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Update: Removed the plunger caps. The plungers were a little sticky. Got them cleaned up. However, the main issue still appears to be that the rack is solidly stuck. I'm not confident that any amount of soaking is going to resolve the issue. I will leave the IP as-is for a couple of days...

Removed the cover (53) and the inner workings are clean as a whistle. Sprayed with brake cleaner and Kroil. Since those fluids will likely get further into the IP, I'll spray with oil, let that soak, then change the oil and filter after the unit runs a bit. Before resorting to pulling the...

Ok. Good tips all around. I'll get back to it next week.

THANK YOU!! I will try that.

Latest update: Removed fuel actuator/governor without issue. (Reviewed how to reinstall before I took it off). Connected 24v to P10, and the actuator works. Tried to move the part inside the injector pump that the actuator attaches to, but it wouldn't budge. Tried to find that part in the...

The attachment screws on the fuel actuator/governor do not appear to have been messed with. Will get back to diagnosing in a day or so - hopefully. It's hot! Will try to find an appropriate resistor for testing the A6.

MAG Pickup Wire 147C to A-5/17 = .794K ohms Wire 147C to A-5/17 = 2.8VAC Fluctuations A-5/9 + and A-5/10 - = 19.6VDC Wire 153A to wire 192B = stationary around 6.74K ohms (no movement at all throughout entire range of Voltage Adjust Rheostat) Points A-5/6 to A-5/8 = 4.57K ohms A5. Adjustment...

Answer to your question is no.

Diagnosis data: Using Guyfang's A5 GCU diagnostic sequence.... MAG Pickup Wire 147C to A-5/17 = .794K ohms Wire 147C to A-5/17 = 2.8VAC Fluctuations A-5/9 + and A-5/10 - = 19.6VDC Wire 153A to wire 192B = stationary around 6.74K ohms (no movement at all throughout entire range of Voltage...

Yep, this gen set has that mod. I know, because I had to borrow the fuse for another gen set, then I ordered more fuses.

So far, only had a chance to check MPU. It had some debris on it, but no damage. I think it wasn't adjusted correctly before I removed it. When I reinstalled it and adjusted it, my meter was reading 2.8-3.0VAC. Still didn't start. I still think it's a fuel flow issue, but will conduct...

I have the attached info, as well as the process for removing, installing, and adjusting the MPU. What is the original source of the attached? If it's in a TM or other available document, please advise. I'd like to have any info that comes before and after.

I’m not being negative. Just a little frustrated I suppose. I have all the TMs and have adjusted the MPU on other units. I’ve been working on this one on and off for over a year, so I don’t remember if I checked the MPU output. I don’t know what the Quad Mod is. I will check the MPU next week...

Full transparency - I haven’t all 319 pages of threads about generators on SS. I, also, haven’t scoured the TMs - yet. (Probably could have during my surgery recovery, but my mind was on other things.) With that said, our museum has an MEP804A that cranks, but won't start (never has in the 2...

Already replaced it, and the generator is working. Was just inquiring. Really sounds like the idea is not worth pursuing. Thanks.

Kurt fixed me up. I was just asking to see if anyone tinkered with restoring these. Thanks.

Is there anyone out there who repairs HMMWV transmission control modules to original specifications?

I know there are alternatives for the original voltage regulator in a MEP 804-A generator. I already purchased the alternative. Just asking the question. Is there anyone out there who repairs these to original specifications?

I'm a little late to the party, but I have a question. Did servicing and adjusting the MPU fix your generator's "run away" issue?

Thanks again. Didn't realize your "unplug the fault indicator" instruction was addressing that clicking issue. @Light in the Dark - looking for replacement gauges