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Volvo D3 Engine Failure

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Mtf View Drop Down
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    Posted: 22 September 2016 at 14:04
I am wondering if anybody else has had significant problems with their Volvo D3 engine?

Our engine (handed over 22 October 2015) stopped turning the prop whilst we were in the bay in St Helier on the 30 August and we had to be towed back into the marina.

Initial thoughts were that it might have been a wrapped prop, but that was rapidly discounted because there were no signs of anything like that having happened.  Even in "Throttle Only" the engine made a noise that sounded like coins in a washing machine.

It took the local Volvo people about an hour to come to the conclusion that the clutch had gone, they had to order parts but when they took it apart they then discovered there were also problems with the flywheel and they ended up ordering more parts after that.  Needless to say it is quite a difficult to see some of these parts and they can't be quickly and easily inspected.

The Volvo people put the engine back together but during testing they realised that certain components were rubbing inside the bell housing, so they had to stop the engine and open it up again.  I am told that over time bolts will wear free inside the bell housing, fall into the space and cause the other damage.

I realise this information probably isn't detailed enough for the mechanics amongst you, but a report has been put out to the Volvo network and a detailed solution should be proposed in due course.  As we have a standard D3 engine and propeller I assume these problems will be experienced by other owners in due course and you might want to check inside your bell housing.

It is worth noting that this engine is less than 12 months old, we had no obvious warning prior to the event, the problem caused a complete loss of propulsion and it is taking weeks to fix.  Hopefully nobody else is going to end up in this scenario.
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seileren1 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote seileren1 Quote  Post ReplyReply Direct Link To This Post Posted: 23 September 2016 at 09:49
Thank you for your information, what boat do you have and what type D3?

Cheers
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Mtf View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mtf Quote  Post ReplyReply Direct Link To This Post Posted: 23 September 2016 at 15:04
We have a Hanse 575.

Looking up the engine by serial number on the Volvo website, I can see that it is:

Product Name D3-C-INB-4
Product Designation D3-110I-H

For reference I am told that the standard Hanse 575 propeller is a 3 blade folding 23x16 R from Flex-O-Fold, so I believe that is what we have.

On a completely unrelated note to the issue we have I have also been told that Volvo have a service bulletin out which says that this propeller and engine combination shouldn't be run at full power, not that we have ever done so, but it is probably worth keeping this in mind.
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Wayne's World View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wayne's World Quote  Post ReplyReply Direct Link To This Post Posted: 23 September 2016 at 15:12
Mtf,

Our 575, hull 65 fitted with the D3110i is fitted with a Flex-o-fold 24x15R.
Wayne W
Cruising, currently in the Caribbean and will head across the Pacific early 2024
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Mtf View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mtf Quote  Post ReplyReply Direct Link To This Post Posted: 03 October 2016 at 14:44
I am told that the repair of our engine should be completed this week.  I believe the final resolution from Volvo is to adjust some of the tolerances to stop things rubbing.

I am still getting the distinct impression that this problem won't be unique to us.
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