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If the connector on the generator still has the cap ( could see the chain), you should be able to screw the two caps together while in use and connected to keep crap and water out of the caps. Watch that you don’t lose the rubber gasket in the cap. Robert

Can you share the story on how you found one new in the wrapper? Robert

I believe he meant to exercise the switches that you can turn from the outside of the panel. I only have 804s in that series but on mine, there is a rotary switch to the right of the main start switch. You will need to flip the control panel down (at least on an 804) to gain access to the back...

Also, when you start one of these, you hold the switch in start for several seconds after the oil pressure stabilizes. It is slight overkill to hold it that long but it doesn’t hurt anything and you have to excite the generator head. It feels like you are going against everything you were ever...

Do not change between single and three phase unless the unit is shut down. During engine start, do not release the start switch until the oil pressure stabilizes and add about 5”, it will not hurt the unit. Robert

Just save “44-12 100 amp connector” in your searches on eBay and be patient. Also, just put that in your searsch engine and see what comes up. In the meantime, you should be able to unbolt that female connector and go direct to the output lugs through the new hole in the side of your...

Moreso on the older sets like 002s and 003s, not as much on the 80x series but worth checking. It seems like the rotary switches need to be exercised and cleaned sometimes. Get a can of DeOxit from ebay (tuner cleaner may work if it is still made), douch it real good into every crevice/hole...

Not to be a jerk but it ran at 416v. Perhaps something put wrong when switching to 208v? I have done it on my 804s but can’t recall the steps right now. I don’t remember if the 3 amp is supposed to be a slow blow type either. Robert

I bet a split bolt electrical connector of the proper size should work. Go to Lowes or HD and buy some that look about the right size, you can always return the unused ones. Robert

In addition to always holding the start switch on for ~10” min, get a can of DeoxIT contact Cleaner D5S6 from ebay (~$17), open up behind the control panel (unit shut down) wiggle every connection. Spray into the rotary switches and cycle around 50 times and spray again and cycle again. You...

When I first started to work (play?) with military generators, it felt extremely wrong to hold the switch in start for so long. This went against everything I had learned about starting engines my whole life. My MEP 003a requires one to hold the switch in start for at least 25”, I guess the...

Search msp6729 on the big auction site. It is 3/8-24 unf-2a. Should be under $20. Robert

Here is the MPU on my 804a. In this case, the crap on the end was the problem. Another time the end had been damaged and I had to replace it. Pictures would help. Below where you type a message, hit go advanced, then hit manage attachments, then upload your pictures. If I can do it , anyone...

On my 804a generator, your symptoms along with still not getting fuel would point me to checking the magnetic pickup (mpu). Sometimes the magnet collects funk so that it does not see the motor spinning and doesn’t let the fuel pass. On the 804a, it is on the same side as the injector pump and...

On the second picture, you can see 16-10. The others probably have a number if you can look straight at the plug. Putting 16-10 military connector in ebay brought up several that looked correct and the descriptions had more complete part numbers but they look to be pretty proud of them. Robert

As Guyfang said above, have you verified that the engine is in the rpm ballpark? I am not very familiar with a 004 but I do have a 003 and 804s. On the 003 and I believe the 004, you have a throttle which is not present on the 80X series. I once had the spring slip on the throttle when I...

So to recap a bit. You need 460v 3 phase to run your pump. A 804a or b ( or a 004) will get you in the ballpark with 416v 3 phase and you will need to check your motor tag to see if that is close enough. You can increase the voltage some but not sure what that will do long range to the...

Are you holding the switch in start at least 10” after it cranks and runs? Robert

Nice setup, does your tank holder have two or three uprights or do you lower it down from the top? Robert

In your searches, don’t ignore the MEP 804b. It has a Yanmar turbo diesel engine. The 804a has the Isuzu with a mechanical main fuel pump. I have both and think my 804b is more reliable than the 804a. I have never had a problem with the 804b and it will handle the starting of a FDECU-5 (5...