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    Terra1936

    Is an M548 Really Amphibious?

    Thread Starter: Terra1936

    I cannot find a single photo of a M548 swimming? The operators manual says to keep it away from water? Every site describes it as amphibious? Anyone with

    Last Post By: Terra1936 Today, 16:44 Go to last post
    m1010freedom

    Has this happened to anyone? (oil cooler lines)

    Thread Starter: m1010freedom

    So i was driving over this mountain pass yesterday on a forest service road and I noticed my radio started to turn on and off when it got bumpy. Thought

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    signalcorps

    2019 Sanford Florida Memorial Day Parade May 27

    Thread Starter: signalcorps

    Monday May 27. It is time for the Sanford Memorial Day Parade. Sorry that Mark (od fever) can't make the parade this year. The parade starts at 10:00

    Last Post By: signalcorps Today, 16:38 Go to last post
    mijoe

    Power Plant Wiring

    Thread Starter: mijoe

    Good Morning,

    I recently acquired a trailer-mounted power plant, with a switch unit in between the generators to allow the load to be swung

    Last Post By: Guyfang Today, 16:30 Go to last post
    oleblue84

    CUCV Dually

    Thread Starter: oleblue84

    recently purchased a dually, going through it making it more road worthy. I've replaced the front springs with the tough country 2 inch HD springs....

    Last Post By: oleblue84 Today, 16:21 Go to last post
    SausageGuy

    Any cool fixes for door wires getting squashed?

    Thread Starter: SausageGuy

    I was trying to find out if anyone has a good way to keep door wires from getting squashed. Was looking at a transit connect rear door wire loom and

    Last Post By: coachgeo Today, 16:11 Go to last post
  • MEP WIKI

    General Information:

    MEP-002A
    This unit is a 5 kilowatt, 60 Hertz Generator Set. It consists of a revolving field alternator powered by an air cooled diesel engine. These sets are not designed for parallel operation.


    Output

    Output voltage is switch selectable. These outputs are via the output lug connections.
    120 VAC 52 AMPs single phase, 2 wire
    120/240 VAC 26 AMPs single phase, 3 wire
    120/208 VAC 17.3 AMPs three phase, 4 wire
    All at a Power Factor (PF) of 0.8

    There are also two 120 VAC 15 AMP on-board convenience outlets next to the control panel.

    Engine.

    1. The engine powering this generator set is a 2 cylinder, 4 cycle, air cooled engine, with a 70 cubic inch (cu. in.) displacement. A mechanical governor keeps engine speed at 1800 revolutions per minute (RPM) under rated load conditions.
    2. Fuel is supplied either from this unit's self-contained fuel tank or, by using an adapter, directly from a 55 gallon drum or other source. The fuel is filtered by two cartridge type fuel filters and a single fuel strainer. Two electric, self-priming fuel pumps supply fuel to the fuel injection pump which delivers the fuel at high pressure to fuel injection nozzles in the cylinder head. When an auxiliary source of fuel is used, three electric fuel pumps are used.
    3. Two 12 volt "wet cell" batteries in series supply power for a 24 volt electric starter and for glow plugs, located in the cylinder head, and for two air heaters located in the intake manifold, used for cold weather starting. An alternator located beneath the blower wheel, and completely separate from the main alternator, automatically recharges these batteries when the engine is operating.

    Generator.

    The generator on this set is a four pole, revolving field type. Alternating current, supplied by the exciter assembly, is rectified and used to create the four pole, revolving field. A solid-state voltage regulator assembly automatically adjusts this current to obtain a constant (3%) voltage in the main stator (output) windings.

    Controls.

    All operator controls and indicator gauges necessary for running the engine generator set are located on the control panel. On ASK equipped generators, an oil pressure gauge is located on the engine under air intake door and a fuel level gauge is located on the fuel tank. The speed control is located behind a small flap on the rear panel assembly below the control panel. Controls for selecting output voltage are located on the output control box.

    Generator Set Electrical System


    The generator sets electrical system consists of two distinct systems: (1) The DC system used primarily for operating control and excitation, and, (2) the AC output system to supply power to the load.

    The DC source consists of a 24 volt battery set (BT1 and BT2) that is kept charged by a battery charging alternator (G2) and voltage regulator rectifier assembly (A5). Fuse (F1) protects the alternator from overload. Circuit breaker (CB2) protects the battery charging system from overload. Slave receptacle (J15) permits an alternate external supply to be connected to the battery circuit.

    Dimensions and weights:

    Without ASK:

    Overall length 51 in. (129.5 cm.)
    Overall width 32 in. (81.3 cm)
    Overall height 37 in. (94 cm.)
    Net weight empty 960 lbs. (435.5 kg.)

    Net weight filled 1040 lbs. (471.7 kg.)


    With ASK installed:

    Overall length 58 in. (147.4 cm.)
    Overall width 36 in. (91.3 cm)
    Overall height 39 in. (99 cm.)

    Net weight empty 1084 lbs. (492.2 kg.)
    Net weight filled 1164 lbs. (528.5 kg.)

    MEP-003A

    The MEP-003A is a 10 kilowatt, 60 Hertz Generator.
    The MEP-112A is a 10 kilowatt, 400 Hertz Generator Set.

    Both consist of a revolving field alternator powered by an air cooled diesel engine. These sets are not designed for parallel operation.


    • Output for the MEP-003A

    Output voltage is switch selectable. These outputs are via the output lug connections.
    120VAC 104 AMPs single phase, 2 wire
    120/240VAC 52 AMPs single phase, 3 wire
    120/208VAC 34.7 AMPs three phase, 4 wire
    All at a Power Factor of 0.8

    There are also two 120VAC 15 AMP on-board convenience outlets next to the control panel.



    • Engine.


    1. The engine powering this Generator Set is a 4 cylinder, 4 cycle air cooled engine, with a 140 cubic inch (cu. in.) displacement. A mechanical governor keeps engine speed at 1800 revolutions per minute (RPM) under rated load conditions for the MEP-003A and at 2000 RPM for the MEP-112A.
    2. Fuel is supplied either from this units self-contained fuel tank or, by using an adapter, directly from a 55 gallon drum or other source. The fuel is filtered by two cartridge type fuel filters and a single fuel strainer. Two electric, self-priming fuel pumps supply fuel to the fuel injection pump which delivers the fuel at high pressure to fuel injection nozzles in the cylinder head. When an auxiliary source of fuel is used, three electric fuel pumps are used.
    3. Two 12 volt "wet cell" batteries in series supply power for a 24 volt electric starter and for glow plugs, located in the cylinder head, and for two air heaters located in the intake manifold, used for cold weather starting. An alternator located beneath the blower wheel and completely separate from the main alternator automatically recharges these batteries when the engine is operating.



    • Generator.

    The generator on the MEP-O03A is a four pole, revolving field type. The generator on the MEP-112A is a 24 pole, revolving field type, alternating current, supplied by the exciter assembly, is rectified and used to create the revolving field. A solid-state voltage regulator assembly automatically adjusts this current to obtain a constant (3%) voltage in the main stator (output) windings.


    • Controls.

    All operator controls and indicator gauges necessary for running the engine Generator Set are located on the control panel. In addition, an oil pressure gauge is located on the engine and a fuel level gauge is located on the fuel tank. The speed control is located below the control panel. Controls for selecting output voltage are located on the output control box.


    • Generator Set Electrical System

    The generator sets electrical system consists of two distinct systems: (1) The DC system used primarily for operating control and excitation, and, (2) the AC output system to supply power to the load.
    The DC source consists of a 24 volt battery set (BT1 and BT2) that is kept charged by a battery charging alternator (G2) and voltage regulator rectifier assembly (A5). Fuse (F1) protects the alternator from overload. Circuit breaker (CB2) protects the battery charging system from overload. Slave receptacle (J15) permits an alternate external supply to be connected to the battery circuit.


    • Dimensions and weights:

    Without AS:

    Overall length 62 in. (157.5 cm.)
    Overall width 32in. (81.3 cm)
    Overall height 37in. (94 cm.)
    Net weight empty 1220 lbs. (553.4 kg.)
    Net weight filled 1360 lbs. (616.9 kg.)

    With ASK Installed:

    Overall length 69 in. (175.5 cm.)
    Overall width 36 in. (91.3 cm)
    Overall height 39 in. (99 cm.)
    Net weight empty 1365 lbs. (619.4 kg.)
    Net weight filled 1505 lbs. (683.9 kg.)

    FAQ:

    • Can I run two in parrallel to increase the output?

    The simple answer is no. These sets are not designed for parallel operation.
    But then, did that ever stop a soldier or sailor from "gitten'r done" - I don't think so....
    A member put together a video showing how to run them in parallel. See: Parallel operation of MEP-002a or MEP-003a, with video


    All the usually disclaimers of liability apply. i.e. Do this at your own risk.


    • What type of oil should I use?

    The LO (Lubrication Order) says 30w above 32F and 10w between 32F and -10F. A lot of users are using a 15w-40 designed for diesels. It is probably more important to use a good diesel motor oil than which of the weights you chose. Many modern automotive oils sold for use in gasoline engine powered cars are also rated for diesel service. If the oil is labelled as passing CH-4, CI-4, or other such diesel engine oil test standards, it is fine for use in MEP-002 and MEP-003 generators. If in doubt about ratings, use oil specifically labelled for use in diesel engines.


    • Where can I get this part?

    Seems most of the posts in the forums suggest Delk's or Saturn Surplus for parts.
    For filters, it appears Race-Mart is currently the preferred site on-line.


    • Is this part the same on both models?

    See TM 9-6115-624-BD Table D-6 for the parts common between the two models. It is two pages, so be sure to look at the second page.


    • What is the fuel consumption?

    Generally, it is 0.5 gal/hr for the -002A and 1.0 gal/hr for the -003A. YMMV


    • Can I get 480VAC three phase out of this?

    Short Answer: NO
    Long Answer: This would be a MAJOR re-engineering effort. The generator head is a 12 lead head. Therefore, theoritically you could re-wire it for 480. You would also need to re-wire the voltage regulator. I don't think you will find any help here for that. After the conversion, it would no longer be a MEP.


    • How do I set it up for automatic starting?

    Check out these threads:
    MEP -002A -003A Automatic Starting
    Auto Start for MEP-003a


    • How to hook this up correctly to my house?

    Hook up Question is a very good thread about that.

    Since grounding the units IAW NEC can be confusing, here is a link to a message about the proper grounding. The message is part of the above linked thread but talks about the grounding issue specifically.

    Tech Manuals:

    The manuals are available from:



    TB 11-6115-741-24 Describes how to revive a "Tan" generator. Good information for the "Green" ones too.
    "Though Army tactical generators are fully maintainable below the depot level, inspections of generators returning from SWA have revealed that the excessive exposure to fine desert/dust-like sand and long periods of extreme heat have significantly accelerated wear on the generator sets. In many cases, the sand has contaminated and compromised the engine, the main alternator, the fuel tank and most electromechanical parts. The excessive heat has made the rubber components hard and brittle. Based on these conditions future generators returning from OIF/OEF will be RESET to the Special Test, Inspection and Repair (STIR) requirements via a National Center of Excellence (COE) and/or service providers from the Government and Commercial Industrial Base."

    MEP-002A
    LO 5-6115-584-12 Lubrication Order
    TM 5-6115-584-12 OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
    TM 5-6115-584-34 INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)AND DEPOT LEVEL MAINTENANCE MANUAL
    TM 9-6115-584-24P REPAIR PARTS AND SPECIAL TOOLS LIST
    TM 5-6115-584-12-HR HAND RECEIPT MANUAL

    MEP-003A / -112A
    LO 5-6115-585-12 Lubrication Order
    TM 5-6115-585-12 OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
    TM 5-6115-585-34 INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)AND DEPOT LEVEL MAINTENANCE MANUAL
    TM 5-6115-585-24P REPAIR PARTS AND SPECIAL TOOLS LIST
    TM 5-6115-585-12-HR HAND RECEIPT MANUAL

    Maintenance Parts:

    Oil Filters


    • FRAM CH6PL has the correct gaskets.
    • NAPA 1004 BUT make sure you get gasket 5108. The NAPA filter does NOT have the correct gasket in the box.

    A fellow SS Member has MEP-002A/003A spin-on oil filter adapter kits available. If you cannot find the ad in the classified section, send a PM to Speddmon. Once installed, you can use a standard spin-on filter.

    Fuel Filters


    • FRAM C1125PL
    • NAPA 3113 (Wix 33113) will work but the tangs inside the filter have to be bent. EDIT: This appears to be 1/4" too short without some sort of spacer.
    • FRAM part number SP101489 is the correct gasket for the filter cannister. It can be special ordered from Tractor Supply or Walmart. (free shipping at Walmart) [From: this thread]


    Air Filters


    • FRAM CAK253
    • FRAM CAK5047S
    • NAPA 2222
    • Donaldson P18-1052
    • Donaldson P101222
    • John Deere AT20727


    Repair Parts:

    As well as buying used parts from the typical suppliers like Delks, Gulf Coast Trucks and Saturn Surplus, a lot of members would like to find new modern replacements for parts. Below are some threads where members have taken the time to track down either the OEM supplier or a suitable replacement part.

    Also: See TM 9-6115-624-BD Table D-6 for the parts common between the two models. It is two pages, so be sure to look at the second page.


    Low oil pressure switch
    MEP-002A and MEP-003A Replacement Oil Pressure Switch.

    Batteries

    MEP-002A Battery
    The OEM Battery is a 2HN 445CCA 45 Amp-hour 12V wet cell. 2 required (10.3"L x 5.3"W x 9.0"H)

    BCI Group 51R is the civilian replacement for the military's 2NH battery. (9.4"L x 5.0"W x 8.8"H) The terminals are set-up the same as the 2HN which is reversed (R) from the size 51. Rumor on the web has it the 2HN is deemed not for civilian sale by Homeland Security. Don't know if true.

    Other BCI Group sizes that might fit:
    51 (9.4"L x 5.0"W x 8.8"H)
    22NF (9.4"L x 5.5"W x 9.0"H)
    45 (9.4"L x 5.5"W x 9.0"H)

    Storeman says this one is a good fit: Interstate SP22NF batteries (requires 2)

    MEP-003A Battery
    6TL is the OEM size.

    Fuel Pumps

    Facet Fuel Pumps are listed HERE

    In particular you want PN 480517E
    That is the Mil-Spec'd Pump.

    Other 24 V pumps from Facet that will work are: 40010E, 477003E, 40128E & 480563E BUT

    40010E & 477003E have 1/8-27 Internal Threads. You will need an adapter to make it 1/4-18 external threads to mate with the hoses. They CAN be used as direct replacements for 480517E. They do not have Positive Shut-off Valves.

    40128E Has a Positive Shut-off Valve, but does have 1/4-48 external threads. It CANNOT be used in series with another pump.

    480563E Has a Positive Shut-off Valve and 1/4-18 internal threads. Requires an adapter to convert to external threads. It CANNOT be used in series with another pump.

    Some pumps have "Positive Shut-off Valves" to prevent siphoning. The mil-spec pump does not have that. So, they should NOT be used as a series pair. (Original Military design) If one of these pumps fails, it will shut-off the fuel. The mil-spec pump does not have a shut-off valve and therefore, if one of the two pumps dies, the other pump will continue to pump fuel through it. IF you want to maintain redundancy with pumps that have the shut-off valve, they can be plumbed in parallel.

    Do not use pumps with Positive Shut-off Valves with a pump that does not have one. BAD THINGS CAN HAPPEN.

    These units will work just fine with one pump. Keep the second one on the shelf as a ready spare.

    Fuel Pump Screen

    You want to search for Facet part number 42370. It is a filter kit consisting of One 479729 filter and one 479136 gasket. The screen will filter down to 74 microns.

    Fuel Strainer Cartridge

    If you are missing the strainer cartridge, or any of the canisters, you should really consider replacing them with spin on cartridge adapters and use elements much easier to find locally. Get a good water/fuel seperator and a filter of 10 micron or better.



    If you really want to restore it to original then here are some ideas.

    • 1752002-01. The original strainer was manufactured by Purolator Facet.
    • FRAM C1824
    • FRAM 35070 is another option.
    • Onan 149-1469.


    Good luck.

    Here is a thread discussing the OEM of the fuel strainer and where to buy a new one:

    Mil Spec. Fuel Strainer for MEP-003a

    Valve Guide Seals

    The part number in the 003 manual is wrong. The correct # is the one in the 002 parts manual. The correct # is 509-0132

    Injector Pump Parts

    The injector pump (IP) is AMBAC (American Bosch) M50/PSU Model PN: 502/4A80A9540AR. The A9540 is important when calling around for parts.

    The plunger guide is PN: GU8546 ~$15
    The rebuild gasket Kit PN: KT85166 ~$36.
    Phone Number: 800-628-6894

    Glow Plugs

    Intake Manifold PN:
    Champion CHA-196 or CH-49
    6A843G049 from INDUSA

    Head GlowPlug PN:
    Onan 333-0107 replaces the 333-0104 found in -24P parts manual
    Champion 182 or CH-42
    (Be careful not to order the CH182 glow plug. It is metric thread and rated for 11V. CH42 is the correct Champion part / SKU number.)
    DRX00042K from INDUSA

    Glow Plugs were discussed here.

    Control Panel Lights

    The part number in the TM is incorrect. The correct part number is 6s6-30V.

    Rotating Rectifier Diodes

    Cross Reference:
    #27 NSN...5961-01-050-7048... 1N1204RA Semiconductor Device, Diode

    #28 NSN...5961-01-054-4151... 1N1204A Semiconductor Device, Diode

    For future Reference: http://www.datasheetcatalog.org/data...semi/coe-3.pdf

    Troubleshooting Helps

    Fuel Line Check valve

    There is a check valve in the fuel supply line to the injector pump. It is located after the third filter in an elbow near the oil pressure gage. These can stick from sitting and prevent fuel from getting to the injection pump. A blast of air usually cures the problem, or a good soak in a solvent.

    Injector Pump

    The Injector Pump is a Model 50 manufactured by AMBAlC Intl. Make sure you are looking at the 50-2/A4-80A-9540A. This is the pump used on the D.O.D., DJE, and DJF models. In addition to the material found in the TM's, here are some good ones from the AMBAC site:

    Selecting Correct Injection Pump Timing Button and Injection Pump Installation
    Service Parts contains better images than the TM. (I think)
    Service Instructions for the Model 50
    BUT
    Before you pull the pump... Verify that there is sufficient fuel going to the pump. Since many of these units have sat for years, the fuel system as a whole can be gummed or clogged. When the Master Switch is in the prime & run position, is there a good stream of fuel back into the day tank? If not, find out why and correct first.

    O.D. Fever posted this help for a Stuck Injector Pump Plunger also: "Before you remove the pump try to unstick it. I have done this with success twice. Remove the long hex nut, then remove the 12 point nut under that nut, use needle nose pliers to remove diverter valve inside the hole, don't lose small plastic spacer. Use a small brass punch and tap the plunger that works the valve back in, roll engine over a crank or two and punch it again. If it starts to go in and out on its own, you're done." I did this and it worked for me. Just be very careful not to damage anything.

    Running at wrong frequency

    Some useful threads:
    http://www.steelsoldiers.com/auxilla...tml#post756034

    Fuel Hoses
    http://www.steelsoldiers.com/auxilla...ep002a-10.html

    Starter Lockout Switch not working?
    http://www.steelsoldiers.com/auxilla...ut-switch.html
    Comments 7 Comments
    1. derf's Avatar
      derf -
      I dunno what happened to the 016 wiki but here's some of it:
      MEP-016

      MEP-016s are very similar to the MEP-021 and MEP-026 gensets, but the 021s produce 400Hz power and the 026s produce 28VDC power.

      "A" and "C" models are 3600 RPM Gasoline, 120/240/208 60Hz single and three phase gensets:

      Manuals:
      TM 5-6115-271-14
      TM 5-6115-271-24P

      "A" models are powered by 4-cylinder, 6 HP Military Standard Engines, Models 4A032-1 or 4A032-2 which are directly coupled to the generator.

      "C" models are powered by Model 4A032-3 or 4A032-4 engines.

      The basic difference between the 4A032-1/-2 and the 4A032-3 engine is that the 4A032-1/-2 engine has a conventional ignition system
      while the 4A032-3 engine has a breakerless ignition system (BIS) and a larger rope cranking pulley. The 4A032-3 engine is far easier to start and also has
      greater reliability and requires less maintenance.

      Dimensions and weight:
      Length . . . . . . . . . . . . . . . . 35 inches(87.5 cm)
      Width . . . . . . . . . . . . . . . . .24 inches (60.0 cm)
      Height . . . . . . . . . . . . . . . . . 25 inches(62.5 cm)
      Weight . . . . . . . . . . . . . . . 275 pounds (123.75 kg)
      Capacities:
      Fuel tank . . . . . . . . . . . . . . 3.75 gallons (15.25 liters)




      "B", "D", and "E" models are 3600 RPM Diesel, 120/240/208 60Hz single and three phase gensets manufactured by Onan:


      "B" models are powered by a single cylinder Diesel engine and are electric start only.


      Manual:
      TM 5-6115-615-12


      Dimensions and Weights:
      Overall Length . . . . . . . . . . . . . . 39 (99 cm)
      Overall Width . . . . . . . . . . . . . . 23.75 (60.3 cm)
      Overall Height . . . . . . . . . . . . . . 28 (71.1 cm)
      Net Weight Empty . . . . . . . . . . . . . 440 lbs. (199 kg)
      Net Weight Filled. . . . . . . . . . . . . 498 lbs. (226.3 kg)
      Shipping Weight . . . . . . . . . . . . . 500 Ms. (227.6 kg

      Capacities:
      Fuel System. . . . . . . . . . . . . . . . 4.5 gal. (17.4 Liters)
      Lubricating Oil . . . .. . . . . . . . . . 3.0 qts. (2.8 Liters)


      "D" models are "A" models which have been modified by replacing the gasoline motor with a Yanmar Diesel motor.

      "E" models are "B" models which have been modified by replacing the Onan Diesel motor with a Yanmar Diesel motor.

      Yanmar L70 and L100 motors have been used in the above conversions and have manual pull start capabilities.

      MEP-701A is the designation for the MEP-016B or MEP-016E models with the Acoustic Suppression Kit (ASK) enclosure.
    1. W8BUH's Avatar
      W8BUH -
      Just purchased a MEP-003A and I think the fuel pumps are bad. Well I think two of the three are bad. Question, does all three pumps have to be working to make the generator start? I know the aux. pump is working. I purchase a pump from the auto parts store which is 24 volts and I have 24 volts coming to it. But not coming out I grounded it and still not coming out. I need some help with this. Is there any fuses in the lines for the pumps?
      Thanks
    1. Jkid3's Avatar
      Jkid3 -
      I Am new here. I have a question about my MEP-002A. I have been told it is hard on voltage regulator to idol for a long period of time. I want to know if it is hard on voltage regulator to idol and warm up and charge the batteries without a generating load on it

      Thanks
    1. Jkid3's Avatar
      Jkid3 -
      Quote Originally Posted by W8BUH View Post
      Just purchased a MEP-003A and I think the fuel pumps are bad. Well I think two of the three are bad. Question, does all three pumps have to be working to make the generator start? I know the aux. pump is working. I purchase a pump from the auto parts store which is 24 volts and I have 24 volts coming to it. But not coming out I grounded it and still not coming out. I need some help with this. Is there any fuses in the lines for the pumps?
      Thanks
      I am new here. I have a MEP-002A my generator only has 2 electric pumps and 1 injector pump on side of motor mechanical pump But I think the MEP-002A and MEP-003A are the same electric fuel pumps. I would check for 24 volts at the pump that is not running. The aux.pump just pumps fuel from aux fuel tank to the on board fuel tank on board has a float in it that turns aux pump on and off
    1. nortonl's Avatar
      nortonl -
      my fuel drain shut off fell off...just want to plug the hole somehow so i can fuel it up 803a
    1. Guyfang's Avatar
      Guyfang -
      So................ What can we help you with?
    1. nortonl's Avatar
      nortonl -
      Quote Originally Posted by Guyfang View Post
      So................ What can we help you with?
      was hoping for a suggestion...I ended up with a fuel rated well nut that did the trick