Volvo penta kad32 problems

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Colin the cat

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Hello all.
I'm having problems with a volvo penta kad32.
I did a filter & oil change last weekend,oil,fuel,crankcase and air filter, since then I can't get it to rev above 2000revs under load.
I''ll rev to max out of gear but I've noticed that the compressor doesn't kick in at all.Now I'm not in the habit of giving it max revs out of gear so,question 1 is,should my compressor be working when it's revving while not under load?
question 2 is why is my engine not running over 2000 revs under load.

I've also noticed that when I push the throttle handle to full open under load,I get a grey sooty like film coming from the exhaust.Would this be semi-burnt fuel?
 
The reason your getting the soot is because fuel is going in the engine but not enough air due to the supercharger not cutting in.

Find the throttle switch on the injection pump, hold a flat blade screwdrivers against it when the engine is at idle, the comp should cut in, if it doesn't then the black box relay has failed, if it does cut in then its either the speed sensor or the fuse , also test the clutch for power it should have 12 volts plus at the plug, the plug is located under the black plastic cover, could it be the belt hats snapped. As you have been servicing maybe you have caught some wiring somewhere for it now not to work. Also check the relay box look at it, does it look burnt or smells burnt? These do fail regularly.
 
Thanks for the reply.
I opened up the black box and found melted circuit board.New 1 is on order and should be here on Wednesday.
What's the usual cause of black box failure or do they just go at random?
 
FlowerPower said:
Often caused by a faulty supercharger clutch drawing too much current and killing the box.
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Not sometimes, always. Fit a new clutch at the same time otherwise you will b buying a new box in a few weeks .

I had a client once who ignored my advise, yes he was back on the phone a month after.
 
I've had the same problem with my kad32.do you need to replace the entire clutch assembly(part#3581724) or just the electrical part of it?
 
OK,so I've replaced the clutch and the relay and I'm still getting the same thing.2000revs max and no compressor.If I unplug the compressor plug and put 12v across it I can hear the clutch engaging but,other than do it that,it's not kicking in at all.
We have a volvo penta dealer here but he doesn't do "leisure engines".
 
Colin the cat said:
OK,so I've replaced the clutch and the relay and I'm still getting the same thing.2000revs max and no compressor.If I unplug the compressor plug and put 12v across it I can hear the clutch engaging but,other than do it that,it's not kicking in at all.
We have a volvo penta dealer here but he doesn't do "leisure engines".
Click to expand...

Place a flat blade screwdrivers across the kick down switch on injection pump while at tick over, does the clutch cut in? If not put multimeter to clutch plug on one terminal you should see 12 volt positive signal attach other lead to earth, do same with screwdriver blade , if still no power then it's a positive supply problem so check input from pop fuse to relay box. Last test is speed switch sensor in front of injection pump, swap from other engine to test if possible. If not test switch for open circuit .
 
volvopaul said:
Place a flat blade screwdrivers across the kick down switch on injection pump while at tick over, does the clutch cut in? If not put multimeter to clutch plug on one terminal you should see 12 volt positive signal attach other lead to earth, do same with screwdriver blade , if still no power then it's a positive supply problem so check input from pop fuse to relay box. Last test is speed switch sensor in front of injection pump, swap from other engine to test if possible. If not test switch for open circuit .
Click to expand...

I'm sure there are better ways to spend a tuesday :confused:
The screw driver will cut the clutch in.WOT cuts the clutch in but only giving 2000revs.
When I put it in forward gear the engine will rise to 1200 fairly easily but after that i get 1200 right up to WOT,then the compressor kicks in and I get 2000revs.
In reverse it's the same story but I get 3000revs.strange thing is the clutch doesn't dis-engage at 2700.it stays on.I did notice that I've got not turbo pressure at all
Out of gear it does exactly what it should do.revs to 1500ish,clutch kicks in,2700 it kicks out.revs freely to 3700 but still no turbo pressure.

I've gone home scratching my head
 
Colin the cat said:
I'm sure there are better ways to spend a tuesday :confused:
The screw driver will cut the clutch in.WOT cuts the clutch in but only giving 2000revs.
When I put it in forward gear the engine will rise to 1200 fairly easily but after that i get 1200 right up to WOT,then the compressor kicks in and I get 2000revs.
In reverse it's the same story but I get 3000revs.strange thing is the clutch doesn't dis-engage at 2700.it stays on.I did notice that I've got not turbo pressure at all
Out of gear it does exactly what it should do.revs to 1500ish,clutch kicks in,2700 it kicks out.revs freely to 3700 but still no turbo pressure.

I've gone home scratching my head
Click to expand...

It sounds like your turbo is not spinning up then or there is a fuel restriction
 
volvopaul said:
It sounds like your turbo is not spinning up then or there is a fuel restriction
Click to expand...

I thought of a fuel blockage from the tank so I connected up a the pipe coming out of the separator to a remote tank with an electric pump.Made no difference.
If I had a failed turbo wouldn't I still get more than 2000revs but with a lot of smoke?

I'm going to investigate the turbo tomorrow when the engines cold
 
Todays adventure went like this.
Took off the air intake from the compressor and turbo to check for blocked pipes,nothing wrong there.Next removed the charge air cooler,checked it for blockages and also checked the pipe from the turbo.
The turbo seems to be spinning freely so I removed the exhaust elbow to check the rotor for movement.everything seems to be ok with it.
I've noticed there's some black smoke,just a whisp though,at 1200 revs just before the comp kicks in at WOT.
I'm thinking a lack of air.
Does the turbo boost gauge measure just turbo boost of turbo and comp pressure?
Is there a limp mode on a kad32?
How can doing a oil and filter change make an engine do this weirdness? because there's another kad32 in the same marina with identical symptoms after doing an oil & filter change
 
Blocked oil intake / return feed pipe from disturbing sludge when carrying out the oil change maybe resulting in a damaged Turbo? incorrect oil viscosity used causing overheat? Have you tried taking off the oil feed and or return pipe and cranking the engine disabling the ignition to see if you're getting a flow of oil to the turbo?
 
colin I take my hat off to you for your persistence but maybe it may be time to call in some professional help, after all we are quickly running out of summer and before long we will all be tucked up in our caravans on water going no where due to bad weather.
 
lanerboy said:
colin I take my hat off to you for your persistence but maybe it may be time to call in some professional help, after all we are quickly running out of summer and before long we will all be tucked up in our caravans on water going no where due to bad weather.
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Like I said at the start of my thread,there isn't a volvo penta dealer within 100 miles of here that'll touch,what they call "a leisure engine" :(
 
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