VOLVO penta engine gremlins

[Cactus Sailing]

Had some issues this weekend with the inboard, it has four buttons on the start panel

Start button
Stop button
Alarm reset
On/off button

Admittedly I left the isolator in over night but I was plugged into the charger but when I came to restart the buttons did nothing, the control box wouldn’t even switch on

Battery voltage was good etc

So I left everything off while I was checking voltage of batteries and switched isolators back on and the control panel beeped back on at the helm

Started engine but it cut out spluttered with stop signal on display

Would not switch back on so I isolated everything waited 5 mins and it started as normal

20mins of motoring later I popped to the fuel berth and needed to switch it off (I had 1/2 tank but wanted to top up) well it just didn’t want to turn off ?!?!?

Used the manual cut off on the engine - filled up started as normal but now the stop button appears to not Be working - any ideas ?

The panel is sealed in at the helm so before I picked the sealant away to test the switches thought id ask for clues? Was working wonderfully only yesterday!

 

[richardh10]

You have my sympathy, as I had this exact same problem. Changed the mdu box (under warranty), didn’t solve the problem. Changed the stop solenoid which did cure it. However, went out last week, after using engine for approx 250 hours last year without any problems, and it all happened again! Called the local Volvo mechanic, who came out and changed the mdu unit again - apparently there has been yet another upgrade. Haven’t had a chance to go out again, but I’m not 100% certain it has been solved, and to say I’m a bit pissed off is something of an understatement.
In a worst case scenario you can unplug the stop solenoid which will mean the engine will keep going, and you can stop it with the manual switch on the engine when safely tied up. Get onto Volvo and tell them the problem. It is obviously an ongoing problem which they haven’t sorted out yet. My engine is a D2-40 fitted Oct 2016. Pm me if you want the full sorry saga!

 

[Neeves]

This is a common problem with the 'D' series - though I thought they had sorted it out. The issue was a poor batch of MDU units (or the sealed unit that replaced the relay box) which have no user servicable parts and cost of the order of Stg150. The situation became so bad last year they ran our of replacement units. They use the same unit on all the engines. There is now a suggestion, in the 2 posts above, there is also another fault in the stop solenoid.

The story I heard was not that they had upgraded the unit but they had received a poor batch.

The whole saga has been downplayed (it seems sufficiently significant a recall would have been appropriate) - but it not difficult to imagine some one losing a yacht when they could not start the engine and had dropped their sails prematurely.

Owners of 'D' series engines need to know how to start by short circuiting the starter motor and how to stop manually - as without this knowledge you could develop a nasty situation.

The fault appears to be around the time of 2015/16 (but may have been earlier - because its been downplayed its difficult to know precisely). Its an international issue - happened in Australia - you are not alone!

When you get the issue sorted - it would be useful if you can post the solution(s) and as much detail of the causes - then others with the Volvo 'D' series might know what to anticipate.

Jonathan

 

[prv]

I don't suppose there's a published range of serial numbers or anything like that? I have a D1-30 with this control system, albeit somewhat earlier than 2015 (not sure of exact date off the top of my head).

For the OP - it sounds like testing the buttons isn't needed, but if you did want to do it there's no need to open up the helm unit. The five-pin cable running to the button panel is simply four switches with a common return (or possibly common supply, I'm not sure which way it actually operates). Unlike the display there are no electronics in the button panel, just the buttons. You can unplug it at the engine end and test it with the continuity setting of a multimeter.

Pete

 

[Ningaloo]

This is a topic that has been discussed at length on the Hanse owners forum. Several boats produced around 2016 seem to have had the MDI replaced more than once. It is reported that the lastest units which have resolved the issue have a serial number starting with letter P.

It is worrying that a failure in this unit makes starting (and stopping) the engine difficult. A safety workaround is described below:

"Solution has been to fit a push button switch on a small panel on the side of the engine next to the MDI. This connects two of the wires under the MDI - the red (battery positive) and the red/yellow (starter solenoid feed). The push button can then always be used to start the engine even if the MDI and/or the engine control panel fail."

 

[Cactus Sailing]

This is a topic that has been discussed at length on the Hanse owners forum. Several boats produced around 2016 seem to have had the MDI replaced more than once. It is reported that the lastest units which have resolved the issue have a serial number starting with letter P.

It is worrying that a failure in this unit makes starting (and stopping) the engine difficult. A safety workaround is described below:

"Solution has been to fit a push button switch on a small panel on the side of the engine next to the MDI. This connects two of the wires under the MDI - the red (battery positive) and the red/yellow (starter solenoid feed). The push button can then always be used to start the engine even if the MDI and/or the engine control panel fail."

I was thinking of fitting a button as a “just in case” as my engine cut out in middle of Portsmouth channel! Scratching around mid channel to find a heath Robinson short circuit lead would be a nightmare

Thankfully there was a little wind in any case - So mooring under sail would have been good practice and I would have just “borrowed” a swinging buoy unitil I fixed it -but it did restart on this occasion and behaved all the way back home

Engine was fitted in 2017 April - for what it’s worth I assume I could disconnect the whole helm control and just put 12v onto the start solenoid if it indeed is the control panel ( I’m thinking of in an emergency wise) the engine is still under warranty so there will be an interesting phone call this morning

ANd it’s a D1-20 F if that makes a difference

 

[Neeves]

You can actually use a screw driver to short circuit the connections down on the side of the engine. But I'm not on a yacht and cannot recall which connections - but an ordinary 150mm long screwdriver is enough.

But you should not need to go to the Hanse owners forum, why would you - if you own a Bav or Benny etc. I accept that suppliers need to subcontract, I also accept that subcontractors screw up and things slip through the net - but its not beyond Volvo's resource to warn customers, tell them about the quick fix, assure them of support and even better - do a recall. There should be no need for users to install a 'just in case' button - its a disgrace that people even need to think this way.

The control box is the same on the 10hp, 20hp, 30hp and 50 hp engine and maybe bigger - its a big issue quietly festering. I guess Volvo have about half the market?? - basically every yacht with a 'D' Volvo unit over the last 24 months? is at risk.

I thought solved - obviously not.

Jonathan

 

[richardh10]

I agree that it’s a disgrace that you need to fit a just in case switch, but I certainly will be before I go out again! If my engine had stopped in the channel coming into Lagos marina, I would have been on the rocks on one side or the other. I can only imagine it’s a matter of time before someone has a disaster

 

[Cactus Sailing]

I agree that it’s a disgrace that you need to fit a just in case switch, but I certainly will be before I go out again! If my engine had stopped in the channel coming into Lagos marina, I would have been on the rocks on one side or the other. I can only imagine it’s a matter of time before someone has a disaster

Do you know whats even more of a disgrace is the company which fitted the engine telling me to deal with a Volvo engine specialist and organise and arrange at my expense and time and claim warranty afterwards. you certainly will get named and shamed once fixed, expect an invoice for my time too in shifting the boat about to get repaired and i aint cheap

^^ and this is a major dealer / service ./ broker in the Solent!!!

What shocking customer service, i had expected " sorry sir we will pick the boat up for you / and or repair at your convenience on your mooring without disrupting you" i know if my car breaks down under warranty they pick the dam thing up and offer me free hire car, Taxi to pick it up, are more than apologetic & clean it within an inch of its life before parking it back on my drive if i so wanted

is it too much to ask ^^ am i a demanding customer really? its 10 months old and i should'nt have an issue with it...

/rant over

but yeah i will fit a switch after this saga or at least research the screwdriver method as i'd hate to be in the middle of a channel entrance and it cut out, could be dangerous in the right circumstance.

 

[Ningaloo]

Although I'm sure it isn't related, I understand that Hanse recently switched back to Yanmar engines, so that will be several hundred engines a year that VP won't be selling.

I agree that it is unacceptable for warranty issues on a component that is known to be faulty to be handled so poorly. I haven't (yet) had any issues with my 2014/15 engine, but I had my B&G masthead wind transducer fail twice and although the item was replaced under warranty, I had to go up the mast to fit it myself. Once again this was a known design fault and other boats reported multiple failures (due to electric static in thunderstorms) before a more robust replacement was delivered.

 

[Neeves]

but yeah i will fit a switch after this saga or at least research the screwdriver method as i'd hate to be in the middle of a channel entrance and it cut out, could be dangerous in the right circumstance.

If its any consolation, which it will not be

I don't think the engine will cut out (that's actually part of the fault - you cannot stop the engine without physically getting at the engine). The fault is - you cannot start the engine - without shorting with a screwdriver (or installing an emergency start switch). But you can still be exposed as we all rely on our engines (and opening up the engine to use the screwdriver trick is really not something you want to do when single handed on a dark night in chop in a busy channel. Stopping the engine is not such an issue, just a nuisance (and not what you bought).

Your rant is perfectly justified - but sadly though the issue has been aired here and on the Hanse forum (and I am sure elsewhere) over the last few months it has had no impact on Volvo (as you attest).

I know about the issue because the local appointed Volvo Service dealer here (one of a few) had a large plastic bag with what looked like around 20 units he had replaced and at the time Volvo had run out of replacements - and he had yachts that could not be used (because owners were, rightly, not prepared to use a screwdriver).

Jonathan

 

[richardh10]

If its any consolation, which it will not be

I don't think the engine will cut out (that's actually part of the fault - you cannot stop the engine without physically getting at the engine). The fault is - you cannot start the engine - without shorting with a screwdriver (or installing an emergency start switch). But you can still be exposed as we all rely on our engines (and opening up the engine to use the screwdriver trick is really not something you want to do when single handed on a dark night in chop in a busy channel. Stopping the engine is not such an issue, just a nuisance (and not what you bought).



Jonathan

Sadly not quite right, as my engine did indeed stop on a few occasions, which was the dangerous part. It was after restarting which was not always immediate, that it would not stop.

 

[Cactus Sailing]

Sadly not quite right, as my engine did indeed stop on a few occasions, which was the dangerous part. It was after restarting which was not always immediate, that it would not stop.

mine too, mine stopped in the channel as the MDI froze up with a stop signal, this happened as i left the fuel berth after posting the OP, i was contemplating sailing to a mooring in 2 knts of wind which would have been difficult but decided to try the engine again and thankfully it switched back on again when i tried, and lukily behaved all the way back home.

if it just didnt stop i dont think i would be that bothered because the mechanical lever is fairly convenient even if not at the helm.

 

[Heckler]

If its any consolation, which it will not be

I don't think the engine will cut out (that's actually part of the fault - you cannot stop the engine without physically getting at the engine). The fault is - you cannot start the engine - without shorting with a screwdriver (or installing an emergency start switch). But you can still be exposed as we all rely on our engines (and opening up the engine to use the screwdriver trick is really not something you want to do when single handed on a dark night in chop in a busy channel. Stopping the engine is not such an issue, just a nuisance (and not what you bought).

Your rant is perfectly justified - but sadly though the issue has been aired here and on the Hanse forum (and I am sure elsewhere) over the last few months it has had no impact on Volvo (as you attest).

I know about the issue because the local appointed Volvo Service dealer here (one of a few) had a large plastic bag with what looked like around 20 units he had replaced and at the time Volvo had run out of replacements - and he had yachts that could not be used (because owners were, rightly, not prepared to use a screwdriver).

Jonathan

A friend of a friend had issues with a 75, he was approaching Cuba with no donk. I was contacted, I said that they could frig it and explained how. I phoned VP in Belgium on the English speaking number. They gave me a case number which I passed on, they sent two boxes to Jamaica straight away, he got them within days. Turned out to be a bad connection!