sticky rod on diesel fuel pump

simonfraser

simonfraser

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kad 44 edc
VP tech plugged in his laptop
rod % shows 50 on startup
disengage gear, move dash lever forwards to give more revs
and the % goes down to 2
engine switches off

error fault shows as code 2.2 = connection fault or sleeve issue inside the fuel pump

do i have the fuel pump serviced or exchange one ?
 
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Simon, I had the same issue (screeching, stalling, hunting, error 2.2) and it was fixed by cleaning the connections and changing the battery and charger.

I believe in an earlier post you had concerns about your battery / charging system. Get those checked before you start messing about with the injection pump (which are normally very reliable).
 
simonfraser said:
engine cutting out when revs increased beyond tick over
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have you/volvo measured the electrical resistances at the injection pump plug? It's in the electrical manual - I can email you a copy if you need it. It could be a wiring issue - I think either way it could be pump to bits time to sort it out. There are loads of youtube videos on Bosch VE EDC controlled pumps and how to take them apart if you are tempted to have a look yourself. They are not especially complicated, just need to keep things clean.
 
kashurst said:
have you/volvo measured the electrical resistances at the injection pump plug? It's in the electrical manual - I can email you a copy if you need it. It could be a wiring issue - I think either way it could be pump to bits time to sort it out. There are loads of youtube videos on Bosch VE EDC controlled pumps and how to take them apart if you are tempted to have a look yourself. They are not especially complicated, just need to keep things clean.
Click to expand...
And you need the special Bosch tool to remove the top cover , this can be changed without taking the pump off .
But it’s not a difficult job to remove the pump .
 
tnx guys, the VP engineer appears to be quite carefull as in checking the connections out first b4 pulling it out of the boat
at least the access is good for this problem
recon it is heading for a bosch engineer

the sudden loss of revs now and the 2.2 rod error is now ringing a bell
i changed the props a few years ago and could not get max revs with any of them, the engine revs suddenly reduced when reaching about 3750
reduced only a bit, but a very sudden hessitation
i did check the revs with a tacho at the time, the VP rev on the dash was accurate

so i recon it was possibly sticking then already ?

what does happen when max revs are reached, it just does not go any higher or it stutters ?
 
I cam across this video yesterday....

Diagnostic session with Volvo Penta KAD44 - ScanMarine V15.30 - YouTube

What's interesting is that at 26 seconds in it shows a 2.2 error with the description "Too low voltage on sender signal" which corresponds with my experience that the error is caused by poor condition batteries, and not a fault with the sensor / pump itself.
 
petem said:
I cam across this video yesterday....

Diagnostic session with Volvo Penta KAD44 - ScanMarine V15.30 - YouTube

What's interesting is that at 26 seconds in it shows a 2.2 error with the description "Too low voltage on sender signal" which corresponds with my experience that the error is caused by poor condition batteries, and not a fault with the sensor / pump itself.
Click to expand...

interesting, def not low battery, but could be low voltage at the supply to the pump ?
poor connection ?

engineer is at the KAD now
 
according to VP man, no error codes now with the pump back on
i shall be running it again connected to the hose this sunday
there is little water sunday and not enough to bring it back to the trailer later if there is a delay due to a 'problem'
if, sorry, when, it runs correctly i will be putting it in the water next weekend

according to VP man Bosch now clean the pump out before they test it, and it tested -ve once cleaned
so i guess we will never know if it was dirt or not
the circular power cable connector from the pump to the KAD could also be suspect ?
i am tempted to see if i can support / tie that one on to something to stop it from flapping about
will check the voltage on the black relay box above the water pump too, that is at least near the power supply to the fuel pump, cant see where else i could check the supply to the injection pump ?
any thoughts ?
 
simonfraser said:
according to VP man Bosch now clean the pump out before they test it, and it tested -ve once cleaned
so i guess we will never know if it was dirt or not
the circular power cable connector from the pump to the KAD could also be suspect ?
i am tempted to see if i can support / tie that one on to something to stop it from flapping about
will check the voltage on the black relay box above the water pump too, that is at least near the power supply to the fuel pump, cant see where else i could check the supply to the injection pump ?
any thoughts ?
Click to expand...
Hi Simon, can you clarify what you meant in bold above? Are you saying that they cleaned it and tested it to find no faults?

I assume that the pump is wired directly to the ECU which has a regulated power supply (assuming it's a 'C' series KAD). If you have an earlier series please say.

It's definitely worth checking and thoroughly cleaning all connectors, particularly the circular injection pump connection that you have identified above and when it connects to the ECU.
 
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