I was thinking about this route. There is also a dedicated generator repair place that does large units not to far. I may ask if they are interested & know about doing the rewind if I bring them specs.
@@CallMeColtLLC we always got the specs when the wire was stripped out, wire size, number of turns, type winding, etc. that’s all assuming the wiring is bad
@@CallMeColtLLC You can call around. Highly doubt you will find it cost effective. Local is your only chance. If you have to ship... the juice will never be worth the squeeze. I see lots of comments to get it rewound. I don't think any of them have ever had such work performed. It is pretty much relegated to large industry stuff. 50HP motor in leading eight pole delta configuration, on a 4" shaft with a mount configuration nobody has seen. Hence why they get repaired over being replaced. If you don't have industry pockets they are not going to give up a slot for low revenue non recurring business that could be utilized with repeat customers that don't wince at the estimate, and pay the invoice even at 2x. I'd like to be wrong, and maybe I will be... but I doubt it.
That thing gave it all. Kept up with 20% over rated load for just under 6 hrs, yeah who would have guessed working it to the max on a questionable history would be a great idea.. Its a shame and a hard lesson learned. I would have tested at rated load for the duration test and not worked it to the max.
It was already doomed the more I've learned. Unit for sure had an issue already inside the generator head & it's why it did this. The same generator head it used in the MEP 1050, so the generator head itself can handle the load.
Your spare DCS on the shelf should work in any 1030, 1040, 1050, 1060, 1070. The DCS on boot up reads the engine configuration DIP switch on the circuit board to the left of the CT's and then it operates accordingly. Thanks for posting part 4!
I appreciate your help as well. Yes, I learned that the DCS works across all models. Huge plus on these! I definitely want to get more if I can for a good price point.
Don’t think you made mistakes. These units are rated at 10kw at .8 PF. With the purely resistive loads you used you used you were under the rated output…. I routinely run my 802A at 6.5KW running 100% resistive loads. Don’t be down, you got a deal on the unit and could make that back on parting it out if you wanted. meanwhile you learned lots and made some interesting videos. As others have said, pull the generator head and have it re-wound. Mechanically it’s solid.
If I get the time to do it, I will get it rewound & confirm. Just not sure it's worth taking time away from other things that make me money right now. But, it's there if I get the time!
You can do a stator insulation/resistance check to rule that out. Chances are the excitation fault is occurring because the stator insulation has broken down and is now shorted.
Great follow up video, I think you are correct, it was already having issues and the load test finished it off, not your fault as you did not know, I'm sure you will find another unit for parts. Do you plan on doing any videos on the HMMWV ? Thanks.
I didn't plan to do anything to in depth on the HMMWV since there is a ton of videos on them already. It will stay at my off-grid place. Might just have a quick overview video of it & then have stuff here & there using it.
I think the issue might have been the gen set's ability to shut itself down, when overloaded. That is why I would never do a test run with overload parameters. My test would be to run 80-100% for 6hrs or so with occasional spikes in load. The gen set is able to handle up to 120% of capacity but not the long term. Also there might have been some dirt or critters nest in stator which eventually caught fire or overheated and caused the stator wires to melt. Either or, I would find a stator specialist and rewind it. Should be around 1000 if you take the stator to the specialist and install it after. Good series though. Really enjoyed it.
Thank you. The MEP 802A & 803A can run 120% all day with no issues. This one, after reading more in depth, should be able to do 110% no problem all day. There definitely was an issue already & I finished it off. I could remove it and get it rewound, be I'm not sure the cost & effort is worth it in my situation. It will take me away from things that make me money instead of costing me money. But, it is there if I get the time!
Are the 1040 Generator covers coming out soon on the ebay store?. One of my 531a customers bought one from you before they even bought the generator. very good quality
I hadn't planned to sell them on my store since I didn't think enough people had them, but if there is enough interest, I would consider a bulk order to make it worth while.
Great video and analyzation. I have one just like it and I need the top enclosure metal. Someone sat something heavy on top and destroyed the metal. Do you know where I can get a new or used piece? I'm in the Houston area. Thanks in advance!
I had a few made by my same manufacture that makes them for the other generators I sell for on my eBay store. I hadn't planned to sell them on my store since I didn't think enough people had them, but if there is enough interest, I would consider a bulk order to make it worth while.
@@CallMeColtLLC I'd really like to see inside the control box to see what's going on inside? See if it's all proprietary or if it's off shelf components packaged into a single unit.
Great series! There are things that we know, things that we know we don't know and things that we don't know that we don't know. Best words ever.
Indeed
A lot of electric motor rewinding shops can rewind your stator for a fraction of replacement, my father did this work
I was thinking about this route. There is also a dedicated generator repair place that does large units not to far. I may ask if they are interested & know about doing the rewind if I bring them specs.
@@CallMeColtLLC we always got the specs when the wire was stripped out, wire size, number of turns, type winding, etc. that’s all assuming the wiring is bad
@@CallMeColtLLC You can call around. Highly doubt you will find it cost effective. Local is your only chance. If you have to ship... the juice will never be worth the squeeze. I see lots of comments to get it rewound. I don't think any of them have ever had such work performed. It is pretty much relegated to large industry stuff. 50HP motor in leading eight pole delta configuration, on a 4" shaft with a mount configuration nobody has seen. Hence why they get repaired over being replaced. If you don't have industry pockets they are not going to give up a slot for low revenue non recurring business that could be utilized with repeat customers that don't wince at the estimate, and pay the invoice even at 2x.
I'd like to be wrong, and maybe I will be... but I doubt it.
@@Failure_Is_An_Option The answer is always no until he asks.
That thing gave it all. Kept up with 20% over rated load for just under 6 hrs, yeah who would have guessed working it to the max on a questionable history would be a great idea.. Its a shame and a hard lesson learned. I would have tested at rated load for the duration test and not worked it to the max.
It was already doomed the more I've learned. Unit for sure had an issue already inside the generator head & it's why it did this. The same generator head it used in the MEP 1050, so the generator head itself can handle the load.
Your spare DCS on the shelf should work in any 1030, 1040, 1050, 1060, 1070. The DCS on boot up reads the engine configuration DIP switch on the circuit board to the left of the CT's and then it operates accordingly. Thanks for posting part 4!
I appreciate your help as well. Yes, I learned that the DCS works across all models. Huge plus on these! I definitely want to get more if I can for a good price point.
With the same Dcs work on the 1070 also?
@@MrTurboCowboy Yes, I should have listed it in my reply .
Hey Great breakdown of the situation. I’m hoping getting the rewind will solve the issue. Excellent tutorial
Thank you!
I think it was damaged before and you just tested it over the edge. Bummer, I hope you find another parts one and can frankenstein one together.
I hope I can find what I need or find a place that can rewind it easily.
Don’t think you made mistakes. These units are rated at 10kw at .8 PF. With the purely resistive loads you used you used you were under the rated output…. I routinely run my 802A at 6.5KW running 100% resistive loads. Don’t be down, you got a deal on the unit and could make that back on parting it out if you wanted. meanwhile you learned lots and made some interesting videos. As others have said, pull the generator head and have it re-wound. Mechanically it’s solid.
If I get the time to do it, I will get it rewound & confirm. Just not sure it's worth taking time away from other things that make me money right now. But, it's there if I get the time!
Someone has battle shorted that unit.
Very possible!
You can do a stator insulation/resistance check to rule that out. Chances are the excitation fault is occurring because the stator insulation has broken down and is now shorted.
Right... everybody has the ability to perform a dielectric withstand test...
According to the TM, without the special tools, it must be removed from the unit to do so or you'll get false readings like I said in the video.
Great follow up video, I think you are correct, it was already having issues and the load test finished it off, not your fault as you did not know, I'm sure you will find another unit for parts. Do you plan on doing any videos on the HMMWV ? Thanks.
I didn't plan to do anything to in depth on the HMMWV since there is a ton of videos on them already. It will stay at my off-grid place. Might just have a quick overview video of it & then have stuff here & there using it.
I think the issue might have been the gen set's ability to shut itself down, when overloaded. That is why I would never do a test run with overload parameters. My test would be to run 80-100% for 6hrs or so with occasional spikes in load. The gen set is able to handle up to 120% of capacity but not the long term. Also there might have been some dirt or critters nest in stator which eventually caught fire or overheated and caused the stator wires to melt. Either or, I would find a stator specialist and rewind it. Should be around 1000 if you take the stator to the specialist and install it after. Good series though. Really enjoyed it.
Thank you. The MEP 802A & 803A can run 120% all day with no issues. This one, after reading more in depth, should be able to do 110% no problem all day. There definitely was an issue already & I finished it off. I could remove it and get it rewound, be I'm not sure the cost & effort is worth it in my situation. It will take me away from things that make me money instead of costing me money. But, it is there if I get the time!
Damn that is an expensive test. I work on home (portable) generators and when you burn the windings up it’s terminal. It’s going to be expensive.
It is what it is. Will be used for parts. Got it cheap enough.
So in your opinion is the 803A a better or more robust unit?
I don't have enough time using the MEP 1040 to make that call yet.
Thank you for your service
Much appreciated
Better it fails during a test than when you actually need it 😢
Very true
Are the 1040 Generator covers coming out soon on the ebay store?. One of my 531a customers bought one from you before they even bought the generator. very good quality
I hadn't planned to sell them on my store since I didn't think enough people had them, but if there is enough interest, I would consider a bulk order to make it worth while.
Quick question ,do you have any suggestions on where I can find the battery for the Tactical Hybrid 3KW Generator
I don't know what that generator is & have been learning about them for a long time.
Great video and analyzation.
I have one just like it and I need the top enclosure metal. Someone sat something heavy on top and destroyed the metal.
Do you know where I can get a new or used piece? I'm in the Houston area. Thanks in advance!
I don't know about sourcing the sheet metal on these. Even the older ones, the real only way is to get it from a person parting them out.
Thanks.
If you ever run across one, please send me a note.
Nice video! Where did you source the cover for your generator?
I had a few made by my same manufacture that makes them for the other generators I sell for on my eBay store. I hadn't planned to sell them on my store since I didn't think enough people had them, but if there is enough interest, I would consider a bulk order to make it worth while.
Get a mega and test the windings. You just guessing at the moment. If it's burned out get it rewound
Meggar the generator.
I hope you are able to find a stator. Without having to auction a kidney.
Yes, me too. Or, find a place that will rewind it for a reasonable cost.
Maybe you can find a electric motor shop that can rewind the generator head or get a quote at least you may be surprise
Was thinking about this after the posting the video.
Shop around get it re wound 16:12
Was thinking about this after the posting the video.
@@CallMeColtLLC I'd really like to see inside the control box to see what's going on inside? See if it's all proprietary or if it's off shelf components packaged into a single unit.
Too bad you can't get into Nikola Tesla's head for the answers!
I'm not that smart!