Motor Volvo

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The Volvo Way to High Perormance and

Reduced Emission LevelsVolvo diesel engines in Volvo construction equipment

Volvo Advanced Combustion Technology

v-act™



The Volvo Way powerful and RELIABLE

The construction and earth-moving world is characterized by the

introduction o increasingly restrictive legislation and increasing

competition in all areas, aecting everyone in the business. As a

construction equipment manuacturer we are continuously aced

with ever-higher user demands on machine productivity.

We meet the requirements o the new, stricter emissions

legislation through state-o-the-art, innovative engine designs

allied to well-proven Volvo engine technology and components.

What is more, we do this while keeping machine perormance high

and uel consumption low.

This brochure is about how our new diesel engines ulfl these

higher demands and also about how every drop o uel is utilized

optimally to deliver outstanding perormance. One secret behind

our world-class engines is the new Volvo Advanced Combustion

Technology, V-ACT, that meets both your demands and those o

society, today and in the uture.

Go or simplicity – go The Volvo Way and stay one step ahead.



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VolVo AdVAnced coMBustiontechnology – V-ActVolvo is taking another major step to optimize combustion eciency

and reduce emissions without any dramatic changes to the basic

engine and its ancillaries. The new generation o Volvo diesel engines,

eaturing Volvo Advanced Combustion Technology, V-ACT, is tailored

or use in demanding o-road applications and is designed to meet

the specic needs o each Volvo machine. This technology eatures

an advanced new uel injection system, a new and more eective 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 unction, I-EGR, see pages 4 and 5.

Medium-size Volvo diesel engines will also share the benets o

V-ACT, see pages 12 and 13.

Volvo diesel engines with V-ACT provide the combined virtues o

excellent engine perormance and Tier 3/Stage IIIA-compliant emis-

sion levels. All this is achieved in an uncomplicated manner without

the need or additional equipment or ater-treatment o the exhaust

gases.

Volvo Advanced Combustion Technology, V-ACT, meets the needs

o today, with an eye on the uture.



4

A

new generAtion heAVy-dutyVolVo engines with V-Act

Exhaust rocker arm tted with apatented, switchable ‘double rocker’device or Internal Gas Recirculation,I-EGR (Volvo D12D).

One o the world’s most modern and ecient diesel engines, the

12-litre Volvo D12 was the platorm or the development o 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 o good design is simplicity. Our new Volvo diesel

engines meet the latest emissions legislation without requiring any

major changes to the base engine. Much o the development eort

has ocused on precise control o the combustion process. Volvo’s

new advanced combustion technology, V-ACT, with internal exhaust

gas recirculation unction, I-EGR, brings benets to users as well as

the environment.

With the new o-road engine generation eaturing V-ACT, Volvo

continues to be one o the world leaders in diesel engine designand emissions control.

I-EGR – a second opening (A) othe exhaust valve allows a controlled

amount o exhaust gas to be ed back into the cylinder or a short momentduring the inlet stroke.

Cleaner emissions:EGR The Volvo Way, I-EGR

By returning a controlled amount o the exhaust gases to the combustion

process, peak combustion temperatures are lowered. This in turn reduces

the ormation o NOx. This technology is commonly known as EGR –

Exhaust Gas Recirculation.

V-ACT provides an uncomplicated, ecient solution

or internal recirculation o exhaust gases, I-EGR.

In the heavy-duty o-road Volvo D12D and D9B

engines, the exhaust rocker arm is tted with a

patented, switchable ‘double rocker’ device

that allows or a small second opening o the

exhaust valve, whereby a controlled amount

o exhaust gas is ed 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 o the

combustion process. The switchable I-EGR

system is electronically controlled by the enginemanagement 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 thereore switched o, en-

hancing engine response and perormance.

Exhaust valve motion

Inlet valve motion



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More V-ACT heavy-dutyengine eatures:

• The latest-generation Volvo engine elec-tronic control unit (E-ECU) with enhancedsotware provides total electronic controlo all engine unctions and, together withthe entire engine management system

(EMS 2), ensures that the engine andmachine perorm optimally. Sensors col-lect real-time inormation and eed theE-ECU with data or optimized combus-tion in each instance.

• A new generation o high-pressure unit injectors or extremely precise uel injection.

• A turbocharger and air-to-air intercoolerwith improved fow characteristics andlarger capacity.

• New steel/aluminium pistons or moreuniorm piston temperature and less‘piston play’, contributing to sustained

ecient combustion.

A new generation oelectronically controlledhigh-pressure unitinjectors or precise

uel injection timing,injection pressurecontrol and uel quantitydelivery or each com-bustion sequence.

d16e – the Most powerfulVolVo diesel engineThe top-o-the range Volvo D16E six cylinder 16.1 litre diesel engine has

tremendous power and impressive torque. The D16E eatures unique air

handling technology including a switchable I-EGR system that incorporatesa urther development o the ‘double rocker’ valve actuation device. In the

D16E, the I-EGR unction is perormed by a Volvo patented extra rocker

arm, tted 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 lit that allows a controlled amount o exhaust gas

to return to the cylinder, resulting in reduced ormation o NOx.

The enhanced electronic controller with its unique sotware or each

application controls the electro-hydraulically actuated exhaust valve yoke

movements or optimum I-EGR and engine perormance.

The I-EGR unction is not required at low engine

speeds and is thereore automatically in the

‘switched-o’ position at low revs. This ensures

excellent engine response all the way up rom

low idle.

The Volvo D16E represents the ultimate in large-

displacement, heavy-duty diesel engine technology.

Section o engine timingmechanism, (D16E).

Section o theVolvo D16E engine.

Valve mechanismwith extra rocker

arm or I-EGRactuation, (D16E).



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lArgest in the world

A part o the Volvo Group

Volvo Construction Equipment is a company in the Volvo Group, one o the world’s leading

manuacturers o heavy commercial vehicles and transport solutions. The Volvo Group pro-

duces construction machines, trucks, buses, marine and industrial engines and drive systems,

aircrat engines and aero engine components. The combined strength o the Volvo Group

enables us to take a leading role in resource-intensive development o powertrains including

diesel engines.

You will nd Volvo diesel engines at work all over the world, in all climates and under all

operating conditions. For more than hal a century, Volvo diesel engines have been the most

modern and advanced engines in the world – highly ecient, reliable and durable. Our aim is

to stay at the oreront and push the development o uture generation diesel engines urther

by continually introducing new and superior technology.

In a straight line rom the start

Volvo has been manuacturing in-line diesel engines right rom the company’s start. Simply

because this design gives you better economy in every respect. The reliability and durability

o Volvo’s in-line engines are excellent, uel consumption is low and maintenance is easy.At the same time, engine response is superb and power is delivered instantly.

Volvo is the world’s largest manuacturer o heavy-duty diesel engines in the 9 to

18-litre category. The Volvo D12 is the world’s most manuactured 12-litre engine.

In 2005, our annual production o heavy-duty engines exceeded 180,000 units.

All told in 2005, 246,000 Volvo diesel engines were manuactured. Volvo possesses some

o the most advanced engine research and test centres in the world. Manuacturing andassembly are carried out at high-tech, highly automated diesel engine plants in Skövde,

Sweden; Cologne, Germany; Lyon, France; Curitiba, Brazil and Hagerstown, MD USA.



The diesel engines used in Volvo construction machines

cover a wide range rom 1 to 16 litres in displacement.

Each one is a state-o-the-art engine tailored specically

or our various construction machines. Volvo diesel en-

gines are built on decades o experience and on the useo advanced technology. Volvo Advanced Combustion

Technology, V-ACT, is yet another example o our engine

design capability based on cutting-edge technology that

is now applied in the new generation Volvo diesel engines

or o-road applications.

Volvo diesel engines give you outstanding perormance,

competitive uel consumption and low emissions. Theyare designed and precision-built to meet your high demands

concerning reliability, durability and operating economy.



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Volvo diesel engines share a number o high-technology design

eatures that provide several state-o-the-art solutions o beneft to

you in a variety o respects. You get outstanding engine response,

superior perormance, unmatched reliability, low emissions, low

uel consumption and long service lie. This is a result o decades

o evolutionary product development including the blend o tradi-

tional and proven engine technology with the successive introduc-

tion o new technology, materials and production methods.

driVes the technology eVen further

Key Volvo heavy-duty engine eaturesor high perormance, low emissionsand low uel consumption

• In-line cylinder conguration, turbo-charging, direct

injection, wet replaceable cylinder liners and air-to-air

intercooling.

• Single cylinder head with overhead camshat or

precise control o valve timing.

• Four valves per cylinder or ecient gas fow.

• Vertically installed unit injectors or optimum

distribution o uel in the combustion chamber.

• Camshat-driven unit injectors or uel injection

with extreme precision under high pressure.

• Electronically controlled high-pressure uel injection

system or precise uel injection. The uel injection

pressure is also electronically controlled to provide

fexible injection which minimizes the ormation o soot

and smoke.

• Turbocharger and intercooler with high eciency rat-

ings or large air surplus and low operating tempera-

tures.

• EMS 2 (Engine Management System) technology.

The E-ECU (Engine Electronic Control Unit) is inte-

grated with the machine’s other electronic control units.

Precise control o engineperormance

Electronic control units that communicate via standard-

ized data links manage the engine and other main

components in the machine and orm a ully integrated

electronic system. Perormance data is registered con-

tinuously and the electronic system continually optimizes

engine and machine unctions. Sensors collect the data

and the electronic system automatically evaluates all

unctions and adjusts operation to optimize perorm-

ance. The use o 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 uel

consumption. The electronics also eliminate the risk o

severe wear or major damage, or example shock loads

or engine over-speeding. When starting the engine, the

electronic system automatically carries out a diagnosis

o all the machine’s unctions.

More in-depth analysis can be perormed with a PC-

based diagnostic tool (VCADS Pro) that can be linked

to the electronic system.



Vv d6e

Vv d9B

Vv d12d

A powerful ae

Total Electronic ControlThe Engine Management System (EMS 2)

links the engine’s electronic control unit

(E-ECU) to the machine’s other electronic

control units to orm a highly ecient, inter-

active and real-time electronic communica-

tion system. The benet is optimum andconsistent engine/machine perormance,

whatever the application.

Volvo diesel engine D9B

The 9-litre Volvo D9B combines the best otwo worlds – it eatures the ‘double rocker’

system o the D12D (see page 4) and theengine timing mechanism located close to theengine fywheel as in the D16E (see page 5).

Vv d1.23 cyl., 1.12 litresRated output13 kW (18 hp)




Vv d3d4 cyl., 3.11 litresRated output range41 - 57 kW

(56 - 78 hp)

Vv d4d4 cyl., 4.04 litersRated output range64 - 75 kW

(87 - 102 hp)



Vv d7e

Vv d16e

The electronic control unit (E-ECU) is mounted

either directly on the engine or on the chassis o

the machine. The E-ECU continuously receives

inormation rom sensors that monitor engine

unction data, see the table to the right.

• Engine speed and piston position.

• Camshat position and speed.

• Fuel pressure and uel temperature.

• Boost pressure and air temperature.

• Negative pressure and air temperature

ater the air lter.

• Oil pressure and oil temperature.

• Engine oil level.

• Coolant temperature.• Coolant level in the expansion tank.

• Cooling an engagement/disengagement.

• Condensate in the uel pre-lter.


97 - 125 hp)

Vv d6e6 cyl., 5.7 litresRated output range90 - 122 kW

(122 - 166 hp)

Vv d7e6 cyl., 7.2 litresRated output range138 - 184 kW

(188 - 250 hp)

Vv d9B6 cyl., 9.4 litresRated output range199 - 252 kW

(271 - 343 hp)


(269 - 426 hp)

Vv d166 cyl., 16.1 litresRated output range346 - 397 kW

(471 - 540 hp)





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the VolVo MediuM-size six-cylinderdiesel engines with V-ActVolvo Advanced Combustion Technology, V-ACT, is also

a major eature o the new generation o Tier 3/Stage

II IA-compliant Volvo medium-size engines.The new engines are 6 and litre, electronically

controlled, six-cylinder in-line diesel engines, spe-

cially adapted or Volvo construction equipment.

Among the basic eatures 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 eature as well as oil spray

piston cooling or controlled operating

temperatures and enhanced service lie.

The new Volvo D6E and DE diesel

engine models eature a Common Railuel system and Internal Exhaust Gas

Recirculation, I-EGR.

The new 4 and 5 liter Volvo diesel engines

are based on their 6 and liter counterparts, but

eature less sophisticated uel- and EGR systems.

Common Rail uel system

‘Common Rail’ is a well-known state-o-the-art engine uel system inwhich uel under high pressure is distributed rom a high-pressure ac-

cumulator, the rail. In the new engines two camshat-driven high-pressure

pumps deliver the uel to the rail and then urther on via high-pressure

pipes to the electro-hydraulically operated uel injectors. A solenoid-

operated uel control valve, a pressure relie valve and rail pressure

sensors are other important elements o the common rail uel system.

The engine electronic control unit, E-ECU – a major element o Volvo’s

EMS 2 engine management system – continuously controls the common

rail pressure, the injection timing and the rate o injection in each cylinder.

Internal Exhaust Gas Recirculation system (I-EGR)

The I-EGR system applied to the new engines eatures a switchable,

hydraulically actuated valve mechanism. The exhaust valve can thus

be opened slightly a second time to allow or the return o a controlled

amount o 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 ormation o NOx. The I-EGR is switched o at low

engine speeds and thereby contributes to excellent engine response

and perormance even at low idle.

The Volvo EMS 2 engine management system electronically controls

the I-EGR system or optimal, reliable engine perormance and low

exhaust emissions.

Other eatures

Apart rom improved power, torque and

engine response characteristics along

with emissions-compliant reduced ex-

haust emissions, the new generation o

medium-size Volvo diesel engines oer

the ollowing signicant eatures:

• High power to weight ratio

• Competitive uel eciency

• Reduced engine sound level

• Very ecient air, oil and uelltration systems

• Easy maintenance

• Reliability

• Durability

• High perormance under all

conditions in all applications

Electronically controlledCommon Rail injector.







15

The Volvo D12C engine with an Engine Manage-

ment System (EMS 2) that communicates with

the machine’s other electronic systems was

introduced in Volvo construction equipment.

This enhanced total perormance, adaptability

and control.

It also made it possible to meet Tier 2/Stage ll

emission requirements well beore they became

mandatory.

2000

Intercooler technology or higher per-

ormance, lower uel consumption

and cleaner emissions was put inproduction. Volvo’s, and the world’s,

rst truly low-emission engines or

construction equipment were born.

1978One o the world’s rst turbo-

charged direct-injection heavy-duty

diesel engines was introduced.

1954The rst diesel engines or construction equip-

ment were introduced as 3- and 4-cylinder

direct injection engines with a displacemento 3.36-4.48 litres, producing 42.5-55 hp at a

maximum o 1800 rpm. They were a success

rom the start thanks to excellent torque charac-

teristics, low uel consumption, reliability and –

as time proved – exceptionally long service lie.

1952

Successive introduction o new en-

gine versions with higher eciency

in order to meet Tier 2/Stage ll

emission requirements while improv-

ing perormance.

2001 - 2004Introduction o a new generation o engines with

Volvo Advanced Combustion Technology, V-ACT.

These engines are characterized by enhanced uel in-

jection and air handling control. One prominent eature

is Volvo’s patented I-EGR design. Low emission levels

have been reached without sacricing engine perorm-

ance. The new engines comply with the stringent US

Tier 3/EU Stage IIIA emission requirements.

2005 - 2006



All products are not available on all markets. Under our policy o continuous improvement, we reserve the right to change specications

and designs without prior notice. The illustrations do not necessarily show the standard version o the machine.

Re. No. 21 3 669 2726 EnglishPrinted in Sweden 2006.04–6Volvo, Eskilstuna

Construction Equipmentwww.volvo.com

Care or Generations to Come

Volvo Construction Equipment is one o the world’s leading manuacturers o construction equipment

and oers a broad range o products and comprehensive customer support that only a major supplier

such as Volvo can provide:

• 170 years o successul industrial and commercial activities and experience.

• More than 100 dierent models o 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 eorts to provide our products with the potential to unction better, last longer and do

more work than other machines. In the cab o a Volvo machine, the operator has a better and more

efcient working environment that provides the highest standards o saety and comort. At the same

time, and in line with our ‘care or the environment’ eorts, uel and oil consumption, exhaust emissions

and noise levels are kept at a minimum.

We care all the way – rom the start o your ownership o 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 our simple words: M a. B .

Motor Volvo

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