One for Spannerman or Volvopaul or anyone else, HELP?

[wakeup]

Hi Guys, Wondering if you can help me diagnose a problem with a 3yr old D4 260hp. The unit will happily run for an hours at lowish revs trolling up a river then when going into min revs or neutral to min revs usually when I am mooring the engine stalls. It starts every time immediately after ward no problem but then stalls again at min revs one in gear ditto going into reverse. The problem is intermittent and tends only to happen if the engine has been running for at least 20 mins. I've changed the batteries, all now good, changed the primary fuel filter and no evidence of contamination, treated the fuel with doses of Grotamar. There is no water in the fuel. Yesterday it stalled three times in succession so I was able to note the diagnostics. The Warning triangle with the '!' marker lights up but I could not tell in the sun if it was red or orange. I then tried accessing the diagnostic codes after ward and all I got was the repeated flashing of the warning triangle '!' flashing red and orange alternately, no morse code. The D4 manual suggests that there is a critical fault with the fuel system but doesn't elaborate, could this be a real error or a sensor, fuel seems clean and filters too and no problem at high revs, turbos and supercharges are able to wind up and clearly get enough fuel to put the boat on the plane as usual. I guess I am going to have to call out a Volvo guy with laptop etc but just wondered if I have missed something. Thanks in advance for any ideas or help.

 

[rafiki_]

Sounds to me like the engine idle is too low when the engine is hot, so the additional drag of engaging gears causes the stall. What are the revs?

 

[wakeup]

don't know exactly, may be 600 o 800 but guessing, the idle rate doesnt sound too low

 

[rafiki_]

I'm not personally familiar with the D4 260, but it might have a stepper motor to raise the idle when there is drag on the engine. It might be this that is not responding correctly, but will only show on a diagnostic.

 

[gingie]

the engine can have the rpm increased but you need vodia to do this.

complete stall could be fuel starvation. the engine ecu needs to see atleast 110bar on the fuel rail or it will shut the engine down dead. if you recrank the engine the pump builds up the pressure again but once load on if the pressure doesnt incresae for demand then it stalls.

be worth checking filters, non return valves, fittings. an air leak will causes same symptoms. does the primer bulb on top of the fuel filter suck down when the engine is about to die? watch it as this is a good indicater for fuel starvation.

might also be worth trying to have gear control recalibrated maybe an issue with that.

dodgy eprom valve on the pump can cause this symptom too

 

[wakeup]

Thanks Ginigie I will have a good look at your suggestions thanks.

 

[spannerman]

You really need to get the codes read as there are so many parameters that can trigger a fault on the Volvo system, at least then you won't waste time or money checking/changing things that are OK. My first reaction is that the idle could be too low as diesels just don't stall, the ECU will hold the idle speed automatically assuming the right speed is programmed in to start with, and it is adjustable via the EVC control panel depending on which version (A,B.C,) you have, the procedure is in the Volvo engine paperwork which should follow with the boat, its a big sheet which shows calibration and set up procedures.

 

[wakeup]

Hi Spannerman, thanks for the info, I have had the boat since new but I have only had the operators manual supplied and a service manual, I am sure I've never received a configuration sheet of any sort. Is this something Volvo would have sent me or the boat dealer?

It does seem to be pointing towards fuel starvation at low revs, I am not sure which rev of EVC I have. I only have the basic control panel with the D N and Backlight control plus the EVC dial announcer lights. Is it possible to tell. When I hold down the D button for five seconds the '!' light just keps bliniking but doesn't give a morse indicator for the actual malfunction. The operator manual states that the only condition that results in an engine shut down rather that a reduction in revs in a severe problem with the fuel system.

 

[gingie]

sounds like you have evc-b going by the button pack you have.

i would still have quick look at fuel system yourself if you know your way with spanner and filter wrench then call in for diagnostics.

 

[wakeup]

Thanks, I have already changed the primary pre fuel filter, haven't change the fuel filter on the engine side, will look at this next and keep an eye on the primer when putting into gear. Other than that I guess I need a voida to read the error codes.