Kad 44 EDC down in power. boat details, condition of hull/props, and observations lis

Colin P

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This boat/engine is new to me and I have done a lot of work to it prior to sea trialing her. I will list all information and hopefully someone can cast some wisdom onto my problem!

I bought her as a non runner. She was running fine up until she was removed from the water after the starter failed.

The boat lay for two years unused. I have added fresh diesel, diesel bug treatment, checked fuel lines for blockages, replaced both fuel filters replaced both batteries, cleaned all electrical terminals, refurbished starter motor, replaced alternator, engine oil & filter, drive oil, boots, shift cable, shift actuator, belts, refurbished both water pumps, new coolant, air filter, refurbished turbo, new supercharger clutch and oil and replaced the potentiometer (also calibrated by the book)

The hull and drive are spotless both being rubbed down and painted with anti foul.

I do not have prop sizes as she is now in the water but they were the props fitted to her before I purchased the boat and I am told the boat performed perfectly. The tacho does not work. 450 hours on engine.

When I press the neutral button to rev the engine out of gear it only rev´s so high (30% on the throttle). When I push the throttle further to WOT it does not rev any higher

I assumed this was a neutral limiter so the engine cannot be rev´d to high in neutral. Does anyone know if this is true?

I have the same problem when I put the boat under load. Engine reaches the same rpm and will not exceed it.

There is no black smoke or any of that matter. Just fuel smoke on start up.

The kompressor engages when cold and when loaded (new clutch and oil)

When I load the boat in the bay the kompressor engages but the turbo doesn´t seem to ´come in´.

There are no ´whoosing´ noises indicating a boost leak.

The turbo to aftercooler pipe is in place with a new clamp and the o rings are present. New turbo clamp and gaskets.

The only thing that I noticed while on the water today was that one the bungs on the inlet manifold had vibrated loose. I initially though I had the problem solved.

There was no ´huge´ rush of air from the inlet manifold while this bung was missing. I replaced it by hand including the brass washer. I know if should be tighter but I had no tools on board today. I checked all the other bungs and they were tight.

So I have nothing abnormal that I can see! No exhaust or air leaks. Can anyone explain where to connect a boost gauge or shed some light on my suspected throttle neutral limiter?

Thanks!
 
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Throttle limiter in neutral is normal for EDC engines - 1500rpm.
Have you checked the turbo can spin freely (by hand) ?
 
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Yes prior to fitting it after it was refurbished by a well know British company so I doubt there are any issues with the turbo.
 
It would be good to know the inlet manifold pressures in the supercharger range and turbo range (under load). A mechanical gauge can be fitted into the inlet manifold where one of the plugs are. An exact rpm achieved under load would also help.
 
Did you check the fuel filters again after running?
You say the supercharger kicks in - what speed rpm do you get under load?
 
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Have you had a look at the exhaust bend... just after turbo ?? Not always noticable but rust builds up where raw water hits exhaust... and restricts exhaust flow... if restricted this may be a problem area as engine cannot get rid of exhaust gas / raw-water fast enough....
 
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