Volvo Penta engines, Nimbus motor cruisers

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cellis

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22 Aug 2005
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Dear All,
This story is offered by way of a warning to owners of recently-purchased vessels equipped with Volvo Penta diesel engines as currently installed in Nimbus motor cruisers.

My wife and me were recently asked by a friend and his wife to accompany them on their first cross-channel voyage in their Nimbus motorcruiser - we having sailed to France and the Channel Islands on a number of previous occasions (though never before in a motor cruiser).
Their Nimbus is powered by a single 300hp (or thereabouts) Volvo Penta diesel and was purchased new from Nimbus UK approximately 6 months ago.
At the time of the crossing earlier this month, the engine had accumulated approx 50hrs running time.
Whilst the outward voyage was not without its moments and disappointingly slow, I'll confine the story to the homeward leg from Cherbourg to Poole that was started at midday with a full fuel tank, in near perfect conditions - no wind, flat sea, cloudless sky, excellent visibility.
Again the speed was disppointingly slow (around 13kts) but there were no indicated problems and with plenty of daylight in hand we made pleasant and reasonable progress.
However, some 30 miles south of Poole, approximately half way into the busy south-west bound traffic separation lane, I noticed some unwanted smoke and vapour in the exhaust and my friend confirmed that he was losing power.
Apart from the tacho now showing 2500 revs with full throttle a quick review of the panel guages revealed nothing untoward so the engine was throttled back and the engine hatch was raised.
To say that everone was absolutely horrified and dismayed to witness the engine compartment awash with diesel, spraying around under high pressure would be an understatement of the first order - A large freighter perceived by some onboard to be bearing directly down on us only added to their understandable horror.
At first the source of the leak could not be determined other than it was roughly top centre of the engine. A number of close inspections with the engine stopped similarly revealed nothing.
We finally confirmed that there was a hairline fracture in No3 (?) fuel injector pipeline, on a short vertical run just above the injector.
With nothing available to effect a proper repair it was decided to concentrate on suppressing the spray (by relocating an anti-vibration clamp and judicious use of tea-cloths) and get out of the shipping lane as quickly as possible.
With the situation by then under a reasonable level of control it was decided to limp onwards to Poole, hoping that the fuel would last the distance.
Suffice to say it didn't - due mainly to a strong, adverse tide as we approached the Dorset coast.
Fortunately we managed to make contact with the skipper and mate of a Poole-bound yacht, explained our plight and asked them to keep an eye on us while we continued.
When the engine finally and with no immediate warning died close to Swanage Ledge, the yacht crew reacted extremely quickly, rapidly dropping their sails and, to their great credit and our huge relief, had us safely in tow within 15 minutes.
By later that evening we were safely back in Poole and on the following day a Nimbus-arranged repair was carried out to my friend's apparent satisfaction.
I personally am not so easily impressed and decided to email Volvo Penta Head Office in Sweden to express my deep concern and dismay that such a simple but safety-critical component on such a new engine could fail as described.
Predictably, my email was simply referred back without direct comment to the VP(UK) office (in Watford?) who apologised for the distress caused but said they could not comment until they had further information, etc., etc. Contact information was provided and nothing more has been heard to-date.
On reflection, we could regard ourselves as unlucky at what transpired on what was after all a confidence-building trip for a person new to channel-crossing but I believe we were extremely lucky that such a potentially catastrophic experience took place in near perfect sea conditions and visibility and that we were blessed with the assistance of a very able and obliging yacht crew.
So, to anyone out there with comparable craft and engine installations I would earnestly recommend that they contact Volvo Penta for assurance (if not a thorough physical inspection), that the problem is not a design defect or manufacturing batch problem.
Coming from the yachting fraternity, I remember clearly around 4 years ago a major problem with a Volvo Penta engine widely used in yachts that was persistently ignored until VP were finally forced to concede under weight of evidence and support of the yachting press and others.
I hope this is of assistance to those to whom it might concern.
Regards,
Chris Ellis
ellis@canddee.wanadoo.co.uk
 
May I enquire, the outward journey was “disappointedly slow” were checks made to condition of engine at arrival on other side of channel, had 50hr service been carried out, also interested to know what model of engine has friend’s boat got please?
 
seem to remember something similar (engine room dripping with diesel and bilge alarms going off as a result) as a result of a fuel line failure. That time it was in rolly seas off Brittany. Dont think the marine life in Roscoff appreciated it either!
 
How easy is it to get to your engines.

Wether your boat brand new or ancient having it conk out on you in the middle of nowhere is a stressful experience,this having happened to me on a couple of occasions.It does make you however very aware that stuff does go wrong,so when returning from any trip and before starting out,I always lift the hatch,just to look for signs of leaks/weeps or mebbe even just extra belt dust anywhere.A couple of times just about to close lid and happen to notice one of the drive belts lying busted on the floor.
Being bit paranoid my first reaction at summat not feeling right would be to stop,not just carry on regardless and check for obvious problems.This problem could have just possibly been avoided by lifting that hatch cover .
However the fashion for hiding the boats oily bits under one carpet and two bits of furniture is for another thread entirely.
 
Something odd here...

Seems unusual that one failed fuel line can have such a dramatic effect. At cruise, we burn about 12 gal/hr across 2 x 230hp KAMD43P's. That's 6 gallons per engine per hour, or 1 gal/cylinder/hr. If I disconnected one fuel line, and crossed from Poole-Cherbourg-Poole, I would probably find 8 gallons or so in the bilge - hardly enough to make me run out of fuel.

Also, I recently replaced 4 injectors on the same engine, of which two were siezed solid, and did not allow any fuel through at all (the other two were hosing, so probably producing some power at higher revs), yet we were still able to manage 28 knots and only noticed the excessive smoke when we came down to idle.

Cracked fuel line apart, it sounds like something else is wrong here. What is the design speed of the boat with that engine?
 
[ QUOTE ]
the speed was disppointingly slow (around 13kts) but there were no indicated problems

[/ QUOTE ]
as you mention it it would seem to me that this was indicating a problem. I also run a single engined boat and have learn't the bitter lesson that everything has a cause; and not all causes as benign.
when the engine bay was checked after the outward trip was there no evidence of any problem then? is it believed that the fracture only occurred shortly before the loss of power on the return journey?
 
Single 300hp odd? So taking a wild guess, having looked at the Nimbus web site, perhaps the boat is a 340 Commander or 29 Nova with probarly Volvo Penta D6-310 or maybe a late KAD300 in the Nova

The 29 Nova indicates 30kts + performance, dont see any figures listed for the Commander but to my mind 13kts does sound poor....

Like Autopilot says, were pre trip checks carried out either side of the crossing, first service as scheduled on new engine, had that happened?

So many variables here as to what cause the apparent failure of this fuel pipe.

Lesson learned here re single engine boats and maybe having suitable selction of repair 'get ya home' kit to hand?
 
Hi Wiggo just a small point re your comments, fuel used is totally different from the amount that is used by the system to lubricate and cool etc the excess which can be more than the consumption is returned after the injectors, also I am not sure on the fuel capacity of this Nimbus but some models do seem to have a very small tank,but I do take your point
 
Chris, I think your experience was very stressful but actually it is quite unusual for a mobo to conk out completely. Firstly, it is a big argument for having a twin engined boat. Secondly, with any single engined boat, it is always a good idea to have a get you home auxiliary engine, usually the tender engine which can be bolted on the transom although obviously steering it is not easy. Thirdly, I do suggest that your friends learn a bit about their boat and engine. From what you say, the boat was not performing well on the outward leg which would have alerted any experienced skipper that there was a problem. Was the engine checked in Cherbourg? My guess is that if anyone had looked in the engine bay, there would already have been diesel in the bilges and the problem could have been sorted in port
 
Don't know about the D6, but the KAD 4x series injectors will return very little fuel from the spill rail. The injector pump recycles a bit of fuel but that is low pressure, and is returned to the fuel intake (I think) rather than the tank, but this wouldn't be affected by a split fuel pipe in any case. The injectors are cooled by the water gallery in the head as well as by the fuel, AFAIK.

Actually, it must be a KAD4x engine, cos the D6 is common rail...
 
I had exactly the same thing last summer.
My boat has a single KAD43.
It had the first service at 20 or so hours.
The high pressure injector pipe to No3 cylinder fractured at 60 hours An inch or two from the injector.
Same result. A gallon or so in the bilge but more worryingly diesel mist everywhere. The vapourised fuel was forming a liquid again and dripping off the alternator and electrics, it was just everywhere.
Interestingly this is a six cylinder engine and there was very little (noticeable) loss in performance. Obviously there must have been some but not dramatic unless looking for the last drop of go.
I always check the engine before going anywhere so at worst it could have been broken and leaking for max an hour or so and there was maybe less than a gallon leaked out.
Fortunately ours happened while blasting (18Kts!) through the Solent so whilst still being traumatic and very messy not like being in a shipping lane.

Someone said that the problem in your case could possibly have been avoided by lifting the hatch cover. Possibly but only if the fracture had already occurred before lifting. Those pipes carry enormous pressure and you would have no chance of knowing in advance of this sort of failure mechanism.

Someone said carry get you home gear or spares. Not sure what get you home gear would help in this situation and spares are out of the question. My engine has six injector pipes, all different lengths etc and they are around £200 ++ each. Would you buy a spare set just in case.

Mine was repaired under warranty and I got good service from both the dealer and Volvo who said the usual, "never heard of that before, it must be an isolated incident" yeh, yeh. I worked in the diesel engine business for 35 years and thats just the stock answer.

I am convinced there is a manufacturing or materials problem in those pipes but its not worth getting worked up about as you will never prove it. My bet is that there are lots of similar failures going on.

I would have thought the Nimbus would be similar performance to my Beneteau so if you only managed 13 kts I would say it was something more than a single injector pipe failure causing it. We were cruising at 18 kts and only noticed the problem when we slowed down going into Osbourne bay, then the whiff of diesel wafted up to the flybridge. Not nice!!

Just a comforting thought for you. I am now a year on and the smell of diesel has almost gone!!!!!
 
I will reserve comment until Chris has responded to the points made, yes carry a spare engine if you need to because you can’t be arsed to check out 13knot performance on a cross channel trip!!

Seriously though it is obviously a worry, my stance on single / twin engine arguments is going to get me into trouble soon (sods law) especially as I am going across channel next week weather permitting.

Mind you one of those nice RNLI twin engined jobs could come out if I need them after all I am an offshore member now! (just joking)
 
[ QUOTE ]
Don't know about the D6, but the KAD 4x series injectors will return very little fuel from the spill rail.

[/ QUOTE ]

I had some figures from Sealine on this for the KAD43 The engine will take 30% of the flow on tickover and 70% on full throttle.
 
Not so, surely! The spill rail only takes the fuel that leaks back through the needle valve into the top of the injector body. The governor in the injector pump should make sure that the fuel being delivered is what is required. Assuming it's a rotary injector pump rather than a DPA, then the pump itself will recirculate fuel, but not back to the tank.
 
Too late to help but I think I would have taken the risk and taken some fuel out of the bilge and put it back in the tank if at all possible, worst you could have done is block the filters (did he carry any spares??) and maybe require the tank cleaning once safely back alongside - maybe even jury-rig a manual bilge pump to return it to the filler????

Just thoughts and it may not have been possible with the equipment you had but it seems a shame to have a stopped engine and a boat full of diesel at the same time!
 
The Volvo Penta D6-310 appears to have a common rail system. The pump supplies fuel at high pressure to the common rail which feeds all of the injectors. The injectors are electronically controlled to open and inject the required fuel into the cylinders. If the common rail fractured then large amounts of fuel could be lost and the pressure supplied to all of the injectors could be reduced causing the loss of performance noted here.

Without common rail, each of the high pressure pipes only carry fuel for one injector and the quantity is metered by the pump so the amount lost would be comparatively small.
 
One cheap spare that may have helped would be some self amalgamating tape, and I mean the proper thick stuff that turns into an almost solid lump when applied under tension. Doubtful it would stop the leak, esp if common rail, but would certainly have slowed the flow. £4 a roll I think.
 
Doubt it. Not sure what the injection pressure is on that engine but it will be running into hundreds of bar. Way back when I used to claibrate injectors it was a big safety issue cos when fuel comes out and vapourises under that kind a pressure it will cut straight through lots of stuff. Especially your finger so if you get such a leak dont go near it!! Only thing to do is wrap a rag round it to stop it vapourising and filling the whole engine room then get back to port. I did think of cutting the pipe and crimping it over with mole grips clamping it but that would just guarantee no back up from VP. If I was a long way from home it may have been a last resort.
 
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