Volvo penta KAD32 P wont rev past 2500

[daleburt]

My volvo penta KAD 32 p wont rev past 2500 when it's in gear.
when the throttle is pushed forward it will rev to 1500 and the compessor cut in but after the throttle handle has gone past 1/2 way the revs wont rise past 2500.
I've disconnected the throttle cable and tried it by hand and the result is the same,no rev increase past 1/2 throttle.so it's not the cables.
The fuel,oil and air filters have been changed but made no difference.

Out of gear it revs past 4000 with ease.

Any ideas??

 

[Don S]

Re: Volvo penta KAD32 P wont rev past 2500

Did this just happen all of a sudden, or was it good one day, as it is now the next.
Is the compressor still running at 2500 rpm when the rpm's stop going up?

 

[oz4winnsH180]

Re: Volvo penta KAD32 P wont rev past 2500

I had a similar issue once fitting a brand new coil module. Apparently volvo have had issues with coil modules. Once i replaced it with another, it ran fine.

 

[Don S]

Re: Volvo penta KAD32 P wont rev past 2500

I had a similar issue once fitting a brand new coil module. Apparently volvo have had issues with coil modules. Once i replaced it with another, it ran fine.

When was the last time you found a coil module on a diesel engine ??????????????

 

[kahuna123]

Re: Volvo penta KAD32 P wont rev past 2500

There's only two reason a diesel won't run. Air or fuel. If you are making black smoke its not getting enough air or is being overworked. If not look elsewhere.

 

[QC]

Re: Volvo penta KAD32 P wont rev past 2500

I understand your point, but oversimplified, especially in this case . . .

Run? Yes. Low Power? Lot's of stuff can cause that Timing, fuel quality, governor issues, Air fuel ratio, turbo, intake restriction, exhaust restriction, injectors. Low speed (boat speed) can be totally unrelated to the engine, bottom condition, propeller condition etc. Define "overworked". Not being argumentative, but the engine runs, and reaches high idle out of gear. This is not as simple as air and fuel being present.

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

Don S.yes it did it all of a sudden.1day it was running great next day problems. The compressor is still running at 2500.
I was down at the boat today and noticed that,when revving it out of gear, the compressor is cutting out aroud the 2550 mark but the I'm not sure that the turbo is kicking in above 2500.I can't hear a turbo whine and the turbo housing isn't getting any hotter than the rest of the exhaust.should I be able to hear the turbo? what temp should a turbo housing be?
also,if it helps,there is no smoke of any colour when the throttle is wide open,just no revs

 

[QC]

Re: Volvo penta KAD32 P wont rev past 2500

The turbine housing shouldn't be hotter and there will be very little turbo whine or speed in an unloaded condition. It's really just spinning along not doing much until you have some real fuel flow (load) which there isn't any until you put her in gear.

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

I've just replaced the fuel filter and seperator again(the last 1s are only 3 weeks old) and managed to get 3600revs for 10 minutes then back to 2500 again.
I tipped out the contents of the seperator into a clear container and there isn't water in it.
Stumped!!

 

[Don S]

Re: Volvo penta KAD32 P wont rev past 2500

Air leak in the fuel system is the first thing that comes to mind for me.
Which filter did you change? Do you have any other filter before the engine mounted fuel filter? I know I see almost every Volvo has a Racor 500FG filter before the lift pump.

Hook up a 6-8" piece of clear hose between the fuel line and the lift pump. Then when running check for air bubble. You shouldn't see any.

 

[QC]

Re: Volvo penta KAD32 P wont rev past 2500

I was thinking something similar . . . and I should disclose that I have zero Volvo diesel experience, but shouldn't she smoke white if there is air in the fuel?

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

There a fleetguard ff105 filter before the engine filter and I changed them both.I'll give the clear pipe a go tomorrow and see what happens.

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

Well,i eventually managed to get a clear pipe fitted between the filter and the fuel pump,ran it at WOT but didn't see any sign of air bubbles.
I'm trying to get hold of a service manual for it but can't seem to find 1.Local volvo dealer can't even get me 1.

 

[Don S]

Re: Volvo penta KAD32 P wont rev past 2500

Did you do your test under load, ie in the water at WOT?

Manuals aren't a problem, try the first 6 downloads in the link below.

http://www.4shared.com/account/dir/sharing.html#dir=11431605

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

The boats in the water and all the tests a done,either,tied to the jetty or out in the bay.
I was down at the boat again today and checked all the filter seals and re-bled the fuel system.same resultd.
I did notice that when it's in forward gear thhat from 1/4 throttle(approx 1400 revs) until nearly full throttle that there is hardly any increase in revs,then at WOT the compressor kicks in and it instantly revs to 2600.so for 3/4 of the throttle lever travel there is no rev increase.
Its like its not getting enough fuel then all of a sudden its getting its getting enough for 2600 revs but no mre than that.
Out of gear if revs smoothly to 4000ish.
Thanks for the manual link but every time i click on it it comes back with "The file link that you requested is not valid".
I downloaded 4shared but that made no difference.
Just something else that i cant get to work :facepalm:

 

[Don S]

Re: Volvo penta KAD32 P wont rev past 2500

They are .pdf (Adobe Acrobat) files. You need the free Adobe Acrobat Reader program on your computer to open them.
http://get.adobe.com/reader/

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

I've got the up to date version of adode.the link send me to 4share but then it says its invalid.I tried doing a search on 4share but it only finds manuals for 4.3 & 5.0l engines and 280dp outdrives.
If there was water in the fuel pump would that give me these symtoms.If it does then is there a drain on the bottm of the pump somewhere?

 

[Don S]

Re: Volvo penta KAD32 P wont rev past 2500

Ok, had to logoff at 4shared to see it doesn't work anymore. They did something different there, they always change things.

Anyway here are the manuals seperately. Hopefully they work.


http://www.4shared.com/document/P1WC708n/41_Fuel_and_Lubrication_System.html?
http://www.4shared.com/document/ou2dtM2J/41_Intake_Exhaust_Cooling_Syst.html?
http://www.4shared.com/document/AIMNwIVK/41_Wiring_Diag.html?
http://www.4shared.com/document/_XYHAfUv/7741725_Engine_Body.html?

 

[daleburt]

Re: Volvo penta KAD32 P wont rev past 2500

they downloaded this time.Thanks for that.I'll go and have another look armed with all the info.Hopefully it'll spead some light on the problem