KAD 44 EDC running issue, videos enclosed

[simonfraser]

Apologies for starting another thread on this same issue, but the other threads getting messy

Few weeks ago doing 3000 revs on the plane, clutch slipped and kad cut out straight away
I limped home on low revs as it did cut out again when rev past 800

Was showing 2.2 fault on VPengineer laptop, I saw this myself
Fault cleared by VPengineer and it appeared again when engine run again above 800
Bosch cleaned injection pump and it tested ok after their clean
They don't test 'dirty' pumps on their rig according to the local VPengineer

VP engineer has no idea as to what the problem is, no fault showing on the dash 1.1

Idles at 500 no prob
In the video I am very gradually increasing the revs

Vid running on solar and battery 13.6V revs not stable above 800, engine cuts out

Vid with shore charger too 14.4V revs not stable above 900, engine keeps going

Tnx for all your comments and Petem charger suggestion

 

[petem]

Apologies for starting another thread on this same issue, but the other threads getting messy

Few weeks ago doing 3000 revs on the plane, clutch slipped and kad cut out straight away
I limped home on low revs as it did cut out again when rev past 800

Was showing 2.2 fault on VPengineer laptop, I saw this myself
Fault cleared by VPengineer and it appeared again when engine run again above 800
Bosch cleaned injection pump and it tested ok after their clean
They don't test 'dirty' pumps on their rig according to the local VPengineer

VP engineer has no idea as to what the problem is, no fault showing on the dash 1.1

Idles at 500 no prob
In the video I am very gradually increasing the revs

Vid running on solar and battery 13.6V revs not stable above 800, engine cuts out

Vid with shore charger too 14.4V revs not stable above 900, engine keeps going

Tnx for all your comments and Petem charger suggestion

Is there some safety code that has been triggered in the KAD due to the sudden propulsion loss ?

Symptoms are the same as we had. I'd be interested to know what your battery voltage is if you left it overnight with the fridge on and no charger / solar plugged in.

 

[simonfraser]

its fixed !! ?

as shown in the previous vids the rev counter does not match with what the kad is actually doing
so i guessed / figured with help from this fanstastic forum, thank you, that it might be the speed sensor
i did not know it even had a sensor until i bugged you all , told ya, i am no engineer
i ordered a volvo truck sensor which according to google was the same
just slapping another part on is not what VP is all about so they were cautious in me blowing the budget, £40 ...

VPengineer pulled the old sensor out today after removing one black U shaped part from the back of the KAD
i have some planks that run accross the KAD, that was very helpful as he needed to lie on top of the KAD with his arms stuck down the back of the KAD to access the speed sensor
he had just been to a shaft driven KAD 44 and checked out where the rev sensor was, that made things a bit easier
the old sensor had picked up a load of cr@p iron filings and was not within 'range' as far as the resistance was concerned
junked the old sensor and fitted the new one

we also ran the starter with a vacuum hose over sensor the hole
and we ran the starter with a small metal brush over the flywheel to remover some more cr@p, VPengineer idea
success, it runs perfect up tp 1500 revs, which is all it will do on the trailer fed by a hose

happy days, i have my boat back for the weekend

so i actually had three !! faults all in one day
slipped cone clutch - fixed
rod issue in fuel pump, 2.2 fault - fixed
contaminated speed sensor - fixed

 

[petem]

Glad you fixed it Simon! And buying the part has saved you a few quid from the VP prices and saved a second mechanic visit.

Where's my "feeling smug" emoji....

sticky rod on diesel fuel pump

 

[bowler]

Great news. Quite a journey!

 

[simonfraser]

Great news. Quite a journey!

yeh, one i could have done without, learned a lot !

 

[BruceK]

Well done!

 

[alt]

Happy days. Where exactly is the sensor located? May help others in future

 

[simonfraser]

Happy days. Where exactly is the sensor located? May help others in future

here is a pic of the dirty sensor hole before cleaning
it's just under the black U shaped air intake for the turbo, on top of the flywheel
you can see the steering ram in the image too, so it's not that far down
the electrical connector is towards the port side, not shown in this image
VP engineer had to lie on top of the kad arms down, removed it by feel
the connector is just as 'easy', fingertip job to change it all


VP 'manager' suggested i have the engine pulled and the flywheel sorted if it happens again
wonder how many times i can just replace the sensor instead

same VP person also suggested i'd have to have the turbo and the intercooler off to replace the sensor

 

[volvopaul]

Oh dear a pump job all for the sake of a flywheel sensor , are they really Volvopenta trained engineers .
looking at the colour and rust on the sensor I deduce two issues ,
Your boat has been flooded at some point for water to enter the bellhousing.
or , your bellows failed allowing water to enter through the Jack shaft past seal into bell housing .
no other explanation as to condition of sensor .

 

[simonfraser]

Oh dear a pump job all for the sake of a flywheel sensor , are they really Volvopenta trained engineers .
looking at the colour and rust on the sensor I deduce two issues ,
Your boat has been flooded at some point for water to enter the bellhousing.
or , your bellows failed allowing water to enter through the Jack shaft past seal into bell housing .
no other explanation as to condition of sensor .

tnx Paul, indeed that is what i am asking myself too
the 2.2 fault was def present on the laptop 2x
so you recon the 2.2 was an error on the diagnostic and not a pump fault ?

how do i tell a genuine VP engineer appart from an 'experienced' mechanic who can supply VP parts ?

 

[petem]

Oh dear a pump job all for the sake of a flywheel sensor , are they really Volvopenta trained engineers .
looking at the colour and rust on the sensor I deduce two issues ,
Your boat has been flooded at some point for water to enter the bellhousing.
or , your bellows failed allowing water to enter through the Jack shaft past seal into bell housing .
no other explanation as to condition of sensor .

Is part of the VP training to totally ignore what the error code and workshop manual tell you is the issue?!

In this case the fuel pump seems to have been working fine but throwing a 2.2 error. The speed sensor was knackered (resistance out if range and dirty) and not giving an error.

 

[simonfraser]

Oh dear a pump job all for the sake of a flywheel sensor , are they really Volvopenta trained engineers .
looking at the colour and rust on the sensor I deduce two issues ,
Your boat has been flooded at some point for water to enter the bellhousing.
or , your bellows failed allowing water to enter through the Jack shaft past seal into bell housing .
no other explanation as to condition of sensor .

boat may have been flooded, no rust on the rest of the KAD
the bell housing is just under the bearing for the helmet and that had not been greased for ages
hard grease in it and was leaking, boat mainly used on inland waters before my time
could that have run into the bell housing ?