Volvo EC60E Excavator Pre-Heat System: Importance and Troubleshooting

[MikePhua]

The Volvo EC60E is a mid-sized crawler excavator designed for both construction and earthmoving applications. One of the essential systems that contribute to its reliability and longevity is the pre-heat system, which ensures the engine operates efficiently, especially in cold weather conditions. Understanding how the pre-heat system works, its benefits, and how to troubleshoot related issues can help operators maintain optimal performance and avoid unexpected downtime.
Overview of the Pre-Heat System
A pre-heat system is designed to prepare the engine for startup, particularly in cold environments where the oil and coolant might be too thick, and the engine might be harder to turn over. The Volvo EC60E features an engine pre-heat system that helps to warm up the engine oil before starting the engine, reducing wear during cold starts and ensuring smooth operation.
The pre-heat system in the Volvo EC60E is typically activated by the operator via the control panel, ensuring that the machine is adequately warmed up before being put into operation. This is especially important in colder climates or during winter months when machines are more prone to difficult starts.
Why Is Pre-Heating Important?
Pre-heating is essential for a variety of reasons, primarily to ensure that the engine starts and runs smoothly:
1. Reduces Engine Wear
Starting an engine in cold conditions without pre-heating can lead to unnecessary wear. Cold oil and thickened coolant make it harder for the engine to turn over, and the additional strain can lead to long-term damage. Pre-heating warms up the engine oil, which allows for better lubrication, thereby reducing friction and wear on engine components.
2. Ensures Quick and Efficient Starts
Cold starts are more difficult and time-consuming, especially in machines like excavators that work in harsh conditions. A pre-heat system ensures that the engine is more likely to start quickly and efficiently, saving time and reducing the strain on the battery and starter motor.
3. Protects the Fuel System
Diesel engines, which power the Volvo EC60E, are especially sensitive to temperature. Low temperatures can cause the fuel to gel, making it harder for the fuel to flow through the system. Pre-heating helps ensure that the fuel is at an optimal temperature for smooth combustion.
4. Boosts Fuel Efficiency
When an engine starts smoothly and is properly warmed up, it can operate more efficiently. Cold starts lead to incomplete combustion and higher fuel consumption. Pre-heating minimizes these issues and ensures that the engine performs optimally, improving fuel efficiency.
How the Pre-Heat System Works on the Volvo EC60E
The Volvo EC60E’s pre-heat system consists of several components working in sync to ensure that the engine is ready to run:
1. Glow Plugs
The primary component of the pre-heat system is the glow plugs. These are used to heat the intake air before starting the engine. When the system is activated, the glow plugs warm up to help ignite the fuel more easily during startup.
2. Electrical Heater
In addition to the glow plugs, the Volvo EC60E also uses an electrical heater to warm the coolant and engine block. This ensures that the engine reaches a temperature where oil viscosity is reduced, and the engine components are more easily lubricated.
3. Fuel Heaters
To prevent fuel from gelling, the Volvo EC60E may have an integrated fuel heater that warms the diesel fuel before it enters the engine. This ensures that the fuel remains in a liquid state, allowing the engine to operate without issues, even in extremely cold temperatures.
Common Issues with Pre-Heat Systems and Troubleshooting
Although the pre-heat system is designed to enhance the Volvo EC60E’s performance, issues can arise, particularly as the machine ages. Troubleshooting these problems early can save time and money by avoiding more serious engine issues.
1. Engine Not Starting After Pre-Heat
One of the most common problems reported by operators is that the engine does not start properly even after activating the pre-heat system. This can happen due to several reasons.
Possible Causes:

• Faulty Glow Plugs: Over time, glow plugs can wear out and stop working effectively. If one or more glow plugs fail, the engine may not receive the necessary pre-heat, making it harder to start.
  
• Weak Battery: A weak battery may not provide enough power for the pre-heat system to function properly. This can also affect the starting power of the engine.
  
• Fuel Issues: If the diesel fuel has started to gel due to low temperatures, the pre-heat system may not be enough to prevent a cold start.
  

Solution:

• Check the Glow Plugs: Test the glow plugs for functionality. If they are not working, replace them with high-quality parts designed for the Volvo EC60E.
  
• Inspect the Battery: Ensure the battery is fully charged and has sufficient cranking power to support the pre-heat and start-up process.
  
• Use Fuel Additives: In colder climates, consider using fuel additives designed to prevent gel formation in diesel fuel. Additionally, ensure that the fuel is being stored properly to avoid contamination.
  

2. Pre-Heat System Not Activating
Another common issue is the pre-heat system failing to activate when the operator tries to start the engine. This can be due to electrical problems or sensor failures.
Possible Causes:

• Faulty Pre-Heat Relay: The pre-heat relay is responsible for activating the system. If it fails, the system will not turn on.
  
• Damaged Wiring or Fuse: If there is a wiring issue or blown fuse in the system, the pre-heat system may not be able to function.
  
• Faulty Thermostat or Sensor: A malfunctioning sensor or thermostat could prevent the pre-heat system from sensing the correct temperature and activating.
  

Solution:

• Check the Relay and Fuses: Inspect the pre-heat relay and fuses for signs of damage. Replace any faulty components.
  
• Test the Sensors: Test the temperature sensors and thermostat to ensure they are functioning properly. If they are not working correctly, replace them.
  
• Inspect Wiring: Check the wiring for any signs of wear, corrosion, or loose connections. Repair or replace as needed.
  

3. Excessive Smoke or Poor Engine Performance
Sometimes, even after the pre-heat system is activated, operators report excessive smoke or poor engine performance. This could be a result of improper combustion due to inadequate pre-heating or fuel issues.
Possible Causes:

• Cold Fuel: If the fuel hasn’t been sufficiently heated or the fuel heater is malfunctioning, the engine may struggle to combust the fuel properly.
  
• Engine Oil Thickness: In cold temperatures, engine oil can become thick, reducing its ability to lubricate the engine effectively. Even with pre-heating, thick oil can cause performance issues.
  

Solution:

• Ensure Proper Fuel Temperature: Verify that the fuel heater is working and that the fuel is at an appropriate temperature for combustion.
  
• Use Low-Viscosity Oil: Consider using a low-viscosity winter oil in colder conditions to help prevent the oil from thickening.
  

Conclusion: Maintaining the Pre-Heat System for Longevity
The pre-heat system in the Volvo EC60E excavator plays a crucial role in ensuring reliable starts and preventing wear during cold weather. By understanding its importance and performing regular maintenance, operators can avoid many common issues related to cold starts and maintain the performance of their machine.
Routine checks of the glow plugs, battery, fuel system, and relays can help identify problems early and keep the Volvo EC60E running efficiently. With the right care, the pre-heat system will continue to provide reliable service, allowing the excavator to perform at its best even in the harshest conditions.