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831a - Tier two replacement engines

Mac3715

New member
11
0
1
Location
Glen Gardner, NJ
First time post here. I can clearly see great forum with knowledgeable members.

The 831a looks like a very good machine for a small emergency gen set. I see many tier 2 engine replacements. Does anyone know why so many engine failures? Did Yanmar have an engine manufacturing problem. I would have thought that Yanmar was bulletproof.
--- mac ---
 

jamawieb

Well-known member
1,435
557
113
Location
Ripley/TN
Most of the time when they return from service, they went through a tier 2 replacement. Tier 2 is when the machine is rebuilt to new standards and several parts are automatically replaced no matter what, that includes engines. They wanted these machines to be like new again for another deployment. It could have a perfectly good engine but they replace it to reduce failure rates. I don't know what the hour limit was for the 831as but the 803as and 802as was around 3500hours.
 

Dewie38

Active member
152
189
43
Location
Milford Ct
3.9 Life (endurance) requirements. The set shall operate for 1500 hours without critical failure at all loads, continuous and intermittent, up to and including rated load under all of the conditions specified. The set shall have a minimum life of not less than 6000 hours.
 

jamawieb

Well-known member
1,435
557
113
Location
Ripley/TN
TABLE 2. Generator Set Hour Point for TIER 2 RESET
Generator Size
and Type
Model Number
Hour Meter Reading
2 kW MTG
MEP-501A/531A
2500
2500
3 kW TQG
MEP-831A/832A
3500
5 kW TQG
MEP-802A/812A
3500
10 kW TQG
MEP-803/813A
4500
15 kW TQG
MEP-804/814A
5000
30 kW TQG
MEP-805/815A/805B/815B
5000
60 kW TQG
MEP-806A/816A/806B/816B
2500
3 kW Mil Std
MEP-016B/701
2500
3 kW Mil Std
MEP-016D Yanmar L70
2500
3 kW Mil Std
MEP-016E Yanmar L100
4000
5 kW Mil Std
MEP-002A
4000
10 kW Mil Std
MEP-003A /112A
5000
15 kW Mil Std
MEP-004A /113A
5000
30 kW Mil Std
MEP-005A /114A
5000
60 kW Mil Std
MEP-006A /115A
6000
100 kW Mil Std
MEP-007B
3000
5 kW APU
MEP-952
4000
10 kW APU
MEP-903A/903B/903C
1.6 The requirements of this Technical Bulletin. The requirements of this Technical Bulletin shall take
precedence over the TM or OEM requirements. As each engine NMWR is published, that NMWR shall
take precedence over the engine requirements in this Technical Bulletin. Questions about conflict
between this Technical Bulletin and other referenced documentation should be directed to the CECOM
Generator Branch RESET Team (DSN 992-1313, generatorreset@mail1.[url]http://generators.tpub.com/TB-11-6115-741-24/TB-11-6115-741-240013.htm[/url]
 

coxju04

Active member
100
55
28
Location
Avery, Tx
I have a one that does not have a tier2 reset tag, but it does have a rebuild date tag only. everything on the genset looks new
 

90cummins

New member
28
0
1
Location
Florida Ma.
Having purchased and repaired 2 of the L70 air-cooled Yanmars to make my own generator I can add some details here.
First as was mentioned some of these engines may have been replaced due to the refurbishment requirements and are in fact fine.
However the 2 I received had issues.
The first one skipped at high speed.
Teardown & inspection revealed filthy internals with a dark brown very hard to remove varnish coating on everything.
The camshaft injection lobe had deep corrosion pits that affected the injection event.
The cylinder bore was polished also.
Other than the camshaft & varnish coating on all internal parts it was serviceable.
I ordered a new camshaft, rings, seals & gaskets and cleaned all parts and honed the cylinder and reassembled.
The engine runs perfectly and is now a backup power source.
The main issue with these engines occurs when operated in cold environments with little to no load. With no load the engine cannot warm up enough to keep moisture from collecting in crankcase oil and it causes corrosion and cylinder glazing which is fatal to it's long term operation.
The corrosion damage appears to happen after the engine is returned to storage and allowed to sit for long periods of time.
The camshaft corrosion occurs at the point where the cam lobes and valve lifters come to rest together.
I would like to add that this scenario is also possible during the warmer summer months if operated in a low load condition for many hours.
The manufacture (Dewy I believe) makes a kit for cold weather operation that keeps a constant minimum load on the engine to keep the unit warm and helps minimize these situations.
Air-cooled engines are at the total mercy of the ambient temperatures and can prevent them from warming up to an acceptable level for proper operation.
The 2nd engine had similar issues although not as severe, it is currently being used as a backup generator.
90cummins
 
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