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You'd think with all the over done stuff on these units, the'd have had put something on those unused mounting holes as guides or holders for that cable.....

I soak with Super Clean first, then spray with a hose. Do it a few times. No need to use a pressure washer as the Super Clean breaks up most anything grimy. If needed, get a brush or something. With just a hose, usually you don't need to worry about electrical, but it's a rule of thumb to never...

I check for 12v on the body harness side. Confirmed wiring is good all along it. Also from the switch to the TCM connector itself. I used a multimeter to adjust it and make sure it opens/closes with a slight pedal touch right at the TCM connector (Not J1, at the actual purple connector) so I...

Well, it is plugged in, brand new, tested good, and everything I can tell so far the wires are good. Two TCMs that are new tried as well. So it more than likely is not the sensor itself, but something messing up the signal coming from it. There is no light with the J1 disconnected and power so...

Tested the wires today. From J1 to h for the Engine Speed Sensor tested good, p didn't give me continuity but looking at the wire diagram, it is shared with the Throttle Position Sensor and then grounds in the transmission itself ultimately..... I think? When you have a bunch of shared...

This may be helpful. The injection pumps can be annoying to remove/install but on an MEP 803A there is MUCH more room! I'm betting that someone already messed with them & installed them improperly. Have seen it quite a few times. Hopefully that rail isn't bent! Usually you can make it move no...

I think I need a few parts from a MEP 501A control box. If you are interested in selling, let me know.

While you have it apart, soak in ATF for 24 hours or so. :)

Injection pump replaced & truck is running. The new Crank Position Sensor didn't do the trick. Will double check the wires between TCM and the sensor. Thinking it's just the TCM at this point. If the wires above test okay, going to install another new one & hope for the best!

I know nothing about this specific setup, but one think I learned about military communications setups.... just because it is the same connector, does not mean it is the same pin out. Unless you can 100% confirm it is the EXACT pin out.... just because it fits, doesn't mean it won't turn...

Funny, once you know, how the stuff starts popping out. Maybe it was for putting the Jerry can handles through? :p

The smoke is more than likely what you suspect... oil & fuel built up in the muffler. Along with anything else over it's time that may be burning off. I would run it at 50% load for one hour & then 100% for 6 hours to fully test it. Make sure it ramps up & down as it should first & adjust the...

Sorry, I must have missed that when reading. Sure looked like a pump issue. I'd replace the China injection pump as soon as you can. They are TERRIBLE. You may get 50 or so hours before it grenades. They don't properly harden the internals. Genuine Yanmar ones seldom go bad.... odd to see one...

I'm late to the game, but you never checked the injection pump or governor adjustment before ripping into the head? I can tell from all of these I worked on that 100%, that was a WAY overfueled engine. The white smoke was unburn fuel. Have seen it many times on these. Caused it a few times...

I wouldn't, except as maybe a quick test to see if the generator indeed works. You are bound to have a major issue using like that for anything but a test. Basic electrical principles should always apply.

You shouldn't. But, it would be simple enough to just replace the valve so it is right if that is all they cut. That was something like a mud dobber doesn't get it's way in there, clog your vent, and then you build up pressure & blow a seal.

Like I said, there is NOTHING the same on these two generators electrically. You need to make everything yourself. Even a MEP 531A control box will not work properly as it is intended for the exact setup it is intended for. You would be double flashing, for example, and destroy & light on fire...

Just wanted to add my experience... my truck was showing speedometer fast. Had the newer 80mph. It was off by 5-10mph depending on actual speed. Swapped to a 41 tooth gear and it is perfect now. Bother were red, so going by color didn't seem to matter. If I were to overlay a 60mph speedometer on...

I sure left this thread dead in the water, just like the project! Ended up selling it. It was picked up about a week ago. Will make a final video to wrap things up on the YouTube channel. I'm not sure if the new owner is a member here but I'd guess they are as they have other military vehicles...