MEP-803a with Start/Stop Lever Issue

[Maestro]

Well is it fixed!!!

The Stop/Start level was assemble incorrectly, the shaft was binding on the bushing, there was some corrosion on the shaft. Clean it all up and it rotated freely. I was able to figure out where the end of the spring should be located, see picture.

The real challenge was trying to assemble it with the spring properly located.

Not sure how to describe this. I put the spring on the spacer and locate it onto the internal lever and put the screw through the spacer and then the internal lever, then inserted the screw into the busing hole. Then inserted the stop/start lever shaft into the bushing then began turning the lever to thread it onto the bolt. There is absolutely no way to thread the bolt into the lever while the lever is installed into the bushing (without pulling the gear and camshaft out of the engine). I was able to get the bolt threaded on most of the way before having to tighten from the inside. The internal lever is keyed to the shaft so you can tighten the bolt most of the way then you have to locate the internal lever on to the key-way of the shaft and finish tightening.

Once reassemble it now rotates on its own like it should.

I just need to reassemble everything.

Does any one know where to get the clip in nuts that go into the sheet metal housing. Some of the bolt broke off in the nuts would like to replace them.

 

[2Pbfeet]

Well is it fixed!!!

The Stop/Start level was assemble incorrectly, the shaft was binding on the bushing, there was some corrosion on the shaft. Clean it all up and it rotated freely. I was able to figure out where the end of the spring should be located, see picture.

The real challenge was trying to assemble it with the spring properly located.

Not sure how to describe this. I put the spring on the spacer and locate it onto the internal lever and put the screw through the spacer and then the internal lever, then inserted the screw into the busing hole. Then inserted the stop/start lever shaft into the bushing then began spring the lever to thread onto the screw. There is absolutely no way to thread the bolt into the lever while the lever is installed into the bushing. I was able to get the bolt threaded on most of the way before I have to tighten in from the inside. The internal is keyed to the shaft so you can tighten the bolt most of the way then you have to then locate the internal lever on to the keyway of the shaft.

Once reassemble it now rotates on its own like it showed.

I just need to reassemble everything.

Does any one know where to get the clip in nuts that go into the sheet metal housing. Some of the bolt broke off in the nuts would like to replace them.


View attachment 956054

Do you mean the 10-32 clip in cage nuts?

If so, Bolt Depot, McMaster-Carr or eBay or Fastenal, or most any other bolt and nut supplier. They are a common nut for computer racks, so that maybe another source.

All the best, 2PbFeet

 

[Toolslinger]

I'm glad you got it straightened out...
I'm more glad you had the issue, and took some photos since I'll be diving in to this area later this year...

 

[Guyfang]

Well is it fixed!!!

The Stop/Start level was assemble incorrectly, the shaft was binding on the bushing, there was some corrosion on the shaft. Clean it all up and it rotated freely. I was able to figure out where the end of the spring should be located, see picture.

The real challenge was trying to assemble it with the spring properly located.

Not sure how to describe this. I put the spring on the spacer and locate it onto the internal lever and put the screw through the spacer and then the internal lever, then inserted the screw into the busing hole. Then inserted the stop/start lever shaft into the bushing then began spring the lever to thread onto the screw. There is absolutely no way to thread the bolt into the lever while the lever is installed into the bushing. I was able to get the bolt threaded on most of the way before I have to tighten in from the inside. The internal is keyed to the shaft so you can tighten the bolt most of the way then you have to then locate the internal lever on to the key way of the shaft.

Once reassemble it now rotates on its own like it showed.

I just need to reassemble everything.

Does any one know where to get the clip in nuts that go into the sheet metal housing. Some of the bolt broke off in the nuts would like to replace them.



It always is a good idea to reference the -24P. TM number, page, Figure and Item number. No mistakes that way.

 

[Maestro]

I have a running Engine!!

I got it reassembled enough to get it to run. After bleeding the lines, it fire right up after a couple second of cranking. It put out a big puff of black smoke and immediately started idling with no black smoke it is running nicely. Only ran it 30 second since I have not put the radiator back in at this point.

I will share after installing the injector pumps and before putting the gear cover back on I found the stop/start lever was not moving on it own nor would the fuel rack spring back to the start position. It was not binding, it just did not have enough spring force to move the levers on all 4 of the injectors pumps. If I tapped the fuel rack it would move and slowly go to the start position. I played with it a while and it was not improving. However, cranking the engine, the lever would move from the stop position to start position on its own. It did this every time. I am not sure if the springs are weak or the fuel levers on the injectors are just a little tight being new or something else is going on.

I decided to finish closing it up and give it a chance. At this point it appears to be working. I will be putting the rest of the unit back together and plan to run it longer and do a small load test to see if the generator part is working.

Thanks everyone for you help!!!

@2Pbfeet , yes those, having the correct name #10-32 spring clip square nut or #10-32 Cage Nut helped, I did not know the name of them so trying to search gets you all kind of results. Amazon has good selection.