Military surplus generator repair, and first start after years of sitting part 2

In part one, I replaced missing parts and made repairs necessary to start the engine after it had been sitting for several years. In this video, I perform a series of functional checks and tests to verify proper engine and generator operation. Some problems are uncovered, which I repair in the video. Watch as this great piece of equipment comes back to life!

[@MattVerley]

Those would be standard Onan DJC parts, available from a onan dealer. I don't have any suggestions about where to purchase them from, but it shouldn't be too difficult to locate something local.

[@damianbrennan2258]

How r u mate I worked on old army gen sets with revs I set stop on pump and lock to 60 hertz speed should not run up and down no good for a v r

[@EphemeralProductions]

I hear a 60 hz magnetostriction buzz in the background. Where is that coming from? Just curious. :)

[@robertchristensen2633]

How does some one buy military surplus I live in okla Can you help me out?

[@user-nd3lx1zg9t]

www.usa.gov/state-surplus-sales es a good starting place.

[@MattVerley]

I suppose it depends on what you are comparing the MEP generators to. There really is no comparison to something that is available at home depot or any other big box store. There are some commercially available generators that have comparable features and build quality, but they typically go for 3-4 times the price that an MEP sells for. The MEP's are rugged and overbuilt (for military field use) and have lots of instrumentation and features not found on civilian sets.

[@norbertgrimm9584]

Hi Matt, I'm from Germany and I have exactly the same generator set, purchased from scrap dealer in the 90's. I use it as emergeny power plant and heating system. Since quite a while it started leaking oil at the front side (belt pulley) and I guess, it's the crankshaft seal... So I have 2 questions: Is it possible to replace it "from outside", which means: After removing the belt pulley and the engine mount bracket (while supporting the weight from the oil pan side), and: Could you give me any advice where I can get such a shaft sealing ring for this engine (Hercules)? I'm also interested in other spareparts like Filters, hoses, waterpump... Many thanks in advance and hoping for your response, Norbert

[@cestiff7177]

You wouldn't happen to have a manual for a Generator by Winpower? Model # D-15h18z 05/11/1964 It has a Hercules Diesel engine with a Roosa Master Injection pump.

[@TomSommer]

I love to watch a REAL tech work. I bet your parents are really proud of you.

[@ashforkdan]

Looks like its time to pick one up.There really nice generators and for a house off grid seems to be the perfect size.Hope you get one soon.Love to see how you fix the rotary switch that seems to fail.I decided to get a 4 position key because of cost of the switch.Looks like that was the only problem they had with it.Its a 4 cylinder onan and runs great.Keep up the good work and please dont stop posting your work on these military generators.

[@user-nd3lx1zg9t]

Great thing about diesels is you can make your own bio-diesel and be truly off-grid.

[@juliocesaraburtotellez8365]

Tengo un generador igual y no me ensiende tenía el mismo problema que tú era el starte selenoide pero ya lo cambie pero no ensiende

[@MattVerley]

The ones with an installed Acoustic Suppression Kit (ASK) are actually very quiet. Without the kit, they are pretty noisy.

[@DieyoungDiefast]

I noticed from your close up of the gauge panel that both your voltmeter and power meter weren't set to mechanical zero. Not worried about that? I noticed them because before I changed jobs I was responsible for the electrics on military generators from 500w Onans to 40Kw trailer mounted Lucas Aerospace gene's.

[@jadesluv]

I am surprised you ran it for ANY time with no water in the block.

[@user-nd3lx1zg9t]

Im not sure that dumping an electrical device that is leaking a black tar-like substance is prudent. Even handling it isn't a good idea. They may be old enough to still contain polychlorinated biphenyl (PCB), which is an extreme carcinogen. Best to isolate and let professionals dispose of those parts.

[@MattVerley]

Assuming you have the -004a without ASK; it is only 2450lbs. The M200A1 doesn't weigh more than 1000 lbs, so well within the towing capacity of a 1 ton truck. The only issue is getting a pintle hitch high enough to match the M200A1's eye. I custom built one for my Dodge so that I could tow these trailers around; I have even pulled a PU650-B/G with it (MEP-006a generator) which weighs close to 6000lbs on the trailer.

[@thomasrackley6920]

I have a 1962 American Marc Navy 5kw diesel. The 24 volt batteries had the ground come off negative post and art and it stopped producing AC power and at the positive side of the batteries with it running is reading 52 Volt's DC. I have a shop manual and some parts but don't know what to do?

[@ashforkdan]

sewerzuk could you tell me where you find parts for these generators?It seems that no one knows.Your the only one that replies.

[@MattVerley]

No problem! Yep; the M200A1 has both air brakes (no spring brakes) as well as a mechanical lock. If the cables are still free (I have seen a number of them that are rusted into place) then your setup should work great! I tow these with my 2001 Dodge 2500 all the time...

[@roberthorner8494]

GREAT JOB EXCELLENT ATTENTION TO DETAIL.

[@markusk.488]

Hi, nice Video :D what load are you using because i bougt an 30 KW military generator and i want to load test it after i figured out why it won't produce any power. I already hooked an adjustable DC power supply up to the two exciter ends and it produced clean power on all 3 phases. So the problem has to be something with the AVR unit.

[@marshallsayre58]

Hi Matt, Ive started to develop an interest in these military type gen sets. Its pretty cool to work on military equipment. I just wondered though what is the application we can use in civilian life:can it support a house when the power goes out or more?

[@jaredwheeler7616]

My 006A Allis Chalmers 60 KW generator is only building 330 volts it wont go to 480. What could the problem be?

[@jefffromjersey52]

What is your recommendation for a 50HZ 3 phase unit.. I am leaning towards the 805A.. but they are hard to find with low hours.. I only need 15- 30KW max.. and I like the idea of the Tactical Quit in the 805A .. Are there any 15KW units available in 3 phase 50hz ?

[@towrecker]

stupid question that I can't find the answer for anywhere , I just bought one of these generators , it is mounted to a m200a1 trailer , do you know the weight of either one of the two , or both , I am debating towing this home with a 1 ton dual wheel pickup , but a friend seems to think this might be a job for the deuce instead , any insite , it's a 400 mile run to get there and back , and the deuce sounds just painful that far ;)

[@jeromeloring7085]

Awesome videos! Thank you. I bought a used trailer mounted one just like this and look forward to many years of use!

[@towrecker]

they assured me the brakes on the trailer lock down , look at my avitar , I I can lock it , and pick it up with a boom cable , kick the jack back , and lower it onto the hitch , I really thought it was going to weigh more than that for some reason , so to this truck it will be like a full size conversion van in weight , this should work well , I really appreciate your time in answering my question , means a lot to me , as very few have the knowledge to answer that question ;)

[@majorpyane8578]

Great videos. I just got a mep 803a and the master control switch is bad; is there a diagram to wire in toggle switches instead? I've looked all over and find no one with the master switch for sale for a reasonable price. many want over 200 for them..

[@ricknelsonm]

Matt is A GOOD SPEAKER!

[@donaldsmith3048]

About how much would a good generator cost? Is there a multi fuel generator, with the engine like is in the older deuce and a half? That thing will run on almost anything

[@blairoconnor7034]

Great job on your videos they are very instructional. I have a mep803a which was running fine last month, but when I went to start it again this month it won't crank. It will turn over at the dead crank switch, but at the start swtich it is dead, nothing. E switch in correct position, battle short in off, but no noise when I move switch to start position. Any common issues that you have encountered would be a big help.

[@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

[@ldr1944]

Brings back memories of my military days. My MOS was 52D30 and I worked on anything from 1.5KW up to 400KW.

[@andrewarmstrong7310]

I was in the U.S. Army Corps of Engineers 249th Engineer Battalion Prime Power Alpha Company Schofield Barracks, Hawaii from 1988 until 2010. Those things were dinosaurs when I enlisted. Mostly I remember running 3 120-volt 60Hz hot legs off them to power housing. I think we also moved them two to an M35A2. They were all over the DMZ in Korea. Those were the days.

[@robertchristensen2633]

Mr Ross thank you for your service

[@yhnbgt365]

Please use a lapel microphone, there is too much background noise to hear you properly.

[@jlucasound]

You know why we are here. We want to hear it run. That is 87% of the function. After that, just make the generator work. :-) That unit is so cool.

[@MattVerley]

Unfortunately I don't have any information on the 803a...

[@MattVerley]

Usually if I need a part, I just look up the NSN for that part in the tech manual and then do a google search for it. I find most of the parts that I need on ebay, or through surplus liquidation places. This works most of the time; but if not there are several surplus dealers that carry parts for the MEP's. Gulf Coast Trucks, Delks, and many more carry many of the common parts.

[@Micscience]

what are the advantages of these generators over say aftermarket generators, is it because of the quality?

[@Scrapy-ih7ob]

Nice rebirth, Nice to see good equipment brought back to life...

[@jagardina]

Do you sell these beasts? I could fit one in my shed and power my house...

[@MrDsmcmeans01]

do you know of a civilian radiator cap that will fit an mep-004a. thats all i need to get mine up and running

[@renesuarez85]

B

[@phooesnax]

Great job Sir

[@jeremylee99100]

is it cummins powered?

[@baldfatgit1]

Great vid one and two thanks for spending the time explaining what you were doing and most important why. thank you for sharing. :)

[@Boodieman72]

Do you just repair these for yourself or do you sell them?

[@MattVerley]

I have bought/repaired/resold several of these in the past, but my local DRMO auction hasn't had any for the last few years.

[@rogersheadrick4689]

I was wondering if you ever ran into a mep 3 that will not let the fuel shut off cylinoid work. If I don't hold the start long enough it will hold idle but it does not create power if the generator is creating power it does not hold idle fuel shuts off. it almost sound like what you just had in this video and it is over generating the gauges don't all work and I I can't adjust the frequency the main selector is also frozen on 1 phase witch is what I need any way. I can manually control fuel it runs and creates power any suggestions

[@MattVerley]

+Roger Headrick Not quite sure I understand the symptoms you have, but here are a few pointers on the -002a/-003a: 1. You should never let the set idle. You should set the throttle for 60Hz and leave it there. Allowing the set to idle can damage to voltage regulator card. 2. To start the generator, you need to hold the start switch in start for about 10-15 seconds AFTER the set comes up to full speed. This bypasses the low oil pressure automatic shutoff and flashes the generator field so that it will start making power. As long as the speed switch is operating properly, the starter motor will disengage. If you hear grinding, then you need to troubleshoot/repair/replace the speed switch. 3. If the generator won't stay running, then you have a few possible problems. But, most likely are the oil pressure switch and/or the speed switch.

[@daniellemus3142]

+sewerzuk hi am Daniel from cal. tell me please where is the speed switch location please.

[@edwardponikvar9645]

+sewerzuk please email me. [e-mail]

[@MrBellboy1234]

Curious Matt, have you encountered one of these with injection pump issues? I am looking at one they say the injection pump is bad. Unit only shows 28 hours on the meter. I have seen some pumps on eBay have also heard talk of rebuilding them. Can you shed any light on that subject?

[@MattVerley]

MrBellboy1234 yes, they use a stanadyne pump similar to the ones in a gm 6.2 diesel. I've sent a few off for rebuild.

[@MrBellboy1234]

Could you send me some info on where to send them off for rebuild?

[@MattVerley]

MrBellboy1234 I sent mine to oregon diesel injection, but I believe that any decent diesel shop should be able to handle it

[@MrBellboy1234]

Were they able to find a rebuild kit or did you have to source a rebuild kit to send them? I have not had much like finding a rebuild kit online.

[@krisjames3]

damn your good

[@KurtRWarner]

Non TQG?????

[@ianrutherford878]

Matt,you go ahead more than any person I've ever heard.

[@MattVerley]

I'll go ahead and take that as a compliment ;)

[@ianrutherford878]

@@MattVerley Yeah,I'm not from your part of the world ,but I now realise from watching other peoples' videos that it is just one of those expressions, ways of talking,that I'm not used to and you do say it more than anyone else I've heard.I'll just go ahead and try and get used to it.

[@joah135]

Cloud I Ask Where You Get These Generators?

[@MattVerley]

I've been buying them from my local DRMO auction yard...but they haven't had any move through in almost 2 years.

[@joah135]

Thanks

[@towrecker]

oh it did work great , I hooked it up around 8 this morning , and got it back home , it towed great , it very much amazed me , it was smooth as glass at 70 mph on the interstate , I just got a few strange looks , no other issues , I really remembered them as being larger than it actually is for some reason lol

[@erneldejesus8395]

thank you, i learn alot!

[@chewbaccasaurusrex692]

Correct me if I'm wrong but water will evaporate in a radiator after the engine heats up and also causes rust when ran in a engine thus why antifreeze was made, I don't know if generators are any different so please correct me if I'm wrong

[@david929190]

He did replace the water with proper coolant if you had watched you would have seen him say so.

[@lesstime1678]

that"s amazing how the americans speak backwards compared the rest of the world .you cal a meter a gauge. gauge is for measure wire size,sheet metal size .steel rod sizes .etc,etc,etc, For electric we cal a volt meter. amp meter, ohm meter ,frequency meter galvanometer ,gauss meter ,capacitance meter,inductance meter siemens meter ,GAS meter ,WATER meter ,etc,etc,etc,etc,etc etc, etc etc etc etc etc etc ,not gauges.

[@TNFSDK]

Would a generator like that be able to supply 230v 50hz or is it too small for that?

[@MattVerley]

They are rated to supply 120/208 3 phase at 50hz; I can modify them for 120/240v single/split phase too...

[@Autotechmechanics]

so your video here is just an explanation of what you did without actually showing us..... and why do you stand so strange? like your on a coat hanger? weird.

[@MattVerley]

You'll notice the "part 2" in the video title. That would indicate that a "part 1" exists, where I DO show the initial repair/test/startup. I assumed that most people didn't care about tasks like hitting linkage with penetrating oil or checking water level...so yes, I did omit filming those tasks. And as for my posture...well, I just don't know. Military background maybe? First time anybody has seen fit to comment on it.

[@1966cambo]

I wouldn't even respond to comments like that, guy obviously has issues! Great job on the videos by the way,love the attention to details!

[@charlesmarks3372]

Matt you are excellent and you posture is awesome.