nice to know how our tax dollars are responsibly disposed of.....

[@Nebulax123]

Boy if I was buying one of these I would like to get it from you a nice, methodical, and through restore before you started it. Great job!

[@zephyrold2478]

I second that.

[@gertraba4484]

@@zephyrold2478 ditto third...................

[@carforumwanker]

Level of training sure worked. This is a guy you need in the team

[@davida1hiwaaynet]

Love seeing the old machinery brought back to life! That's a happy engine.

[@andrewarmstrong7310]

Many years ago a friend of mine brought one form a government auction really cheap with just a few pics of the generator, sight unseen, with the model and needs repairs, think it was 2 or 300 hundred. He drove five states to pick it up. I went over to his place to look at it when he got back and he started pointing out places where they had drilled holes in the housing with a dull drill bit, his words. I laughed and told him those look like mortar fragments to me.

[@billjenkins687]

I admire your skills. These gensets are no match for you, brother.

[@brucew44guns]

I've got a modern 20 KW generator here for my home as stand by power, but I still want one of these miltary babies juust for no reason but to own one. Nice machine and thanks for the vgideo. I'm close to Fort Riley, Kansas.

[@MattVerley]

Be careful while trying to flash the field that way...I'm sure you understand, but if the set does begin generating power while you are doing this you'll end up with an exploding battery, melting wires, etc! The most common mistake people make when starting these sets is that they let go of the start switch as soon as the engine starts running. You need to continue to hold it in start after the engine starts for around 10 seconds for the field flash (the starter will automatically disengage)

[@mhaskins3769]

Great video! We have about 40 of the mep003a at our fire stations in California. Was told the one at my station was no longer serviceable. Fixed it for free with some common sense. Thanks for the video even if it’s 6 years old.

[@crossbowsniper]

My volunteer station has a military -004 for pulling out to run the command tent for wild land firefighting and search and rescue, and a military issued Lombardini 12.5 Kw that came off Camp Pendleton that we use for auxiliary power at the station. the 003's and -004's are tough units, and i've found a lot of common sense can go a long way. replaced hoses on our generators from the fuel tank, by going down to the auto store (didn't have any special connectors from the fuel tank to the fuel pump).

[@billmain4090]

Wish I'd had all those spare parts when I was in the Army. That motor isn't even broken in good. Hard to believe I ran a couple dozen GP Mediums , few shop vans and a bunch of coffee makers off one of those back in the day.

[@alvinolson1]

Enjoyed your methodical approach to the restoration. A great watch . Thanks

[@kpdvw]

all that Military Training sure paid off, keep up the good work!

[@GooglFascists]

Those sets will come in handy IF and when the SHTF.

[@JimmysTractor]

I sold a toro grounds mower with a 4500hr kubota diesel. Sat 5 years and before it could make a full turn, it fired up an ran smooth- no smoke or nothing!

[@FoulMouthActual]

I need to hang out with more people like Matt!

[@MrTimerider1160]

I felt this video was very informative and easy to understand. I would enjoy seeing more video's of this type on this same topic. Keep up the good work!

[@Barnekkid]

I've worked with these before, they are excellent units.

[@louisreyes-layne5008]

Excellent video. Learned a lot on the mechanical requirements. I like how you eliminated unnecessary checking, which I would have done first, by short duration operational tests. That main engine belt for instance, was looking suspect and scary; wasn't sure if it would hold up. Great job bro.

[@dukeman7595]

Man you know your stuff. The engine sounds fantastic, you did a great job, good luck and hope to see more videos.

[@jantsbenzproaudio]

I can't believe you have all the spare parts for that!

[@numberyellow]

"I happen to have a spare" That line will plague my dreams, lol.

[@jlucasound]

Wow. Just Wow. OK, I'll add awesome unit. And great knowledge. Matt! Thank You! Yes, you are awesome too, Matt. Attention to the details.So important. Especially the fluids and fluid delivery. If they are not there, the unit will suffer irreversible damage. Great Video. I Love Generators.

[@gertraba4484]

luv the methodical; start up procedures and logic prob solving .................... and NDT testing ofparts tooo!

[@emildekoven4872]

Actually, one of the best NARRATIONS of such an operation on You Tube. Seeing the complete restoration will be an additional satisfaction. Could you not have "bandaged" the radiator hose suff. for temp. use.....since you indicated that its ilk is problematic to acquire?

[@MattVerley]

No; I've never had one not shut off. What I would do depends on the circumstances; if it keeps running at normal RPM, then it isn't an emergency and I would just pull power from the injection pump, or remove the fuel line. If the engine was running away, I would discharge a CO2 extinguisher into the air intake, or cover the air intake with a board (or other handy air-sealing rigid object).

[@SeasideBJJ]

A must have for winters when we lose power for days on end!

[@FrancoisLabelle-yf8tj]

Nice video! Thanks...on these engine that have not run for more then 6 moths I think it is a good idea to run the engine with the starter with the fuel pump shut off for a while...the idea is to get the oil to circulate throughout the engine before firing up...this may prevent damage to the bearings. But you did not leave anything out for pre check!

[@MattVerley]

The most common reason for no output is that people forget to hold the start switch in start for 15-20 seconds after the set has come up to full operating speed (this flashes the field). The second most common reason is that the output transistor on the VR card goes bad.

[@MattVerley]

The -004a is rated at 41HP@1800 RPM. Its rated fuel consumption is 1.5 GPH under 100% load. My experience suggests they consume a little less than this...

[@regsparkes6507]

I enjoyed this video,..night Saturday evening's entertainment for me. I used to be a Kohler Gen-set dealer back in the 1970's. The models we had were powered with Lister 3 cylinder air cooled diesels. This one , I notice is a White, am I correct ? This is a lot of fun watching you go through the procedures. Where were you when we needed good service people back then. ( I know, I know,...age difference right. But you folks know what I meant ) You said it has 2060 hours on it, that would equal approximately 61,800 miles, if it were a vehicle. That's an old rough calculation that was used to gauge engine oil change intervals of heavy equipment back in the day. 2060 running time hours X 30 miles per hour = 61,800. There now, some useless information for you . Thanks for the video. I always appreciate the effort required to make this and put it on KZbin too. Cheers.

[@doddsy799]

hey Reg, ive just been working on an old lister 3 cylinder, (27KVA) its been sitting on standby for years and years, only ran 90hrs in its life time, got it in our workshop for full service, load test, and the customer wants it re-commissioned on auto start in the event of a powercut, by far the oldest set ive worked on, however it runs a dream and is a testiment to old skool engineering. - chris.

[@regsparkes6507]

Yessir Chris, if these older style Lister's ( of course, this applies to almost all diesel engines ) were given good maintenance and service, they'd run almost forever. Imagine only 90 hours on the clock ! That's just about new ! Well, good luck with this one, you'll be rewarded with a great running gen-set. Cheers.

[@doddsy799]

Reg, I am away on my holidays tomorrow for a couple of weeks, when i return I can make a video showing you around it if you'd like? - chris

[@regsparkes6507]

Sound's like a good idea Chris. Enjoy your vaation.

[@MattVerley]

I've found them very easy to work on...but I do have a background in military electronics. I would rather tackle an electrical problem than a mechanical one with these generators any time. If you can follow schematics and troubleshooting guides, then you can work on these generators. If all you can do is basic automotive wiring, then repairing an MEP will be a steep learning curve.

[@MattVerley]

There are quite a few surplus dealers that carry most parts for this set. However, I've found that it is cheaper (and often times easier) to just modify with off the shelf parts; the generators are build using a standardized design and are easy to modify/repair.

[@2e0lgz]

Well done Matt totally enjoyed the vid

[@RSBSTEADICAM]

You're really amazing and really seem to know your stuff since you make it all look easy.

[@mickgatz214]

@Matt Verley < Awesome and thorough work! Now to watch part 2 :) Cheers!

[@electrickal1]

Nice methodical work through, looks like you worked for the army engineers. As for that faulty oil pressure switch you should have gotten a new micro switch from Radioshack and installed that. Always much better to keep things original and with a new switch it would have been as good as new!!

[@grasscutter88]

Seems like most of this was done so it could be shipped without fluid.

[@TysonLee38]

Hey man great video. Thanks for posting. Really enjoy watching you work.

[@marceltimmers1290]

Hi mate.This was an excellent presentation.Marcel.

[@dschis1000]

I can't remember exactly how that model is set up, but a lot of the MEP family has the field flash going through the overspeed switch. Should be able to see on the wiring diagram. Used to work on those MEPs and Mil Standard for a long time while I was a 52D in the Army. The overspeed switch is partly reponsible for starter kickout, field flash, and of overspeed protection

[@MattVerley]

yes, with a little creative wiring. I have set a couple of these up this way, using a custom program in a PLC. I believe it would also be possible with a commercial control panel (such as one of the deep sea controllers) but I haven't tried it yet.

[@daved6708]

Very well done - I enjoyed watching! Thanks

[@pensive69]

yes loose stuff is a hazard 1st rank. excellent info rich video nice job! i always run our gensets with a fan shroud on them, best to have one with no gaps. the air flows from a full speed runner can suck things and hair into the belt and blade areas without much notice. your helpful hints are appreciated. if you know...what is the typical run time on these size units with an average load/ ty!

[@Lasselkv28]

Good filters, those Wix (Napa). We also import those for industrial and agri here in Denmark. Really neat video

[@MattVerley]

It looks like a Fermont set from the 50's. I've worked on a few of them; gauges and layout are very similar to yours. I'm not familiar with your exact set though; it isn't exactly like anything I've worked on before. Best bet is to post your video in the SmokStak and Steel Soldiers forums...somebody there will know something about it!

[@scottdowney4318]

You can repair th hose with Loctite Black PL Roof and flashing polyurethane. Clean up hose well. smear on the black PL Wrap fiberglass tape around hose and saturate it with the goo. Can use marine grade cloth or even fiberglass drywall tape. Build it up at least 3/16 inch. Let it set for a week. I have repaired hose ends on my marine exhaust where they had worn on the ends doing this type repair.

[@mikestrophytruck]

When you flip on the primer switch should I hear anything? Cause I don't. Also how do you turn the fuel pumps on like you did in this video and can I do it on a MEP 114A. It seems I am not getting fuel.

[@MattVerley]

It is possible for the governor linkage inside of the injection pump to become "sticky." If the actual throttle position is not changing during operation but the engine speed is, then you will most likely need to disassemble/clean the pump. Are you asking about pulling 120/208 off of 2 legs for single phase power? Nothing wrong with doing this, if your loads work with 208 (most are fine with it). You can only get about 10kw out of the generator this way.

[@francoisdastardly4405]

Excellent job !

[@MattVerley]

The MEP-701A is an MEP-016B with an acoustic suppression kit. They are decent little sets, but they do run at 3600 RPM (instead of 1800 RPM like the MEP-002a and larger). But, to answer your question, yes...it will supply normal household current without a conversion. It should have a switch to go from single phase 120/240 to 3 phase 120/208. On another note, they are not powerful enough to run any large appliances (dryer, oven, range, hot water heater, etc.)

[@comtrans123]

great video i was wondering why you used deep cycle batteriws. i think they are designed to drain all the way down then be charged all the waY BACK TO FULL CHARGE. I USED ONE IN AN OLD CAR ONCE DIDNT LAST VERY LONG. BUT MAYBE IM MISSING SOMETHING?

[@MattVerley]

I would be cautious with the pressure washer...the components can surely take water on them, but it would be possible to force water into places that it could not normally find its way into. I typically used compressed air with a piece of hard brake line bent into a "u" shape to clean the inside of the gensets.

[@scottraymond558]

Nice video... Mite not have learned anything..but it kept my attention..

[@Scholarshipweekly]

thanks for the input . im looking for one for a travel trailer to use to fire up a infrared heater at night in winter / small ac in summer, tv , laptop etc. I think Im gonna take a shot at this one. let me know if you think this is an appropriate unit for this application

[@MattVerley]

@kmluddy You adjust frequency with the engine throttle. Frequency varies with engine RPM. A few things to know as well; 1. the frequency meter won't move if the generator isn't making power, so make sure the voltmeter is reading voltage first. 2. The MEP-002a is not designed to idle! Idling the set for even just a few seconds can burn out the voltage regulator. So, set the throttle to 60hz and leave it there.

[@PMMM9]

Fantastic. Just found your KZbin channel. Great job.

[@MattVerley]

This one had a 4 cylinder White Engines diesel in it. Cost varies based on condition and included accessories...but anywhere from about $2500-$3500. Never have run into any issues with the oiling systems on any of these MEP's...

[@treybolinger]

Not bad at all. I could use a little project like this sometime. Thanks for the information.

[@acusurplus]

I just found it strange that i had to unlock the knob for the throttle and re-adjust and back it up, becuase the 60hz was slowly increasing. I have a 3 phase panle that i have my004a hook up too, and i have it set to L1 for now, and it seems to be working, but i was planning in hooking up a 50amp plug to it, it needs two pole wire so i was planning in setting up the gen in L2 mode to activate the second phase. i was reading on another fourm its not good to run it with so little load thanks

[@jamesben-smith1115]

I live an work in Houston so getting the $$ to you is not an issue, i really do need a gen set if you can help me out.

[@cdrom1070]

imo give it a brighter outline (keep the military main colors but I feel like everything would work better if it had a outline (beige maybe)

[@MattVerley]

Did you check the output with the main breaker closed? And verify that the breaker for the convenience receptacle isn't tripped. You can check for output on the upstream (right side) of the main breaker, too. Also...check for output with your voltmeter while you are flashing the field (with the start button in start with engine running). Let me know what you see on the voltmeter..

[@MattVerley]

The -004' shown in this video with the ASK will go for around $3k. The prices vary based on hours, condition, and included accessories though...

[@chuckbear1961]

I have a MEP-004 AAS unit like yours it runs buth the fault system check dosn`t work fuse is ok along with the frequincy adjust control to adjust the frequiency you have to adjust the throttle pull knob below . I was running a 3 phase motor with no load and the ampers fluctuate with my clamp on meter on the motor line.like to have a insite on what the problem maybe . the voltage adjust functions ok.

[@MattVerley]

OK; sounds like you've tracked it down. Good news is that the VR/exciter is probably good...it just isn't getting that initial flash during startup. Most of the components are a standard design and readily available ate Digi-Key or other electronics parts store. If you can find somebody comfortable with soldering you can likely fix it yourself.

[@8180634]

For only 15kW that thing is big! It must be built to do 15kW 24/7 for a long time, probably a good home backup generator to have around for storm season. Do you have any idea what the fuel burn rate is for a few kW of load?

[@kazsmaz]

Its designed for some men that don't have time to coddle a machine to drop out a plane and work for 4 years straight. Its probably not too efficient but it'll run forever

[@TqFinax]

Yes, Thank you for your response. I appreciate it. I'm not too worried about the Job I get, cause no matter which one I get, I will try my best everyday. Although, considering I get to choose my Job I want to have a better knowledge of what I might be doing. Thank you.

[@thatguywill066]

This video did a great job of putting me to sleep . Thanks

[@BusbyBiscuits]

I was too distracted by the fact his hoodie is tucked into his trousers

[@gertraba4484]

boooooooooooooooooooooo!

[@thatguywill066]

@@gertraba4484 no really I had a great nap

[@davekauffman8727]

I've always heard about military surplus things being good bargains, I wish I knew where to find an outlet.

[@gertraba4484]

110 0r 220? :))

[@fjb4932]

@@gertraba4484 , Rich (-:

[@americanmade389]

Do know what air filter for this unit? Thanks

[@tectalabyss]

I subscribed,Liked,Shared,Added to Playlists. All my best.

[@MattVerley]

@3cl1 down to just 2! Hoping to find a few more at Ft. Lewis soon...

[@MattVerley]

Once you have the set up and running at normal operating speed, try holding the start switch in start for 10 seconds or so...tell me what the voltmeter does during this time (the starter motor will not "grind" assuming the speed switch is working properly).

[@KPearce57]

Have you ever gotten ahold of a Military 400KW generator, ours had Allis-Chalmers V12 Engine, 2 on a trailer, used in Nike Hercules Hi-power Radar sets.

[@jimmiebrawner7679]

You RULE!! keep the video's coming

[@mansnilsson4382]

New micro switches are like €1, and the form factor is standard. Should give you a new pressure sensor.

[@ralphstrainsllc6409]

Was wondering if I could ask a no start question. Have 802-a, new starter, jump across and it will crank, no start on master switch. Turn switch and dead crank clicks, and no signal to starter to turn. AH1 fuse, 30 amp good, and push button is in. wires in tack although they had wire 2 and 4 switched, I traced number on wire to verify. Any Idea? Thank You. Anybody you can recommend? In Virginia

[@MattVerley]

Ralphstrains LLC very difficult to troubleshoot without being there in person, but by far the most common reason for no start is a failed speed switch

[@ralphstrainsllc6409]

SPEED SWITCH???? I know master switch, I know dead crank switch. Which on is the speed switch> Thank You very much for replying. Ralph

[@ralphstrainsllc6007]

Where is the speed switch? I cannot find anything in regards to it. Changed out all relays and nothing. Changed silinoid and nothing. Is the speed switch on the side of the motor? Any help would be great. Thank You

[@MattVerley]

Frequency will not register if the gen is not producing power. Most likely is a bad VR card. The power transistor on the card (metal can about the size of a dime) is usually the culprit. If you really want to verify there is no power, measure output at the convenience outlet on the front of the set. It should produce 120v regardless of the position of the voltage selector switch. No power there, most likely a bad VR card.

[@kodiak410a]

Nice looking guy. Smart and good looks.

[@Captainkleen]

Just out of curiosity what does those sale for in the general public market compared to a 16K standby unit? Thanks for sharing!

[@ldangussca]

Hearing rumors about the EPA halting the sale of this type of generator and old surplus trucks... have you heard of this???

[@Wildcat5181]

Great job, very meticulous.

[@davidtownsend2818]

We have a 30 kw unit at my shop. I exercise it monthly. Last month it made power perfectly. When I tried it this month, the engine runs perfect but the unit will not start making power. I tried it several times with no luck. Any help you could give me would be greatly appreciated

[@3cl1]

I was stationed at Ft. Lewis for 4 years.

[@oymate]

Great video - as are all your MEP uploads; this is practically a repair tutorial. I had 2 questions regarding the -004, if you do not mind responding. 1) Why can't you take the lower hose to an auto supply store, ask to browse the hose rack, and to try to match it up to an existing aftermarket hose? 2) I see that you have the (unused) mounting plate for the precision timing electronic governor. Do you happen to use these panels elsewhere, or would you be willing to part with one for a price?

[@kevyncardona9792]

Thanks. Great video and answers. Wish you the best.

[@duncanmacleod7210]

Great video very informative. Semper Fi

[@MattVerley]

It is interesting to me that my choice of attire is what you took from this video... Insulated flannel because it was cold. Tucked in because I was working with machinery with moving parts. Ever see somebody get his shirt caught in a milling machine or grinder? I have seen both...and it wasn't pretty either time. Dork, well...maybe. You're entitled to your opinion.

[@chipps1066]

Do you sell to the public or back to the military?

[@erikssugarbush1936]

If they are rewired will the generator controls still work? Have you done this and what do you need to change or replace? Thanks for your time

[@MattVerley]

I have rewired for other voltages. I have a video on my channel that describes the process of re-wiring for split phase 120/240. All of the instrumentation and control systems are based on 120v across individual windings. But...this answer got me thinking...I think I need to take back my initial answer and say that no...480v delta is not possible without a transformer. Because the instrumentation and control relies on 120v per winding, 240/120 delta is possible, but 480/240 is not. Each winding would need to be operating at 240v. I think that, if I needed 480v out of one of these, I would configure it for 417/240v wye (this is a factory configuration) and then get a transformer with a 417v primary and 480v delta secondary. That would be the easiest solution...

[@llama473]

Great video, thanks!

[@Scholarshipweekly]

i dont have the items yet however I researched some ones I am leaning toward and they are ac at 6 amps and heater at 12 amps

[@MattVerley]

How many amps do the infared heater and A/C unit draw? They will likely be very close to, if not exceeding, the capacity of that generator.

[@timl3417]

How much did you buy that generator for? You really look like you know what you’re doing and I must say you must have a lot of stuff in your yard. You did a great job on your video.