MEP-803a Crankcase full of fuel...

[Spud_Monkey]

It's the reason for new gasket set going in, maybe grab some new injectors along the line with the stainless steel nuts and bolts instead of the regular ones and Loctite to hold them it. I do go the extra mile. I have rebuilt engines and transmissions and my pet peeves go a long way when it comes to turning wrenches.

My newest vehicle is 21 years old here, gets 45 mpg and will spin the tires

 

[Guyfang]

If I was still running a DS shop, you and I could work together!

 

[Daybreak]

Looks like it and who ever did it sucked at it. Some of the nuts and bolts are mismatched on the housing body and a lot of them are falling out over time I have to go buy some more nuts and bolts and just replace them all with stainless then Loctite them to ensure a clean job. Lot's of work to make this gen set right again, at least I got some use before it kicked over.

Howdy,

No Loctite is needed with the proper screws and nuts.

MEP-8xx stainless steel screw information

The screws with the lock washer K-Lock nut holds nicely.

 

[Spud_Monkey]

Apparently whoever reset this gen set didn't realize either it was aluminum or understand metallurgy on mixing metals they put regular zinc hardware in.

 

[Spud_Monkey]

If I was still running a DS shop, you and I could work together!

My apologies but I am retired thanks to US government, they would have a field day if they caught me working at business or holding a job. 100% P&T disabled.

 

[Guyfang]

That makes us both retired.

I was hoping you would jump in here Mike!

 

[Daybreak]

Apparently whoever reset this gen set didn't realize either it was aluminum or understand metallurgy on mixing metals they put regular zinc hardware in.

Howdy,
That is part of the problem. They did not use stainless steel hardware. I have replaced most screws and nuts. The newer units started using caged nuts. That really makes it easy not trying to hold a wrench up above the air filter. It also speeds up the time to take panels off and on.

RIVNUTS = are a great idea for replacement. The newer AMMPS generators all use rivnuts at all locations.

I would like to retire, but, it seems I am just tired. but working harder and longer each day

 

[Ray70]

Hello everyone, I'm just finishing up a similar problem with fuel metering pumps and thought I'd share my findings.
Got this 803A from GP, they said it wouldn't start and made it sound like the reason was that the fuel hoses, filter housings and fuel solenoid were missing. When it arrived I immediately noticed the exhaust flap missing and thought "Oh Crap!" bet there's water in the motor. So sure enough, water in the center 2 cylinders and engine is frozen.
Took it apart, honed cylinders, cleaned up the rings, lapped the valves and put it together.
Go to prime the injector lines and not getting fuel out of any lines. I noticed the fuel shut off linkage feels like its not doing anything so I pulled the metering pumps 1 at a time... the last one I pulled was frozen in the fuel off position.
When I went to reinstall, I had a finger down 1 pump hole to try to align the rack and just couldn't get any 1 pump to drop in without binding up the rack.
After reading this post, I went back, installed 1 pump and then tightened the holding clamp down. once the pump was seated, the rack moved freely.
The problem was just as the guys mentioned above. If the pumps are not fully seated, the linkage will hit the underside of the block, causing the rack to bind up.
Thanks to rhurey for the pictures, it may have saved me from pulling my hair out!
Now I just need to clean and install last 2 pumps, then try starting it again...