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Volvo EC15 Starter removal

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  • Volvo EC15 Starter removal

    Hello fellow knuckle skinning fans

    We recently had an EC 15 that had a starter motor that intermittantly wasn't releasing when the engine was started, and continued to 'mesh' with the crown ring on the fly wheel when the engine was running.

    If this was allowed to continue, the motor would burn out, and possibly catch fire leading to an expensive (or catastrophic) repair. The suspected cause was the starter motor relay, but both the ignition switch has to be checked for ingress of water and general failure (if its a canopy machine especially) and the starter removed and inspected for problems with the pull hold circuit and throw out mechanism.

    Well .. starter removal is almost an engine out job on this machine, as one of its major failings is that there is no hatch through from the cab to the engine, to remove it and its on the fire wall side.

    However there are a few things you can do to make your life easier .. but put aside 2 to 3 hours to get the damn thing out.

    First you need to remove all the air filter and fuel filter gubbins .. disconnect all the hoses and remove the plate with 3 bolts ontop of the fuel tank and all the filters will come away.. watch though .. you need to disconnect the air filter sensor connectors and the 12V power outlet socket will still be attached, dont bother with its fiddly 7mm connectors, just undo the 13mm nut on its mount bracket and it slips off the plate

    Then disconnect the fuel send line, the return line, and the breather line and whip out the fuel tank

    Img_1566.jpg

    Underneath it .. as shown above ..disconnect the high pressure pump output line as there is no slack on it what so ever and will not allow you to pull the engine forward

    I have photos of my work, but I only thought about posting it after I had a lot of stuff removed

    Anyway the next thing is to drop off the back ballast at its four bolt fixings and then... use the little free movement on the engine tray, and slide the engine out to give you more room round the back, I've posted elsewhere about doing this, but basically the engine sits in a tray that bolts to the digger chassis in 3 places .... one 18mm bolt on the right under the RAD and 2 on the left as you stand looking at it from the back, the front one is visible but the second one isnt, its recessed under the engine, but theres a hole in the digger floor pan to let you get to it.

    Once you have them removed the whole tray will slide out 2 inches .. not a lot .. but its vital to let you get access to the starter .. and the real bad guy in this job .. the exhaust

    First you need to remove the down pipe from the exhaust manifold

    Img_1567.jpgImg_1565.jpg


    Both these pics have the pipe removed (and the starter cos I took this shot at the end of the job) but you cannot get to the starter lower bolt without taking this pipe off or the manifold sooooooo.. then you have to drop the manifold box off (after undoing the starter harness)

    and its a pig ...... it has two mounting bolts on the top and one you need to get from below

    Img_1569.jpg

    the pic above shows the two bolts on the top mount attached to the engine mount and where they would mate up, with the bolts removed the box is dropped down

    but you need to do the underside one too from below AND the one on the tail pipe attached to the fly wheel housing to allow it to drop completely .. YOU WILL NOT GET ACCESS TO THE BOTTOM STARTER MOTOR BOLT WITHOUT DOING THIS !!

    And to make matters worse the Cunning @*%^$???? at Volvo have put a 15mm nut on a 17mm bolt which you have to work with blind to get these three bolts out, which will then drop the box

    After all of this you will get access to the bottom starter motor 12mm bolt and be able to remove it, and you will have your prize

    Img_1571.jpgImg_1564.jpg

    To finish this story .. the starter was working perfectly after checking !! .. welcome to plant repairs everyone
    Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

  • #2
    Thanks Muz typical designed for assembly not for repairs............some of those designers should be sent out in to the field preferably knee deep in mud to change stuff like that,then I reckon they'd change their mind........................
    A driven man with a burning passion.

    Comment


    • #3
      Originally posted by Stock View Post
      Thanks Muz typical designed for assembly not for repairs............some of those designers should be sent out in to the field preferably knee deep in mud to change stuff like that,then I reckon they'd change their mind........................
      Yep .. got it in one fella .. imagine if the digger had stopped in a busy road crossing works, with a road closure coming to an end and a starter had failed ? .. hopeless
      Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

      Comment


      • #4
        Originally posted by Stock View Post
        Thanks Muz typical designed for assembly not for repairs............some of those designers should be sent out in to the field preferably knee deep in mud to change stuff like that,then I reckon they'd change their mind........................
        Mud? I thought it was COMPULSORY to work on an EC15 in mud.......is there any other way

        Muz, is that the same motor from Diamond Diesels?

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        • #5
          Originally posted by jackpreacher View Post
          Muz, is that the same motor from Diamond Diesels?
          No mate ... a bog standard one out of the fleet But the engines the same .. what do you need to know ?
          Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

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          • #6
            I remembered you'd had issues with the flywheel compatibility when you swapped the motors out - but if that isn't the DD motor then it can't be related.
            Did you get the starter refitted?

            Comment


            • #7
              Originally posted by jackpreacher View Post
              I remembered you'd had issues with the flywheel compatibility when you swapped the motors out - but if that isn't the DD motor then it can't be related.
              Did you get the starter refitted?
              You are correct .. the replacement DD engine came fitted with a starter and crown ring with a different number of teeth IIRC I swapped the ring and fitted the old starter, so the starters would never get mixed up in the fleet ... I doubt it would actually be a major issue on reflection, because the starter pinion is so small compared to the ring, it would still mesh ok, but have the effect of the teeth pitch being a little out, and maybe wear slightly more quickly but not overly so.

              Yes I checked functionality cleaned it and gave it some fresh lube and refitted it.

              I'm kicking myself though .. because one of the silencer box bolts has dropped out , I definatley torqued one up, and the bottom one, but must have left the other slack by mistake .. hay ho .. it should hold ok with the two as they are pretty beefy . I'll maybe see if I can get at it from below, but I doubt it unless the engine is moved out again .. what a PITA
              Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

              Comment


              • #8
                Is this EC15 back 'online' yet?

                Comment


                • #9
                  Yes .. back to work today
                  Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

                  Comment


                  • #10
                    Well that was another starter out today on a different one .... again the motor looks fine .... cant remember how I fixed the earlier one in this thread... must be getting energised somehow after engine start, and I forgot what an utter shit this job is .... I'm remembering you need the following items

                    1. The patience of a saint
                    2. Arms like a gorilla
                    3. Fingers like a midwife
                    4. The strength of specialist goliath, for minature bolts in keyhole spaces
                    5. Every goddam spanner in the box, long ones, short throw, ratchet ring etc

                    Heres some pics of the hoormeister

                    IMG_1038.jpgIMG_1039.jpgIMG_1040.jpgIMG_1041.jpgIMG_1043.jpg

                    With the 12mm spanner finally on the lower nut .. and you cant get a ratchet in there no no no .... nor a ring ratchet, just a plain old ring spanner .. oh and the bolt is torqued to 30000000000Nm .... so you can imagine what its like levering that off with a 5" throw on your spanner
                    Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

                    Comment


                    • #11
                      always sideways shots with Iphones ? anyway ..... can you see the hidden spanner that wee er takes a while to get to
                      Please don't PM me for plant advice.. thanks .. Post in the forum where I will gladly help, as will many of our contributors.. as the info and responses will help everyone else, which is why we exist

                      Comment


                      • #12
                        Any banana spanners Muz
                        A driven man with a burning passion.

                        Comment


                        • #13
                          Originally posted by Muz View Post
                          Yep .. got it in one fella .. imagine if the digger had stopped in a busy road crossing works, with a road closure coming to an end and a starter had failed ? .. hopeless
                          Go find a pikey ..... they'd have it away out the way in a nano second
                          If it's got tracks, wheels, t*ts, or an engine, at some point it's gonna give you trouble!!

                          Comment


                          • #14
                            me ..... an' I thought I'd had a busy-ish day ..... call Stock next time ...... to torch the bas--rd
                            If it's got tracks, wheels, t*ts, or an engine, at some point it's gonna give you trouble!!

                            Comment


                            • #15
                              Originally posted by v8druid View Post
                              me ..... an' I thought I'd had a busy-ish day ..... call Stock next time ...... to torch the bas--rd
                              Yea yea yea
                              A driven man with a burning passion.

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