Volvo EW160B Starting Hot Problem: Troubleshooting and Solutions

[MikePhua]

Introduction
The Volvo EW160B is a popular wheel excavator used in construction and heavy-duty operations. However, like many machines, it can develop issues over time. A common problem faced by operators of the EW160B is difficulty starting the engine when the machine is hot. This issue can cause significant downtime and delays in operations, making it essential to understand the potential causes and solutions.
The Problem: Starting the Volvo EW160B When Hot
One of the primary concerns raised in the forum post is the starting difficulty that occurs when the machine has been running for a while. After the engine is turned off and left to cool, it can start without issues. However, when trying to start the engine while it is still hot, the operator finds that it either struggles to turn over or won’t start at all.
This issue can happen with various types of machinery, and while the symptoms are clear, identifying the exact cause can be a bit more complicated. Several factors could contribute to hot-starting issues in the Volvo EW160B.
Potential Causes

1. Fuel System Problems:
   One of the most common causes of hot-start issues in any diesel engine, including the Volvo EW160B, is problems with the fuel system. When the engine gets hot, it can cause the fuel to vaporize or become less dense, making it harder for the fuel system to inject it into the engine. This could result in incomplete combustion, making it difficult to start the engine.
   
2. Weak Battery or Electrical Issues:
   Another possible cause could be a weak battery or problems with the electrical system. If the battery is not providing sufficient power to turn the engine over when it’s hot, it may struggle to start. The heat can also exacerbate any existing electrical faults, leading to inconsistent power delivery.
   
3. Starter Motor and Solenoid Issues:
   The starter motor or solenoid may also play a significant role in hot-starting problems. Over time, the starter motor can wear out, or the solenoid may not engage properly when the engine is hot. A faulty starter motor will struggle to engage the engine, especially under high temperatures, leading to difficulties starting the machine.
   
4. Heat Soak Problems:
   Heat soak refers to the condition when the engine or parts of the starting system get excessively hot after the engine has been running for a while. This can impact components like the fuel pump, starter motor, or even the battery. These components may work fine when the engine is cool but struggle when exposed to the high temperatures of the engine bay.
   
5. Crank Position Sensor Failure:
   In some cases, the crank position sensor, which determines the engine’s position for proper starting, may malfunction due to heat. A failed sensor will prevent the engine from turning over properly, especially when it’s hot, as it sends incorrect signals to the engine’s control unit (ECU).
   

Troubleshooting the Issue

1. Check the Fuel System:
   Inspect the fuel system for any leaks or signs of wear. Consider replacing the fuel filter and checking the fuel lines for any blockages. Additionally, verify that the fuel tank is clean and that no contaminants have entered the fuel system. If vapor lock is suspected, the fuel return lines should be inspected for proper function.
   
2. Test the Battery:
   Measure the voltage of the battery when it is hot and cold. A healthy battery should deliver a strong 12-13 volts. If the voltage drops significantly when hot, it could indicate a failing battery that needs to be replaced. Check the battery terminals for corrosion and ensure the connections are tight.
   
3. Inspect the Starter Motor:
   The starter motor and solenoid should be tested for proper function. If the starter motor is worn or the solenoid is not engaging, it could be preventing the engine from starting when it’s hot. Replacing the starter motor or solenoid may be necessary.
   
4. Look for Heat Soak Damage:
   To solve heat soak issues, check the positioning of components within the engine bay. Ensure that the starter motor and solenoid are not too close to hot components that can increase the temperature around them. In some cases, heat shields or thermal barriers can help protect critical components from excessive heat exposure.
   
5. Test the Crank Position Sensor:
   The crank position sensor can be tested using an OBD-II scanner to check for any error codes. If the sensor is malfunctioning, it should be replaced. Testing the sensor while the engine is hot can help identify intermittent failures due to temperature changes.
   

Conclusion
A hot-starting issue in the Volvo EW160B can be caused by several factors, ranging from fuel system issues to electrical failures. Identifying the root cause requires systematic troubleshooting and may involve inspecting key components like the fuel system, starter motor, battery, and crank position sensor. By addressing these areas, operators can resolve the issue and prevent further disruptions, ensuring that the Volvo EW160B runs smoothly, even in hot conditions.