Kad 44 EDC down in power. boat details, condition of hull/props, and observations lis

ColinP25

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Nov 5, 2012
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This boat/engine is new to me and I have done a lot of work to it prior to sea trialing her. I will list all information and hopefully someone can cast some wisdom onto my problem!

I bought her as a non runner. She was running fine up until she was removed from the water after the starter failed.

The boat lay for two years unused. I have added fresh diesel, diesel bug treatment, checked fuel lines for blockages, replaced both fuel filters replaced both batteries, cleaned all electrical terminals, refurbished starter motor, replaced alternator, engine oil & filter, drive oil, boots, shift cable, shift actuator, belts, refurbished both water pumps, new coolant, air filter, refurbished turbo, new supercharger clutch and oil and replaced the potentiometer (also calibrated by the book)

The hull and drive are spotless both being rubbed down and painted with anti foul.

I do not have prop sizes as she is now in the water but they were the props fitted to her before I purchased the boat and I am told the boat performed perfectly. The tacho does not work. 450 hours on engine.

When I press the neutral button to rev the engine out of gear it only rev?s so high (30% on the throttle). When I push the throttle further to WOT it does not rev any higher

I assumed this was a neutral limiter so the engine cannot be rev?d to high in neutral. Does anyone know if this is true?

I have the same problem when I put the boat under load. Engine reaches the same rpm and will not exceed it.

There is no black smoke or any of that matter. Just fuel smoke on start up.

The kompressor engages when cold and when loaded (new clutch and oil)

When I load the boat in the bay the kompressor engages but the turbo doesn?t seem to ?come in?.

There are no ?whoosing? noises indicating a boost leak.

The turbo to aftercooler pipe is in place with a new clamp and the o rings are present. New turbo clamp and gaskets.

The only thing that I noticed while on the water today was that one the bungs on the inlet manifold had vibrated loose. I initially though I had the problem solved.

There was no ?huge? rush of air from the inlet manifold while this bung was missing. I replaced it by hand including the brass washer. I know if should be tighter but I had no tools on board today. I checked all the other bungs and they were tight.

So I have nothing abnormal that I can see! No exhaust or air leaks. Can anyone explain where to connect a boost gauge or shed some light on my suspected throttle neutral limiter?

Thanks!
 

Don S

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

What is the max rpm of the engine under load?

Did you get any fault codes on the control panel?
 

ColinP25

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

4000 I believe, no faults present
 

Don S

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

What model KAD44 is it?
 

Don S

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

3700 to 3900 is max rpm for all of that series those engine under load, so if you are getting 4000 you are under propped. May be why it feels under powered.
Why do you think it feels under-powered?

In neutral, with no load the rpms are limited.
 

ColinP25

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

Kad44edc 260hp
 

ColinP25

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

This engine won't exceed circa 2500RPM turbo isn't spooling and topping out at 8-10 knots estimated
 

Don S

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

I asked "What is the max rpm of the engine under load?"

Your answer "4000 I believe, no faults present"

Now you say 2500, so which is it 4000 or 2500?
If you can't hear the turbo, it's probably defective, new or not.
Have you done a compression test on the engine yet? That would be a good thing.

What is the letters after KAD44? and it's not EDC, that stands for Electronic Diesel Control. It's either a P, or P-A, or P-B, or P-C. Was trying to find out which one.
 

ColinP25

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

I asked "What is the max rpm of the engine under load?"

Your answer "4000 I believe, no faults present"

Now you say 2500, so which is it 4000 or 2500?
If you can't hear the turbo, it's probably defective, new or not.
Have you done a compression test on the engine yet? That would be a good thing.

What is the letters after KAD44? and it's not EDC, that stands for Electronic Diesel Control. It's either a P, or P-A, or P-B, or P-C. Was trying to find out which one.

Sorry I have taken you up wrong. I thought you initially wanted to know the max RPM of the engine which I believed to be around 4000. You have now kindly stated the official max rpm of the engine.

I am getting approximately 2500rpm under full load (tacho isn't working)

I will get the model today wen I am back at the boat. Here's what I have saved on the laptop for ordering spares

Volvo Penta KAD44 EDC KAD44P PS 2204401559 B69061‏

I will strip and check the turbo today and post my findings.

Thanks again
 

Don S

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Re: Kad 44 EDC down in power. boat details, condition of hull/props, and observations

2204401559 is the serial number and told me what I needed, it's a KAD44P-A . That last A is what I was looking to verify.

If the turbo checks out ok, you might want to check the intercooler. If it's partially plugged, only so much air can get past it, and all the air has to go through it to get to the engine.
 
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