MEP 802A Fix-up Thread

Light in the Dark said:

Per the -10:

Normal Operating Temperature 170-200 °F (77-93 °C)

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Thanks, I guess I am well within that range & the bad radiator had me running a but more hot than that.

Made the angle iron brackets with some stainless that was scrap at work. Came out good & evens the load on the tank tabs a bit more.

So, I found some of the padding that is used as a sound damper in the dumpster while at work. It was in all kinds of strange cuts, but I took what I could from it & placed it around the generator. Not sure if it will make a difference at all, but it won't hurt anything. Made a small holder for my logbook for maintenance as well. Hopefully, more will pop up so I can finish it off. Ashamed how wasteful the military is. The stuff I find in there...

CallMeColt said:

So, I found some of the padding that is used as a sound damper in the dumpster while at work.

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Is that kind of sound dampening something you added on yourself or something mine is missing? Either way, I like the idea.

Sgt Jiggins said:

Is that kind of sound dampening something you added on yourself or something mine is missing? Either way, I like the idea.

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I think some units have it, others don't. I'm not sure if it was on there at new. It was just something that I got for nothing & figured, why not?

People. If you want to know if something is in the set, look at the parts TM. As far as I remember, the only place the sound deadning material is installed in the 802, is on the bottom of a plate under the engine. On the 803, as far as I remember, its only installed also on the plate, and the rear air intakes.

I'm at 402 hours & really have not had issues.

A small crack at the muffler flange has popped up but that is an easy fix.

Still a real slight oil leak that I can't quite pinpoint. I changed the oil last month & it wasn't really down at all so for a 26 year old generator, I'm not going to complain. Did toss some stop-leak stuff in there to see if it will help.

A few broken wire connectors right inside the doors but easy, in the field fixes.

Very happy this project has finally just gotten to the point where I use it & just change the fluids.

So, I got my hands on a LPW2 motor that was being scrapped to take some parts off of. I took a little bit of time & made a video explaining the injetion pump installation & removal.

I previously was a bit confused on this & saw that many others on the forum were as well. Since I'm more of a visual, hand on person, I thought a video showing what was figured out a few times would be helpful. The TM does explain this, but sometimes that can be more confusing & doesn't always tell you why it needs to be done.

Hopefully this is helpful to some people moving forward!

CallMeColt said:

So, I got my hands on a LPW2 motor that was being scrapped to take some parts off of. I took a little bit of time & made a video explaining the injetion pump installation & removal.

I previously was a bit confused on this & saw that many others on the forum were as well. Since I'm more of a visual, hand on person, I thought a video showing what was figured out a few times would be helpful. The TM does explain this, but sometimes that can be more confusing & doesn't always tell you why it needs to be done.

Hopefully this is helpful to some people moving forward!

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Holy crap! It all makes sense now!!!! Thanks !

Another video on the motor in the generator.

It's been a while, but a problem popped up.



The mounting tab on the generator head broke that is on the output power lugs side!

For the longest time, I could hear a clunky type vibration noise but could never figure it out. Must have been this before it completely failed.

Noticed the engine moving more than usual when doing a test load. Made me start to look around & I noticed it. Hard spot to see.

Not really sure how I am going to fix it. Thinking I will remove all the side panels (oh fun) & then get some sheet steel about as thick as what was there to wedge under & bolt down. Then, give it a few tack welds. Remove the rubber mount & finish welding. All while making sure there is a VERY good ground.

Anyone else find one of these broken?

I never, ever, saw such a failure.

Guyfang said:

I never, ever, saw such a failure.

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I'm good at doing things for the first time!

Here's my guess on how it happened...

Over the years, water made its way in & it ended up settling out in the mount there making it weak.

I got it & mounted it on the trailer. When I tow it, I do a lot of off-road to get to my off grid cabin. Some of it is pretty bad after rains wash out roads & stuff.

Between that & it being used, finally gave up.

Got the mount repaired over the past few days.

Spent the first day getting it all opened up. Some of these bolts are a big PITA to get at!


Drilled the 1/2in hole in a plate I had so it would make the most contact with what was left & then welded it. Not bad for my $80 harbor Freight Tools welder. For some reason, the paint made it look worse than it was... not that my welds are good anyways!


I replaced the fuel/water separator filter while I had that side off since it was much easier to do like that.

I also put some of the sound dampening material in the vent area as well as on the inside wall since I had it off & had extra laying around.

I definitely think I had this issue for a while. After getting everything back together, I noticed the exhaust sits more centered. You can see where it had been hitting.


Did a 2 hour 100% load test... all is well!

So, took it out this weekend. Just before going to sleep, I checked on the generator & found some fuel leaking.

Fuel/water separator failed at the drain fitting! Tried to tighten it & it got way worse to the point I couldn't run the generator.

Glad I had the L.I.P.S. for a backup out at the off-grid place!

Replaced it with another I had & just ran it for about 2 hours. All is good now.

The military contract filters suck. Very thin metal. I will not get anymore.


Off topic...
... Here is a quick fly over of my off grid place in case anyone who has watched this thread over the years in curious.

I don't use the stock separator on the machines I go through. I cut and remove the drip line and replace with a Napa Gold 3472:


Have not experienced a failure after the sale with this filter. I can say though that I have had very sporadic failures of the line that goes from the separator base mount, over to the cartridge fuel filter. That is a leak that will stop you dead in your tracks, that I think very few plan for. A part never thought about, that it would not hurt to have made up for anyones part shelf.

Edit: I have also used the Wix model of this filter (33472) and its available at a much better price: https://www.amazon.com/gp/product/B000C9TB90/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

And I like the aerial view... and lack of neighbors

I

Light in the Dark said:

I don't use the stock separator on the machines I go through. I cut and remove the drip line and replace with a Napa Gold 3472:

https://www.napaonline.com/en/p/FIL3472

Have not experienced a failure after the sale with this filter. I can say though that I have had very sporadic failures of the line that goes from the separator base mount, over to the cartridge fuel filter. That is a leak that will stop you dead in your tracks, that I think very few plan for. A part never thought about, that it would not hurt to have made up for anyones part shelf.

Edit: I have also used the Wix model of this filter (33472) and its available at a much better price: https://www.amazon.com/gp/product/B000C9TB90/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

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I had the WIX one on before this one for a few years & had no issue. I get filters for free from time to time & had a Fleetguard one that fit so that's on there now. I'm sure it will be fine.

I was thinking about having some extra fuel line & adapters on hand. If I did, I could have bypassed the filter to keep it running. might add 5ft of 5/16 line & some fittings to the parts bag for this.

Thanks for the videos. Big help for a guy like me. I am going with the ultimate well nut on my 803 drain. Curt

Funny, it has been so trouble free I didn't realize I was way past due for an oil change! I'm at 618 hours now.

After using it this past weekend, I realized I needed to change the oil and spend a little time with it doing some minor things to it along with the trailer, but I will only talk about the generator here.

I'm pretty sure that after the many years of owning this, I found the culprit for the very minor oil leak... the 90 deg fitting for the oil drain.

Figured I would tighten it or swap it out while changing the oil. Right became loosy! The reason why it was leaking was someone cross threaded the fitting when installing it or over tightened it.


After quite the match getting it off, found the threads in the block okay. I have a ton of fittings around and have a 1/2 NPT 90 deg fitting. The one on there is odd, like a 1/2 to 3/4 NPT. So, I had to order a 1/2 NPT to 3/4 barb fitting to mate up with what was there.

https://amzn.to/3cKrI3b

Ultimately, got it all done and it seems like it's okay now. So much oil spilled that it's hard to tell if the actual leak stopped but time will tell. I'm just glad the block was not stripped.



A while back, I had wired in a switch off the solar charger controller to add some lights inside the engine area for checking things in darkness. Got some LED lights and used a 24v to 12v converter that I had laying around and started putting some in. I will run more at a later time, but having some on the important side where the oil dipstick and most of the wires are is good for now.



I'd like to get a few more of these to fix up but it seems like the days of them being reasobable are gone. Getting a commercial unit is better off it seems.