Volvo Advanced Combustion Technology v-act

Volvo Advanced Combustion Technology v-act The Volvo Way to High Performance and Reduced Emission Levels Volvo diesel engines in Volvo construction equipment

The Volvo Way powerful and RELIABLE The construction and earth-moving world is characterized by the introduction of increasingly restrictive legislation and increasing competition in all areas, affecting everyone in the business. As a construction equipment manufacturer we are continuously faced with ever-higher user demands on machine productivity. We meet the requirements of the new, stricter emissions legislation through state-of-the-art, innovative engine designs allied to well-proven Volvo engine technology and components. What is more, we do this while keeping machine performance high and fuel consumption low. This brochure is about how our new diesel engines fulfil these higher demands and also about how every drop of fuel is utilized optimally to deliver outstanding performance. One secret behind our world-class engines is the new Volvo Advanced Combustion Technology, V-ACT, that meets both your demands and those of society, today and in the future. Go for simplicity go The Volvo Way and stay one step ahead.

Volvo Advanced Combustion Technology V-ACT Volvo is taking another major step to optimize combustion efficiency and reduce emissions without any dramatic changes to the basic engine and its ancillaries. The new generation of Volvo diesel engines, featuring Volvo Advanced Combustion Technology, V-ACT, is tailored for use in demanding off-road applications and is designed to meet the specific needs of each Volvo machine. This technology features an advanced new fuel injection system, a new and more effective air management system and enhanced engine management. In order to lower nitrogen oxide (NOx) emissions, Volvo heavy-duty engines are equipped with an ingenious Volvo patented, switchable Internal Exhaust Gas Recirculation function, I-EGR, see pages 4 and 5. Medium-size Volvo diesel engines will also share the benefits of V-ACT, see pages 12 and 13. Volvo diesel engines with V-ACT provide the combined virtues of excellent engine performance and Tier 3/Stage IIIA-compliant emission levels. All this is achieved in an uncomplicated manner without the need for additional equipment or after-treatment of the exhaust gases. Volvo Advanced Combustion Technology, V-ACT, meets the needs of today, with an eye on the future. 3

New Generation heavy-duty Volvo Engines with V-ACT 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 introduced 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 the pressure pulses in the exhaust being higher than the in-cylinder pressure during part of the 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. The I-EGR is activated at high engine speeds and loads. At low engine speeds, the I-EGR is not required and is therefore switched off, enhancing engine response and performance. Exhaust rocker arm fitted with a patented, switchable double rocker device for Internal Gas Recirculation, I-EGR (Volvo D12D). A Exhaust valve motion Inlet valve motion I-EGR a second opening (A) of the exhaust valve allows a controlled amount of exhaust gas to be fed back into the cylinder for a short moment during the inlet stroke. 4

D16E the most powerful Volvo diesel engine 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. More V-ACT heavy-duty engine features: The latest-generation Volvo engine electronic control unit (E-ECU) with enhanced software provides total electronic control of all engine functions and, together with the entire engine management system (EMS 2), ensures that the engine and machine perform optimally. Sensors collect real-time information and feed the E-ECU with data for optimized combustion in each instance. A new generation of high-pressure unit injectors for extremely precise fuel injection. A turbocharger and air-to-air intercooler with improved flow characteristics and larger capacity. New steel/aluminium pistons for more uniform piston temperature and less piston play, contributing to sustained efficient combustion. Section of the Volvo D16E engine. The I-EGR function is not required at low engine speeds and is therefore automatically in the switched-off position at low revs. This ensures excellent engine response all the way up from low idle. The Volvo D16E represents the ultimate in largedisplacement, heavy-duty diesel engine technology. A new generation of electronically controlled high-pressure unit injectors for precise fuel injection timing, injection pressure control and fuel quantity delivery for each combustion sequence. Section of engine timing mechanism, (D16E). Valve mechanism with extra rocker arm for I-EGR actuation, (D16E). 5

LARGEST In the World 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. A part of the Volvo Group Volvo Construction Equipment is a company in the Volvo Group, one of the world s leading manufacturers of heavy commercial vehicles and transport solutions. The Volvo Group produces construction machines, trucks, buses, marine and industrial engines and drive systems, aircraft engines and aero engine components. The combined strength of the Volvo Group enables us to take a leading role in resource-intensive development of powertrains including diesel engines. You will find Volvo diesel engines at work all over the world, in all climates and under all operating conditions. For more than half a century, Volvo diesel engines have been the most modern and advanced engines in the world highly efficient, reliable and durable. Our aim is to stay at the forefront and push the development of future generation diesel engines further by continually introducing new and superior technology. In a straight line from the start Volvo has been manufacturing in-line diesel engines right from the company s start. Simply because this design gives you better economy in every respect. The reliability and durability of Volvo s in-line engines are excellent, fuel consumption is low and maintenance is easy. At the same time, engine response is superb and power is delivered instantly. 6

The diesel engines used in Volvo construction machines cover a wide range from 1 to 16 litres in displacement. Each one is a state-of-the-art engine tailored specifically for our various construction machines. Volvo diesel engines are built on decades of experience and on the use of advanced technology. Volvo Advanced Combustion Technology, V-ACT, is yet another example of our engine design capability based on cutting-edge technology that is now applied in the new generation Volvo diesel engines for off-road applications. Volvo diesel engines give you outstanding performance, competitive fuel consumption and low emissions. They are designed and precision-built to meet your high demands concerning reliability, durability and operating economy.

Drives the Technology Even Further 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 traditional and proven engine technology with the successive introduction of new technology, materials and production methods. Key Volvo heavy-duty engine features for high performance, low emissions and low fuel consumption In-line cylinder configuration, turbo-charging, direct injection, wet replaceable cylinder liners and air-to-air intercooling. Single cylinder head with overhead camshaft for precise control of valve timing. Four valves per cylinder for efficient gas flow. Vertically installed unit injectors for optimum distribution of fuel in the combustion chamber. Camshaft-driven unit injectors for fuel injection with extreme precision under high pressure. Electronically controlled high-pressure fuel injection system for precise fuel injection. The fuel injection pressure is also electronically controlled to provide flexible injection which minimizes the formation of soot and smoke. Turbocharger and intercooler with high efficiency ratings for large air surplus and low operating temperatures. EMS 2 (Engine Management System) technology. The E-ECU (Engine Electronic Control Unit) is integrated with the machine s other electronic control units. Precise control of engine performance Electronic control units that communicate via standardized data links manage the engine and other main components in the machine and form a fully integrated electronic system. Performance data is registered continuously and the electronic system continually optimizes engine and machine functions. Sensors collect the data and the electronic system automatically evaluates all functions and adjusts operation to optimize performance. The use of data links with digital transmission increases reliability and durability. Utilizing all the available operational data, the engine s electronic control unit (E-ECU) controls combustion to optimize output and minimize emissions and fuel consumption. The electronics also eliminate the risk of severe wear or major damage, for example shock loads or engine over-speeding. When starting the engine, the electronic system automatically carries out a diagnosis of all the machine s functions. More in-depth analysis can be performed with a PCbased diagnostic tool (VCADS Pro) that can be linked to the electronic system. 8

A POWERFUL range Volvo D6E Volvo D9B Volvo D12D Volvo D1.2 3 cyl., 1.12 litres Rated output 13 kw (18 hp) Volvo D1.6 3 cyl., 1.64 litres Rated output 20 kw (27 hp) Volvo D3.1 4 cyl., 3.05 litres Rated output 38 kw (52 hp) Volvo D3.4 4 cyl., 3.32 litres Rated output 42 kw (57 hp) Volvo D3D 4 cyl., 3.11 litres Rated output range 41-57 kw (56-78 hp) Volvo D4D 4 cyl., 4.04 liters Rated output range 64-75 kw (87-102 hp) Volvo diesel engine D9B The 9-litre Volvo D9B combines the best of two worlds it features the double rocker system of the D12D (see page 4) and the engine timing mechanism located close to the engine flywheel as in the D16E (see page 5). Total Electronic Control The Engine Management System (EMS 2) links the engine s electronic control unit (E-ECU) to the machine s other electronic control units to form a highly efficient, interactive and real-time electronic communication system. The benefit is optimum and consistent engine/machine performance, whatever the application.

Volvo D7E Volvo D16E Volvo D5D 4 cyl., 4.8 litres Rated output range 71-92 kw (97-125 hp) Volvo D6E 6 cyl., 5.7 litres Rated output range 90-122 kw (122-166 hp) Volvo D7E 6 cyl., 7.2 litres Rated output range 138-184 kw (188-250 hp) Volvo D9B 6 cyl., 9.4 litres Rated output range 199-252 kw (271-343 hp) Volvo D12D 6 cyl., 12.1 litres Rated output range 198-313 kw (269-426 hp) Volvo D16e 6 cyl., 16.1 litres Rated output range 346-397 kw (471-540 hp) The electronic control unit (E-ECU) is mounted either directly on the engine or on the chassis of the machine. The E-ECU continuously receives information from sensors that monitor engine function data, see the table to the right. Engine speed and piston position. Camshaft position and speed. Fuel pressure and fuel temperature. Boost pressure and air temperature. Negative pressure and air temperature after the air filter. Oil pressure and oil temperature. Engine oil level. Coolant temperature. Coolant level in the expansion tank. Cooling fan engagement/disengagement. Condensate in the fuel pre-filter.

High torque at low engine speeds for excellent engine response. Sustained high torque over a broad engine speed range and high torque rise. Power Torque Engine performance to match the application The need for engine performance, including power and torque, differs from one type of equipment to another and from one application to another. At Volvo, we optimize the performance of each Volvo diesel engine model for operation in each of our construction machines. All Volvo engines have excellent power and torque characteristics with high torque across a wide engine speed range including at low engine speeds and with peak torque at modest engine speeds. As one of just a few manufacturers of both engines and equipment, we enjoy the benefits of a completely integrated 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 emissions requirements. Main benefits: Power when and where needed. Torque as needed, with peak torque at low to modest engine speeds. Ample torque rise as required by application. Smooth, direct throttle response for optimum operability and maximum operator satisfaction. Low fuel consumption. Low exhaust emission levels. Low noise levels. The Volvo diesel engine the heart of Volvo construction equipment Sustained high power over a wide engine speed range and excellent low-end torque to power through as load levels change. High power and torque for acceleration and high average speed and for operation with full load in poor underfoot conditions and on gradients. Fast response to changes in engine load essential for achieving high performance, for instance during tough trenching tasks and in mass excavation operations. Power Torque Power Torque Power Torque Power Torque Environmental care a Volvo core value Volvo applies a holistic view which encompasses every phase of the life-cycle of our products from design, procurement and manufacturing all the way to operation, maintenance and scrapping. Our environmental programmes are characterized by continual improvement, technical development and resource efficiency. The result is products designed to create a low environ-mental footprint throughout their service life. Volvo s first environmental policy was established in 1972 in connection with the first UN conference on the environment. Long before this, however, care for the environment played an important role in our company s operations and in the design of our products. For us, environmental care is an important driving force in developing products that are efficient and at the same time environmentally optimized. 11

The volvo medium-size six-cylinder diesel engines with v-act 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, specially 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. Common Rail fuel system Common Rail is a well-known state-of-the-art engine fuel system in which fuel under high pressure is distributed from a high-pressure accumulator, the rail. In the new engines two camshaft-driven high-pressure pumps deliver the fuel to the rail and then further on via high-pressure pipes to the electro-hydraulically operated fuel injectors. A solenoidoperated fuel control valve, a pressure relief valve and rail pressure sensors are other important elements of the common rail fuel system. The engine electronic control unit, E-ECU a major element of Volvo s EMS 2 engine management system continuously controls the common rail pressure, the injection timing and the rate of injection in each cylinder. Internal Exhaust Gas Recirculation system (I-EGR) The I-EGR system applied to the new engines features a switchable, hydraulically actuated valve mechanism. The exhaust valve can thus be opened slightly a second time to allow for the return of a controlled amount of exhaust gas into the combustion chamber. This is done at high engine speeds and loads. Peak combustion temperature is then lowered and so too is the formation of NOx. The I-EGR is switched off at low engine speeds and thereby contributes to excellent engine response and performance even at low idle. The Volvo EMS 2 engine management system electronically controls the I-EGR system for optimal, reliable engine performance and low exhaust emissions. Other features Apart from improved power, torque and engine response characteristics along with emissions-compliant reduced exhaust emissions, the new generation of medium-size Volvo diesel engines offer the following significant features: High power to weight ratio Competitive fuel efficiency Reduced engine sound level Very efficient air, oil and fuel filtration systems Easy maintenance Reliability Durability High performance under all conditions in all applications Electronically controlled Common Rail injector. 12

Common Rail Fuel System Internal Exhaust Gas Recirculation, I-EGR Rail pressure and timing (start and duration) of fuel injection in each cylinder are electronically controlled. Via the solenoid valve, the E-ECU activates the I-EGR system. 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 the exhaust rocker for a small second opening of the exhaust valve. Via the slave piston, the control valve hydro-mechanically controls the actuation of the exhaust rocker. A fully in-engine solution no external channels or pipes are needed. E-ECU Injector Rail pressure sensor 2-way solenoid valve Rail PRV Slave piston Oil Supply High-pressure circuit High pressure pumps From tank Fuel pump Main filter Master piston Low-pressure circuit FCV Control valve Return to tank PRV= Pressure relief valve FCV= Fuel control valve Exhaust rocker Intake rocker sustained performance and Maximum uptime We have made considerable efforts to reduce to a minimum the need for service and maintenance of the new generation of Volvo diesel engines and to facilitate service and maintenance work on these engines as much as possible, bearing in mind that the ultimate objective is maximum uptime and productivity. As a leading engine and equipment manufacturer we offer a wide selection of customer support facilities and services for the support of our equipment through our global network of qualified dealers and strategically located parts warehouses. Simplified service and maintenance work and long service intervals - Oil change at 500 hour intervals (normal operating conditions) Efficient filtration systems with filters regrouped for ease of service and maintenance - Oil filtration system with two full-flow and one by-pass oil filter (D9-D16) - Fuel filtration system with prefilter including water separator, condensate sensor and main filter - Air filtration in three steps pre-cleaner, main filter with replaceable insert, safety filter; optional oil bath filter Volvo Ultra Diesel Engine Oil (VDS-3) ** - Developed for the Volvo diesel engines for optimal per formance and longer service life - Lower oil and fuel consumption due to low friction - Good lubricating and cleaning characteristics - Minimal engine wear - Excellent protection against corrosion and rust Volvo oil analysis provides a comprehensive diagnosis of the condition of the engine VCADS Pro a PC-based diagnostics and service software tool for swift and accurate fault-tracing, diagnosing and programming. MATRIS a PC-based software that produces the oper ating history of the machine, including the engine data. Volvo Factory Remanufactured Components, REMAN the range includes complete engines as well as critical engine components. CareTrack a telematics system providing remote machine tracking, alarm- and error code monitoring, service& fleet management data as well as operation reports, including engine hours and fuel consumption rate. Volvo Customer Support Agreements Volvo diesel engines are designed and built for high performance. Proper service and maintenance are prerequisites for sustained performance, maximum uptime and long service life. Our flexible service and maintenance concept embraces four different levels of support, market-adapted to suit varying customer needs, from the regular inspections and servicing White Agreement level to the full-support, allinclusive Gold Agreement level. ** Volvo Drain Specifications. Volvo s extra-high requirements on oil properties and quality. 13

SINCE 1893, ALWAYS ONE STEP AHEAD We build on 150 years of engine experience and on 100 years of internal combustion engine development and manufacture. V-ACT (Volvo Advanced Combustion Technology) is the latest step in our development of the modern diesel engine. Over the years we have developed and manufactured steam engines, crude oil engines, gas engines and petrol engines. And since 1936 we have been a leader in the development of diesel engines for every possible application. The Volvo diesel engine family for Volvo construction equipment currently consists of three-, four- and six-cylinder engines from 1 to16 litres with power ranging from 13 to 397 kw (18 to 540 hp). 1893 Our first internal combustion engine was presented. This was the start of the company s success as one of the world s leading manufacturers of crude oil engines. 1936 Production of our first diesel engines started with two small two-stroke, low-speed (900-1000 rpm) engine models for marine and stationary use: the single-cylinder 10 hp DW3 and the twin-cylinder 20 hp DW5. In the 1940s Volvo also produced twoand four-stroke semi-diesel engines in the 40 to 50 hp range. 1946 The first Volvo 6-cylinder diesel engine was introduced the 96 hp VDA (Volvo Diesel engine type A). 1980 During the 1980s, fuel injection systems underwent constant improvement to ensure greater fuel efficiency, at the same time as the demand for and delivery of low-emission engines increased steadily. 1991 In 1991, the air-to-liquid intercoolers received a Twin Pump device to give the charge air optimal temperature for even better engine efficiency, higher performance and lower emission levels in anticipation of the Tier1/ Stage I emission limits due to be enforced a few years later. 1993 The first Volvo diesel engine with a high-pressure, electronically controlled fuel injection system was launched: the six-cylinder, 12-litre D12A then the world s most modern diesel engine featuring considerably higher engine efficiency and performance and greatly reduced emissions. 14

1952 The first diesel engines for construction equipment were introduced as 3- and 4-cylinder direct injection engines with a displacement of 3.36-4.48 litres, producing 42.5-55 hp at a maximum of 1800 rpm. They were a success from the start thanks to excellent torque characteristics, low fuel consumption, reliability and as time proved exceptionally long service life. 1954 One of the world s first turbocharged direct-injection heavy-duty diesel engines was introduced. 1978 Intercooler technology for higher performance, lower fuel consumption and cleaner emissions was put in production. Volvo s, and the world s, first truly low-emission engines for construction equipment were born. 2000 The Volvo D12C engine with an Engine Management System (EMS 2) that communicates with the machine s other electronic systems was introduced in Volvo construction equipment. This enhanced total performance, adaptability and control. It also made it possible to meet Tier 2/Stage ll emission requirements well before they became mandatory. 2001-2004 Successive introduction of new engine versions with higher efficiency in order to meet Tier 2/Stage ll emission requirements while improving performance. 2005-2006 Introduction of a new generation of engines with Volvo Advanced Combustion Technology, V-ACT. These engines are characterized by enhanced fuel injection and air handling control. One prominent feature is Volvo s patented I-EGR design. Low emission levels have been reached without sacrificing engine performance. The new engines comply with the stringent US Tier 3/EU Stage IIIA emission requirements. 15

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. Construction Equipment www.volvo.com Ref. No. 21 3 669 2726 Printed in Sweden 2006.04 6 Volvo, Eskilstuna English