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The Volvo Way to High Performance
and Reduced Emission Levels
Volvo diesel engines in Volvo construction equipment
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One of the world’s most modern and efficient diesel engines, the
12-litre Volvo D12 was the platform for the development of Volvo’s
new heavy-duty engines. The basic D12 engine design was intro-
duced by Volvo in 1993 and was a revolution in the diesel engine
world. Today all Volvo heavy-duty engines – 9, 12 and 16 litres
– share the same world-leading basic engine design concept.
The secret of good design is simplicity. Our new Volvo diesel
engines meet the latest emissions legislation without requiring any
major changes to the base engine. Much of the development effort
has focused on precise control of the combustion process. Volvo’s
new advanced combustion technology, V-ACT, with internal exhaust
gas recirculation function, I-EGR, brings benefits to users as well as
the environment.
With the new off-road engine generation featuring V-ACT, Volvo
continues to be one of the world leaders in diesel engine design
and emissions control.
Cleaner emissions:
EGR The Volvo Way, I-EGR
By returning a controlled amount of the exhaust gases to the combustion
process, peak combustion temperatures are lowered. This in turn reduces
the formation of NOx. This technology is commonly known as EGR –
Exhaust Gas Recirculation.
V-ACT provides an uncomplicated, efficient solution
for internal recirculation of exhaust gases, I-EGR.
In the heavy-duty off-road Volvo D12D and D9B
engines, the exhaust rocker arm is fitted with a
patented, switchable ‘double rocker’ device
that allows for a small second opening of the
exhaust valve, whereby a controlled amount
of exhaust gas is fed back into the cylinder
during the inlet stroke. This is possible thanks to Exhaust rocker arm fitted with a
the pressure pulses in the exhaust being higher patented, switchable ‘double rocker’
than the in-cylinder pressure during part of the device for Internal Gas Recirculation,
I-EGR (Volvo D12D).
combustion process. The switchable I-EGR
system is electronically controlled by the engine
management system (EMS 2) based on machine
and engine operating conditions.
The engine’s own oil pressure system is used
in an intelligent way to actuate the rocker arm
device. A
The I-EGR is activated at high engine speeds
and loads. At low engine speeds, the I-EGR is Exhaust valve motion
not required and is therefore switched off, en-
Inlet valve motion
hancing engine response and performance.
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The top-of-the range Volvo D16E six cylinder 16.1 litre diesel engine has
tremendous power and impressive torque. The D16E features unique air
handling technology including a switchable I-EGR system that incorporates
a further development of the ‘double rocker’ valve actuation device. In the
D16E, the I-EGR function is performed by a Volvo patented extra rocker
arm, fitted in parallel to the exhaust rocker arm. When needed – at high
engine speeds and loads – this device creates during the inlet stroke,
a second exhaust valve lift that allows a controlled amount of exhaust gas
to return to the cylinder, resulting in reduced formation of NOx.
The enhanced electronic controller with its unique software for each
application controls the electro-hydraulically actuated exhaust valve yoke
movements for optimum I-EGR and engine performance.
Valve mechanism
with extra rocker
arm for I-EGR
actuation, (D16E).
A new generation of
electronically controlled
high-pressure unit
injectors for precise
fuel injection timing,
injection pressure
control and fuel quantity
delivery for each com- Section of engine timing
bustion sequence. mechanism, (D16E).
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Volvo is the world’s largest manufacturer of heavy-duty diesel engines in the 9 to
18-litre category. The Volvo D12 is the world’s most manufactured 12-litre engine.
In 2005, our annual production of heavy-duty engines exceeded 180,000 units.
All told in 2005, 246,000 Volvo diesel engines were manufactured. Volvo possesses some
of the most advanced engine research and test centres in the world. Manufacturing and
assembly are carried out at high-tech, highly automated diesel engine plants in Skövde,
Sweden; Cologne, Germany; Lyon, France; Curitiba, Brazil and Hagerstown, MD USA.
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The diesel engines used in Volvo construction machines design capability based on cutting-edge technology that
cover a wide range from 1 to 16 litres in displacement. is now applied in the new generation Volvo diesel engines
Each one is a state-of-the-art engine tailored specifically for off-road applications.
for our various construction machines. Volvo diesel en- Volvo diesel engines give you outstanding performance,
gines are built on decades of experience and on the use competitive fuel consumption and low emissions. They
of advanced technology. Volvo Advanced Combustion are designed and precision-built to meet your high demands
Technology, V-ACT, is yet another example of our engine concerning reliability, durability and operating economy.
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Volvo diesel engines share a number of high-technology design
features that provide several state-of-the-art solutions of benefit to
you in a variety of respects. You get outstanding engine response,
superior performance, unmatched reliability, low emissions, low
fuel consumption and long service life. This is a result of decades
of evolutionary product development including the blend of tradi-
tional and proven engine technology with the successive introduc-
tion of new technology, materials and production methods.
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6 cyl., 16.1 litres 6 cyl., 12.1 litres 6 cyl., 9.4 litres 6 cyl., 7.2 litres 6 cyl., 5.7 litres 4 cyl., 4.8 litres
Rated output range Rated output range Rated output range Rated output range Rated output range Rated output range
346 - 397 kW 198 - 313 kW 199 - 252 kW 138 - 184 kW 90 - 122 kW 71 - 92 kW
(471 - 540 hp) (269 - 426 hp) (271 - 343 hp) (188 - 250 hp) (122 - 166 hp) (97 - 125 hp)
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struction machines. All Volvo engines have excellent High power and torque
Torque
power and torque characteristics with high torque across for acceleration and
a wide engine speed range – including at low engine high average speed
and for operation
speeds – and with peak torque at modest engine speeds. with full load in poor
As one of just a few manufacturers of both engines and underfoot conditions
equipment, we enjoy the benefits of a completely inte- and on gradients.
grated organization. We can thereby create an optimized
match between engine, machine systems and operator
controls. The result is the highest possible fuel efficiency
and productivity, while at the same time meeting emis-
sions requirements.
Power
Main benefits:
Torque
• Power when and where needed. Fast response to
• Torque as needed, with peak torque at low to changes in engine
load – essential
modest engine speeds.
for achieving high
• Ample torque rise as required by application. performance, for
• Smooth, direct throttle response for optimum instance during tough
operability and maximum operator satisfaction. trenching tasks and Power
in mass excavation
• Low fuel consumption.
operations.
• Low exhaust emission levels.
Torque
• Low noise levels.
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Volvo Advanced Combustion Technology, V-ACT, is also
a major feature of the new generation of Tier 3/Stage
IIIA-compliant Volvo medium-size engines.
The new engines are 6 and 7 litre, electronically
controlled, six-cylinder in-line diesel engines, spe-
cially adapted for Volvo construction equipment.
Among the basic features are turbo charging,
air-to-air intercooling, direct injection, single
cylinder head and replaceable cylinder liners,
valve guides and seats. An oil cooler is an
integral design feature as well as oil spray
piston cooling for controlled operating
temperatures and enhanced service life.
The new Volvo D6E and D7E diesel
engine models feature a Common Rail
fuel system and Internal Exhaust Gas
Recirculation, I-EGR.
The new 4 and 5 liter Volvo diesel engines
are based on their 6 and 7 liter counterparts, but
feature less sophisticated fuel- and EGR systems.
Electronically controlled
Common Rail injector.
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Common Rail Fuel System Internal Exhaust Gas Recirculation, I-EGR
Rail pressure and timing (start and duration) of fuel injection in each Via the solenoid valve, the E-ECU activates the I-EGR system.
cylinder are electronically controlled. Upon activation, the solenoid opens the channel from the
engine’s lubrication oil gallery, pressurizing the I-EGR system.
A master piston connected to the intake rocker generates, at the
end of the inlet stroke, the higher pressure necessary to actuate
E-ECU the exhaust rocker for a small second opening of the exhaust
valve. Via the slave piston, the control valve hydro-mechanically
Injector controls the actuation of the exhaust rocker.
A fully ‘in-engine’ solution – no external channels or pipes are
needed.
Rail pressure
sensor
2-way solenoid valve
Rail PRV
Slave piston
Oil Supply
High pressure pumps High-pressure circuit
From tank
Master piston
FCV
Fuel pump Main filter Low-pressure circuit
Control valve
Return to tank
PRV= Pressure relief valve
FCV= Fuel control valve
Exhaust rocker Intake rocker
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We have made considerable efforts to reduce to a mini- As a leading engine and equipment manufacturer we
mum the need for service and maintenance of the new offer a wide selection of customer support facilities
generation of Volvo diesel engines and to facilitate service and services for the support of our equipment through
and maintenance work on these engines as much as pos- our global network of qualified dealers and strategi-
sible, bearing in mind that the ultimate objective is maxi- cally located parts warehouses.
mum uptime and productivity.
• Simplified service and maintenance work and long service VCADS Pro – a PC-based diagnostics and service
intervals software tool for swift and accurate fault-tracing, diagno-
- Oil change at 500 hour intervals (normal operating conditions) sing and programming.
• Efficient filtration systems with filters regrouped for ease of MATRIS – a PC-based software that produces the oper-
service and maintenance ating history of the machine, including the engine data.
Volvo Factory Remanufactured Components, REMAN
- Oil filtration system with two full-flow and one by-pass oil
– the range includes complete engines as well as critical
filter (D9-D16)
engine components.
- Fuel filtration system with prefilter including water separator,
CareTrack – a telematics system providing remote ma-
condensate sensor and main filter
chine tracking, alarm- and error code monitoring, service-
- Air filtration in three steps – pre-cleaner, main filter with
& fleet management data as well as operation reports,
replaceable insert, safety filter; optional oil bath filter including engine hours and fuel consumption rate.
• Volvo Ultra Diesel Engine Oil (VDS-3) ** Volvo Customer Support Agreements – Volvo diesel
- Developed for the Volvo diesel engines for optimal engines are designed and built for high performance. Pro-
performance and longer service life per service and maintenance are prerequisites for sustai-
- Lower oil and fuel consumption due to low friction ned performance, maximum uptime and long service life.
- Good lubricating and cleaning characteristics Our flexible service and maintenance concept embra-
- Minimal engine wear ces four different levels of support, market-adapted to suit
- Excellent protection against corrosion and rust varying customer needs, from the regular inspections and
• Volvo oil analysis provides a comprehensive diagnosis servicing ‘White Agreement’ level to the full-support, all-
of the condition of the engine inclusive ‘Gold Agreement’ level.
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We build on 150 years of engine experience and on And since 1936 we have been a leader in the develop-
100 years of internal combustion engine development ment of diesel engines for every possible application.
and manufacture. V-ACT (Volvo Advanced Combustion The Volvo diesel engine family for Volvo construction
Technology) is the latest step in our development of the equipment currently consists of three-, four- and
modern diesel engine. Over the years we have devel- six-cylinder engines from 1 to16 litres with power
oped and manufactured steam engines, crude oil en- ranging from 13 to 397 kW (18 to 540 hp).
gines, gas engines and petrol engines.
Our first internal combustion engine Production of our first diesel engines started The first Volvo 6-cylinder diesel engine
was presented. This was the start of with two small two-stroke, low-speed was introduced – the 96 hp VDA
the company’s success as one of the (900-1000 rpm) engine models for marine (Volvo Diesel engine type A).
world’s leading manufacturers of and stationary use: the single-cylinder 10 hp
crude oil engines. DW3 and the twin-cylinder 20 hp DW5.
In the 1940s Volvo also produced two-
and four-stroke semi-diesel engines in the
40 to 50 hp range.
During the 1980s, fuel injection systems In 1991, the air-to-liquid intercoolers re- The first Volvo diesel engine with a
underwent constant improvement to en- ceived a Twin Pump device to give the high-pressure, electronically controlled
sure greater fuel efficiency, at the same charge air optimal temperature for even fuel injection system was launched: the
time as the demand for and delivery of better engine efficiency, higher perform- six-cylinder, 12-litre D12A – then the
low-emission engines increased steadily. ance and lower emission levels in anticipa- world’s most modern diesel engine –
tion of the ‘Tier1/ Stage I’ emission limits featuring considerably higher engine
due to be enforced a few years later. efficiency and performance and greatly
reduced emissions.
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The first diesel engines for construction equip- One of the world’s first turbo- Intercooler technology for higher per-
ment were introduced as 3- and 4-cylinder charged direct-injection heavy-duty formance, lower fuel consumption
direct injection engines with a displacement diesel engines was introduced. and cleaner emissions was put in
of 3.36-4.48 litres, producing 42.5-55 hp at a production. Volvo’s, and the world’s,
maximum of 1800 rpm. They were a success first truly low-emission engines for
from the start thanks to excellent torque charac- construction equipment were born.
teristics, low fuel consumption, reliability and –
as time proved – exceptionally long service life.
The Volvo D12C engine with an Engine Manage- Successive introduction of new en- Introduction of a new generation of engines with
ment System (EMS 2) that communicates with gine versions with higher efficiency Volvo Advanced Combustion Technology, V-ACT.
the machine’s other electronic systems was in order to meet Tier 2/Stage ll These engines are characterized by enhanced fuel in-
introduced in Volvo construction equipment. emission requirements while improv- jection and air handling control. One prominent feature
This enhanced total performance, adaptability ing performance. is Volvo’s patented I-EGR design. Low emission levels
and control. have been reached without sacrificing engine perform-
It also made it possible to meet Tier 2/Stage ll ance. The new engines comply with the stringent US
emission requirements well before they became Tier 3/EU Stage IIIA emission requirements.
mandatory.
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Care for Generations to Come
Volvo Construction Equipment is one of the world’s leading manufacturers of construction equipment
and offers a broad range of products and comprehensive customer support that only a major supplier
such as Volvo can provide:
• 170 years of successful industrial and commercial activities and experience.
• More than 100 different models of wheel loaders, excavators, articulated haulers, motor graders,
backhoe loaders, compact loaders, compact excavators and skid-steer loaders.
• A company with a sales and service network that spans the globe.
We make great efforts to provide our products with the potential to function better, last longer and do
more work than other machines. In the cab of a Volvo machine, the operator has a better and more
efficient working environment that provides the highest standards of safety and comfort. At the same
time, and in line with our ‘care for the environment’ efforts, fuel and oil consumption, exhaust emissions
and noise levels are kept at a minimum.
We care all the way – from the start of your ownership of a Volvo machine, throughout your operations
and with an eye on the operator’s working conditions. In other words, our ambition is to always give you
more. In four simple words: More care. Built in.
All products are not available on all markets. Under our policy of continuous improvement, we reserve the right to change specifications
and designs without prior notice. The illustrations do not necessarily show the standard version of the machine.