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Not sure. Exhaust flap is currently installed correctly. I have a USB inspection camera. I looked in the crankcase (through the oil fill port) and didn't see anything obvious.

Working through another MEP-803a. This one has a seized engine. When I engage the starter, I hear a solid clunk of the starter engaging the flywheel, but the engine doesn't turn. I can see the generator barely moves when the starter is engaged. Unit looks clean, no obvious problems, 1700...

FYI, you can check the burden resistors without desoldering them if you disconnect 1, 2, & 3 from K8 and 14 from S8. That effectively isolates R10 through R13.

Fixed it. Turns out the Quad fuse upgrade fuse was burnt out. I'm sure I checked it when I started. When I first tried to start this unit, the MPU was disconnected and the fuel solenoid would not stay engaged. I think through the process of diagnosing and fixing those problems, the fuse might...

Ok, more progress! Normally, I've had the panel open during start to measure various voltages. I started with the panel closed and noticed that I have full (240VAC) voltage on M1 when S1 is in Start. I guess my DMM didn't respond fast enough to catch that when I measure A1-5 and A1-6 before...

That's very nice! It shows that what I'm measuring is normal in Start, that is K1-7 voltage goes up to K16. I thought that voltage was supposed to be present during Start on A1-5 & A1-6 (F+, F-), but according to the schematic, it's not.

Checked S1-7 again and it has about 20 VDC. I think my meter leads were loose last time. Anyway, I can trace the voltage from S1-7 to K12-8, K12-2 to K16-9, but nothing out of K16-3. I checked this with the starter solenoid disconnected so the engine wouldn't crank which maybe messing up the...

Just checked the magnetic pickup. I pulled it out and it looks good. No damage. Reinstalled it per your instructions and it's showing 2.7 VAC.

Just checked pin 7. No voltage on 7 while cranking. Should I check K15?

Nothing else unhooked. When I crank (S1 to start), 7 volts on pins 5 & 6 on A1. Drops to 0 volts when S1 released to Prime/Run. I haven't got a chance to check the voltage of just the magnetic pickup, yet. Will probably get to that on Thursday.

Yes, it has the quad circuit mod. Fuse is good, not blown. A1 is at 7.0 volts during start, 0 volts in run. I reconnected the speed sensor the problem in the fuel solenoid is weak on won't always stay open in run. Right now I'm using a string to hold it open. It shows good voltage across...

I will check for the mod and let you know. Also, speed sensor is disconnected. I assume that will keep the circuit from flashing since it never senses the unit rotation? When connected, the starter cuts in and out before unit gets to operating speed. I'll swap in another controller (left...

More diagnostic info: The convenience outlet reads 24.75 VAC, 0 VDC, 60Hz. Voltage is the same when S1 held up or when released. I have the unit set to 240V/1Phase. Voltage between L1 & L3 is 48.5 VAC. DC exciter field voltage (pins J&F on the diagnostic connector) is 0 VDC. 0 VDC on pins...

Yes, I meant the 120 volt outlet. Also, yes, by idle I mean no load. It runs right at 60 Hz, so it's not under speed. I will try your suggestions this afternoon.

Ok, next question. I have a 1997 MEP-803A that was reset in Sep 2011. It has 440 hrs. It'll start up and idle at 60hz but the output voltage is low. I have it set to 240V/single phase and the voltmeter needle is pegged to the left (voltage not high enough to make the scale). My DMM is...

That makes sense. Thanks for the tip. I'll look it up in the TM.

What pressure are you suggesting I measure? The output pressure of the injection pump is around 3000 psi. That's a big water manometer!

Thanks for the advice. Only the top 1/8" of the piston was polished, so hopefully it won't affect the overall sealing capability of the pump.

Fixed it! Turns out the top of the piston was mushroomed out about .0005" more than the rest of the shaft. Polished it down and it works great!

When you reassemble the pump, how do you ensure the locking collar is in the correct position to limit the piston control arm correctly?