MEP-803A - New to me, excited to get it going.

[KD7CAO]

Greetings:

Found an MEP-803A on Facebook Marketplace for a steal of a price, guy claims it doesn't run. Drove a couple hours to Canton to pick it up (have it sitting in the bed of my pickup, my tractor is way too small to lift this thing).

Discovered the fan belt was missing, she has 1247 hours and looks like it was maintained some. The previous owner acquired it as part of a mobile clinic. Didn't want it anymore and had no interest in tinkering with it.

I have the MOV and spare fuses on order along with a new fan belt. Figured I would give it a try to start. Full tank of fuel and just cranks over, no exhaust smoke.

Started reading the TM. Wonder how far into the unit the issue will be. I got the impression it was running well until the pandemic and the mobile clinic ceased running around.

So starts my journey.

 

[Light in the Dark]

You turn it over by the S1 switch up near the gauges, or by the switch inside the engine bay?

 

[KD7CAO]

Using primary user start switch on the front panel. Internal switch on Normal. Inside switch, if I am reading correctly cranks only without start. I assume for troubleshooting purposes.

 

[Light in the Dark]

Have you confirmed the fuel stop solenoid is retracting when the unit is cranking? Have you done any filter service on this yet?

 

[KD7CAO]

No I have not verified the fuel stop is moving and no I have not done any filters yet. I may not have the right TM. TM 9-6115-642-10 it says reference a higher level tech, lol.

 

[peapvp]

No I have not verified the fuel stop is moving and no I have not done any filters yet. I may not have the right TM. TM 9-6115-642-10 it says reference a higher level tech, lol.

the higher level of maintenance is here:

all the TM’s for 803

 

[Light in the Dark]

No I have not verified the fuel stop is moving and no I have not done any filters yet. I may not have the right TM. TM 9-6115-642-10 it says reference a higher level tech, lol.

I think there are plenty of steps before higher maintenance level. The right book will work wonders. Like this section from the -24 that can be found in the directory peapvp linked to:



Once you know where to look, these things become a whole lot less mysterious.

 

[Light in the Dark]

The easy shortcut to life with these is knowing the right book, at the right time

TMs ending -10 are Operating Instructions
TMs ending -24 are Technical Troubleshooting
TMs ending -24P are Exploded Parts Diagrams

There are manuals for the complete machine, and manuals for the engine alone.

 

[KD7CAO]

Have you confirmed the fuel stop solenoid is retracting when the unit is cranking? Have you done any filter service on this yet?

Seems the fuel solenoid may be intermittent. Sometimes it moves sometimes it does not. Going to top up my batteries and try again.

 

[Light in the Dark]

Seems the fuel solenoid may be intermittent. Sometimes it moves sometimes it does not. Going to top up my batteries and try again.

As part of your baseline on this, I would consider investing in a bottle of two of Deoxit D5 contact cleaner. Before you go too far into things, corrosion is a known problem in these sets (because they have been used in all conditions across the world, and the newest one is 13 years old now).

I would recommend you disconnect the batteries, pull the roof over the gauge cluster, and deoxidise every screw, contact, terminal board, and liberally spray ALL switch contacts (and excercise the switches till your elbow needs a beer). Your solenoid might be fine, might not... the magic in a can will definitely take some question out of a lot of things.

Feel free to share a photo of the interior of the gauge area, as well as the backside of the gauge panel. Helps the folks around here a bit get you to a more solid start if we have a better idea of what you are dealing with.

 

[Light in the Dark]

My oldest splits time between MA and Sherman, stones throw from you.

 

[KD7CAO]

My oldest splits time between MA and Sherman, stones throw from you.

Ah. Sherman is about 40 minutes away on a good day. I am in Aubrey area.

How common is a stuck valve? Pulled air cleaner and was getting a little exhaust back and noticed the exhaust felt a little bit like a vacuum.

 

[Light in the Dark]

Its not common, but its not uncommon. Even if one was stuck, it should run on the other cylinders (and you would be aware that its not running right). Going through the TM steps first is your best bet.

 

[KD7CAO]

 

[KD7CAO]

It wants to start. I have fuel at the injectors. But nothing coming from exhaust, just partially combusted smoke coming out of the air cleaner box. Smells like my old 7.3L IDI on a cold morning with no glow plugs.

 

[Guyfang]

When starting normally, will the gov linkage move?
Might want to revue the MPU removal, then clean the MPU. Reinstall it, IAW the TM. Read the instructions at least twice, then reinstall, adjust it and try again.

 

[FarmingSmallKubota]

After you get it running looks like it will need a good high load run, i see signs of Wet stacking,IE the black goo coming out of the exhaust manifold. But obviously get it running first.

 

[Light in the Dark]

Ah. Sherman is about 40 minutes away on a good day. I am in Aubrey area.

How common is a stuck valve? Pulled air cleaner and was getting a little exhaust back and noticed the exhaust felt a little bit like a vacuum.

I read it as Denison! Now I feel stupid

 

[Ray70]

How does the motor sound when cranking? does it spin abnormally easy and smooth ( lack of compression pulses? )
The black goo leaking from the muffler joint indicates a fair amount of wet stacking has happened.
I've seen several 803's where the carbon buildup was causing the exhaust valve to not seat fully, resulting in Zero compression.
It was easy to fix, but wouldn't start otherwise.
If it cranks fast with little change in sound when pistons come up on compression ( combined with the pulsing you feel in the air cleaner ) leads me to think your valves may be hanging open a little.

 

[KD7CAO]

After you get it running looks like it will need a good high load run, i see signs of Wet stacking,IE the black goo coming out of the exhaust manifold. But obviously get it running first.

I noticed that too. Sadly, that is the most common thing I see with people that have no experience with diesel generators, they just don't run them under load. It can cause issues with bearings and rings too. At work we had to have a 1.5MVA rebuilt in place because the one time it needed to run under load it couldn't. They always run it for an hour every week with no load on it.