MEP-002a only outputting 125v

[Cm131]

@Ray70 thank you for the input!!
@Chainbreaker
Good eye as I saw the two in the very front and two on top. Not sure why. Maybe it sat outside? The access door doesn’t seal well. Once I get it figured out I will fix that as well. @Guyfang pointed out the different stud nut on L1 that I hadn’t noticed. Without a doubt someone has been in the box changing something. According to @Guyfang 5k box mine is definitely different (10k). Is there a way to convert this to work with the 5k that I have. If so what needs to be changed or how do I go about doing it? @Guyfang I had the thought earlier today to pull the box and go one by one with the wires but wanted to wait and hear what you guys had to say. I don’t mind doing the work as long as it’s doable. Would it be better to try and source a 5k box. Not sure what’s involved to get this to work with my 5k set or how expensive a replacement box would be. Anyone have one for sale?

 

[Guyfang]

The only thing that needs to be changed is the wires wrapped around and through the CT's and then the R3 needs to be adjusted. That procedure is in the -34. Not hard. So if you disconnect everything, that would mean the wires to the CT's anyway. A tip, there are two different Phase selector switches. Both types are in the -34 TM, and that helps with re-hooking them up. Lot of work, and don't drink beer or spirits while doing it. Do not attempt doing this on the machine. You will cripple yourself. Take the box off, and put it on a work bench. I would print out all the wire diagrams, and have them handy. Laminate them. Your dirty paws will make them up readable. Clean it all up, fix as needed. Good time to do it is when the Old Lady is mad at you.

 

[Chainbreaker]

Yep, as I recall the -002a Output Control Box has 8 loops (need to verify) through the transformer not 4 as yours shows, so that's a 10k -003a box. Again, from recollection I think your in luck that the winding loop count is the only difference. But need to verify, I know there is a thread somewhere from a ways back discussing the differences to convert from one to another configuration.

Edit: Guy beat me to the draw and has explained the differences very well! I'm glad my hunch that it is a -003a (10K box) has been confirmed by "MEP Master Guyfang"!

 

[Guyfang]

My cheeks are red!

 

[Cm131]

Thank you both @Chainbreaker and @Guyfang! I will be looking this info up in the manuals and see what I can figure out. As far as adding the wire wraps back is there a certain wire I need to use? Do you know where I can find it? I’m assuming not at the big box store. I will also try to find the post where someone else made the swap but I have trouble finding things from past post. However I will look as I think that would be a big help as well.

 

[Chainbreaker]

edited above...Guyfang is now all RED /\

 

[Chainbreaker]

I seem to recall a member that had bought the required Output Control box wire that goes through the transformers. It might have been @Ray70 ...

 

[Guyfang]

Or are you talking about wire wraps? OH! Cant remember the English word........ Wire ties?

 

[Mullaney]

Or are you talking about wire wraps? OH! Cant remember the English word........ Wire ties?

.
Zip Ties maybe?

 

[Guyfang]

Thats the words I wanted. I am old and in the way.

 

[Chainbreaker]

Or are you talking about wire wraps? OH! Cant remember the English word........ Wire ties?

I took it as relating to your post #22... as in the wires wrapped (looped) through the current transformers. As in the specifications for those wires... gauge etc.

 

[Cm131]

@Ray70
Can you advise if you have the wire I need or if you can tell me what wire to use?

Also is there a wiring diagram specifically for the 002 showing the wire wraps?

 

[Chainbreaker]

This might prove helpful... Can't believe I found it on SmokStak. It describes the differences between the -002a box & -003a Output Control Box in detail. Get ready to do some deep dive reading. Lots of info to digest but I think it might get you what you need... hopefully!

Mep 002a vs mep 003a voltage / phase switch boxes | Smokstak® Antique Engine Community

 

[Cm131]

This might prove helpful... Can't believe I found it on SmokStak. It describes the differences between the -002a box & -003a Output Control Box in detail.

Mep 002a vs mep 003a voltage / phase switch boxes | Smokstak® Antique Engine Community

Thank you @Chainbreaker ! I was just reading that earlier. However I’m a little confused because in his case he is removing wires but I’ll have to add them. But to me it looks like the manuals use the 003 windings for illustration. Also I can’t find in the TM about where the 002 connects since it will have more connections I’m assuming.
He is using an 002 for his 003 and I’m using an 003 for my 002

 

[Chainbreaker]

Thank you @Chainbreaker ! I was just reading that earlier. However I’m a little confused because in his case he is removing wires but I’ll have to add them. But to me it looks like the manuals use the 003 windings for illustration. Also I can’t find in the TM about where the 002 connects since it will have more connections I’m assuming.
He is using an 002 for his 003 and I’m using an 003 for my 002

Yes, your going from a -003a box & need to convert to -002a Output Control Box. I will see if I can find detailed pictures of -002a box internal wiring configuration, or good schematic depicting it better... somewhere.

 

[Ray70]

I should be able to provide you with whatever you need.
I have a couple spare ( partially disassembled ) parts Ac connect boxes from 002's
I have all the wiring, switch breaker etc. whatever you need.

 

[Cm131]

I should be able to provide you with whatever you need.
I have a couple spare ( partially disassembled ) parts Ac connect boxes from 002's
I have all the wiring, switch breaker etc. whatever you need.

@Ray70
Thanks Ray. I definitely need some items. Problem is I don’t know exactly what. How do I get in touch with you so I can get some parts on the way.
I believe I need to get at least the wiring for sure for the CT’s, breaker as mine feels weak and one terminal seems a tad loose, and possibly a switch! If you know of anything else I’ll take it. I need to get this up and running sooner than later if at all possible.
I also had planned on getting a spin on oil filter as well but I would like to get this working properly first.

 

[Cm131]

@Chainbreaker

If you could that would be a great help. I’m not sure if I’m making this harder than it is. This is the first diesel motor I have worked on and first gen set I have messed with. I can do the work if I can figure out what I need to do connections wise.

 

[Chainbreaker]

I dunno... the more I look at one attempting a conversion of a -003a Output Control Box to a -002a configuration the more tempted I would be to locate a MEP-002a Output Control Box if any are out there.

I see lots of work & patience to perform a conversion with having to remove parts inside the very tight box to gain access. That's a 10lb box with 90lbs of parts & wiring stuffed inside! If only it had a backside access cover that could be removed...

It's not impossible but looks tedious & time consuming to rewire the transformer as lots of stuff would be in the way & have to come out just to gain access to turn screws to detach & rewire the transformer wires.

Now I know why I buy spare generators...

 

[Chainbreaker]

If you can find a MEP-002a genset advertised for sale nearby that has problems with let's say... the engine, fuel system, or whatever & the "Output Control Box" is intact & looks good inside you might be better off going that route.

I've seen units advertised as not running go for a song. That way, not only do you get the correct Output Control Box...that works hopefully (you can closely inspect & take the front & top cover off of easily to look inside)... but you also receive a lot of other spare parts that you might need down the road. Granted not all the parts work or it would be advertised as running. Just gotta inspect carefully & hope for the best.