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My Mep-803a standby generator project

windyhill

Member
31
16
8
Location
PA
So I thought I'd start a thread on my 803a project. I've wanted a good standby generator for years and stared looking in earnest last spring. After watching auction sites for months I finally pulled the trigger and won a 2010 803a on GP a few weeks ago. I drove out and picked it up in Pa. this was my first experience with buying surplus. GPS sent me to the front gate at the base. I went threw lots of security and after wasting two hours getting checked through security and getting run all over the Military base I finally was told Government Planet pickup was an unmarked gravel drive a few hundred feet before the base entrance and off base! 😡 Darn GPS and darn clueless security! Anyway after I got to the correct location and handed my paperwork to the right person it was rather painless. By the way, thanks to all on this site, So much great info on here and helpful people!
So I'm really excited about my generator and can't believe what good shape it's in. It has 91 actual hours and has never been reset or worked on. Everything is like new, not even any spider webs! Oil and coolant changed in 2015 and only 1 hour run time since. All tools, rods etc. In tool box. Even has a new cd and all the manuals still sealed in plastic. The trailer has LED lights, tires and wheels have the little nibs on the flat parts of the tread still. I paid $3800 which is more then some but I think I got a pretty good deal. Here's some pictures.
 

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windyhill

Member
31
16
8
Location
PA
I put a few batteries in it, checked the oil and it fired right up! one of the return lines was seeping some fuel so I shut her down and started ordering parts. This weekend I did the gauge light mod, I also went on line and after some searching I found some 24v LED white lights. The idea is to replace all the green bulbs with brighter LEDs. When they arrive I'll let people know how they are. I replaced all the return fuel lines, and also drained the fuel tank, (fuel was bright red and clean!) I noticed the bung where the return line goes in has a few cracks, after some reading it sounds like this is common so I ordered two new ones. I also researched batteries. Lots of info on here but I found that the type 34/78 non optima batteries have posts that are to close to the tie down bar and the block for my liking. Supposedly type 34R (reversed posts) aren't easily available, the best match I found was a MT-47/H5-1 It's a near perfect fit, and posts are away from the block.
Mice can be a problem here in PA I wanted to block off the holes in the bottom of the generator housing while batteries where out. I used SS fire screen I had from another project. I will also be adding a acid absorbing mat under batteries just in case to keep everything clean and have a Noco Genius G7200 on order to keep my batteries fresh. Id like to mount it in the cabinet to keep it protected.

Here's where I got fuel return line, great quality and fast shipping good price:
https://www.ebay.com/itm/5-Meter-Ro...e=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2661
Charger:
https://www.amazon.com/gp/product/B004LWTHP2/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
bulbs:
https://www.lightexports.com/led-t6-candelabra-screw-base-30v-e12-warm-white/
https://www.lightexports.com/led-w2-1x4-9d-t1-3-4-wedge-white-24vdc/
Best priced fuel filters:
https://www.ebay.com/itm/Fuel-Water...e=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
https://www.amazon.com/gp/product/B0014BHVEM/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1
Air filter:
https://www.amazon.com/gp/product/B000CSD322/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1
Oil filter, better quality Wix XP:
https://www.amazon.com/gp/product/B00C5TB8ZA/ref=oh_aui_detailpage_o03_s01?ie=UTF8&psc=1
Fuel Additive:
https://www.amazon.com/gp/product/B008MPDJL2/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B007ILFKS6/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
Battery mat:
https://www.amazon.com/gp/product/B00APKZU3C/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1
 

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windyhill

Member
31
16
8
Location
PA
Thanks kloppk! For me it hss been hard to really gauge price as well as there condition of these generators. It did make me feel better when the guy loading it came over and looked at it and was impressed with the condition. He's said he's seen them come through with over 7K hours and still running fine. It's good to hear on the charger, I've had really good luck with my CTEK MULTI US 3300 smart chargers, but I wanted a 24v one I could dedicate to the generator
.
 
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csheath

Active member
714
213
43
Location
FL
Looks like you got the deal of the year. I have seen some crazy prices fetched for much worse looking machines since the last hurricane.
 

Bmxenbrett

Member
602
30
18
Location
NY
You may want to put screens over the intake grates too. Mine has a screen over the bottom hole and still got mouse poop inside.
 

Triton

Active member
240
81
28
Location
Houston, Texas
Nice snag! I have the exact unit in a 2009 model, I noticed your 2010 unit's S-1 switch is the round metal type, mine was the square blue one. Strange how they come out slightly different.
Enjoy!
 

Guyfang

Moderator
Staff member
Moderator
16,761
24,067
113
Location
Burgkunstadt, Germany
Nice snag! I have the exact unit in a 2009 model, I noticed your 2010 unit's S-1 switch is the round metal type, mine was the square blue one. Strange how they come out slightly different.
Enjoy!
Not strange at all. When the government buys several thousand switches, you have to do something with them. Yes version three switch is the best. But you can still use a version two or even a one. They work. You just have to know that they fail earlier. And, you don't HAVE TO BUY NEWER ONES; UNTIL THE OLD ONES ARE GONE. I hate caps lock. Then there is also the problem that the supply activity's often don't REALLY know what, is in what drawer. In 1975, we ordered a new flag for the unit. It came to us in a nice new box. We put it up, and weeks later, our Chief Warrant marched in and asked why we had a 48 star flag on the pole?
 

mcii

New member
72
2
0
Location
Wimberley, Texas
Nice report thanx for the effort.. Tell me/us about your towing setup or experience, I ask because I have an 804 to bring home and just wonder how you did this effort.. thanx mac/mc
 

windyhill

Member
31
16
8
Location
PA
I towed it home with my F350. it pulls great. I got a set of magnet tow lights from Walmart and stuck them on the two tow hook mounts. I checked tires for air and added a little at the gas station before hopping on the highway. The surge brakes worked great, really no issues at all but my trailer is like new. Tires had the nibs on the flat tread still.
 

Zed254

Well-known member
866
466
63
Location
S. Hampton Roads, VA
Tell me/us about your towing setup or experience, I ask because I have an 804 to bring home and just wonder how you did this effort.. thanx mac/mc
Lot of suggestions in this thread regarding trailer recovery: https://www.steelsoldiers.com/showthread.php?172833-Missing-handle-on-a-M116A3-(PU-797-recovery)

In my limited experience the safety chains are usually too short - take some shackles to 'stretch' the chains, need a trailer light kit and zip ties, I've got a Mil trailer to Civ truck connector that I like to use - means I also take extra 12 volt light bulbs, check hubs for heat when on the road and take the tools needed to turn a castle nut on the axle if overheating, pintle hitch, air tank because tires WILL need air, and put the trailer brake levers in up position.
 

windyhill

Member
31
16
8
Location
PA
Well, still waiting on my fuel tank well nuts, and last night we lost power! 803 wasn't ready...but at least I have a backup generator for the backup 803 generator so I was ok. :) So talk to me about fuel senders and gauges. My tank is drained and dry, but fuel gauge is still reading a little over a 1/4 full? I looked inside my tank with a scope light (its clean as a whistle) and float looks new, it moves up and down fine. How should I trouble shoot? I haven't turned unit back on yet because there isn't any fuel, is there a chance it will reset when I do? Also whats the bleeding procedure for getting air out of the system? It was running perfect before, but I've since replaced all the return lines and drained the fuel tank so I'm guessing air is inevitable.

On another note, I got my Noco Genius G7200 charger, and tied it into the slave connector contacts. I want to mount it inside the 803 housing to protect it, but also be easily able to plug it in. I found this nice plug on Amazon. turns out its made by Noco Genius as well! Nice unit, I'm impressed so far with there quality. It will make a clean install, I plan on installing it on the passenger side where there's already a hole plated off.

https://www.amazon.com/gp/product/B009ANV81S/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

Here's a picture of the new MT-47/H5 batteries installed. I'm happy with the fit.
IMG_1826 a.jpg
 

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dav5

Active member
396
183
43
Location
Mono, Ontario
Are you sure you are looking at the fuel level float. It doesn't go straight up and down, the float acts on a pivot arm. Make sure the float almost touches the bottom of the tank when it is empty. There is a thread MEP803A fuel level adjustment that should help.
 
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robson1015

Active member
515
132
43
Location
New Concord, Ohio
Well, still waiting on my fuel tank well nuts, and last night we lost power! 803 wasn't ready...but at least I have a backup generator for the backup 803 generator so I was ok. :) So talk to me about fuel senders and gauges. My tank is drained and dry, but fuel gauge is still reading a little over a 1/4 full? I looked inside my tank with a scope light (its clean as a whistle) and float looks new, it moves up and down fine. How should I trouble shoot? I haven't turned unit back on yet because there isn't any fuel, is there a chance it will reset when I do? Also whats the bleeding procedure for getting air out of the system? It was running perfect before, but I've since replaced all the return lines and drained the fuel tank so I'm guessing air is inevitable.

On another note, I got my Noco Genius G7200 charger, and tied it into the slave connector contacts. I want to mount it inside the 803 housing to protect it, but also be easily able to plug it in. I found this nice plug on Amazon. turns out its made by Noco Genius as well! Nice unit, I'm impressed so far with there quality. It will make a clean install, I plan on installing it on the passenger side where there's already a hole plated off.

https://www.amazon.com/gp/product/B009ANV81S/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

Here's a picture of the new MT-47/H5 batteries installed. I'm happy with the fit.
View attachment 714788
No worries about air in the fuel line as the return fuel line purges the air back to the tank which is vented.
 

windyhill

Member
31
16
8
Location
PA
Thanks for the reply's, I've been searching and reading tons on here but missed some of the info on the fuel well nut threads. Darn! I'll learn my way around here eventually! I had ordered from GMG and it's taking for ever and it was expensive. I Just read the tread about GMG being expensive and slow..and then found the thread on the actual way to fix the tank permanently. Darn! guess I'll be ordering again. Found some threads on the fuel gauge "parking" when off as well. I'll fire it up again after working on fuel tank and see how it goes.
 
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