V-ACT D16E Brochure 22 A 100 3523_2007-07

VOLVO D16E The Power of Volvo in Construction Equipment Volvo is a major manufacturer of diesel engines and is the world’s largest producer of heavy-duty diesel engines in the 9 to 18 liter size bracket.

• A new air management system incorporating a unique, patented, switchable I-EGR system, a new standard turbocharger and a new air-to-air charge air cooler;

Volvo diesel engines are powering the trucks, buses and construction equipment produced by the company and is a major power source in marine and industrial applications.

• An enhanced electronic controller for precise control of the fuel and air handling systems.

We presented our first internal combustion engine in 1893. Ever since, we have been in the forefront of engine technology and performance. The new generation Volvo heavy-duty diesel engines featuring ‘V-ACT’ (Volvo Advanced Combustion Technology) for off-road applications is further proof of Volvo’s high level of engine technology and of the company’s solid experience to successfully apply innovative solutions to well-proven Volvo engine designs and to optimize the integration of engine and equipment for maximum machine performance and productivity.

Volvo D16E diesel engine in Volvo construction equipment • The Volvo D16E is Volvo’s most powerful diesel engine with a power-range that in its various on- and off-road applications spans from 346 kW (471 hp) to 604 kW (821 hp). • The design of the Volvo D16E is based on a solid evolution of the world-leading diesel engine technology introduced in the Volvo D12, the world´s most manufactured diesel engine in the 12-liter size class, and represents a new generation of high performancelow emission Volvo diesel engines. • The Volvo D16E has many design features in common also with the 9 liter Volvo D9B, such as the configuration and location of the timing mechanism. • Featuring Volvo’s advanced electronic engine management system – another shared element and a major V-ACT feature used with all six-cylinder medium and large size Volvo diesel engines for offroad applications – that instantaneously adapts performance to suit each new operating situation.

The new-generation Volvo diesel engines with V-ACT provide, in an uncomplicated manner, high engine efficiency and output, optimized fuel economy, maintained performance and lower emissions in compliance with US (EPA) Tier 3 / EU Stage IIIA exhaust emission requirements for non-road machinery. With V-ACT, no external devices or after-treatment of the exhaust gases are required for Tier 3 / Stage IIIA compliance.

Engine performance matching the application – optimized performance of each Volvo diesel engine model for operation in each individual model of Volvo construction equipment. Volvo – as one of just a few manufacturers of both engines and construction equipment – enjoy the benefits of an entirely integrated equipment/engine system, creating an optimized match between engine, machine systems and operator controls.

Volvo Construction Equipment is different. The company’s products are designed, built and supported in a different way. That difference comes from our 175-year engineering heritage. A heritage of thinking first about the people who actually use the machines. About how to make them safer, more comfortable, more productive. About the environment we all share. The result of that thinking is a growing range of machines and a global support network dedicated to helping you do more. People around the world are proud to use Volvo. And we’re proud of what makes Volvo different – More care. Built in.

The resulting main benefits are: • Power when and where needed • Torque as needed, with peak torque at low to modest engine speeds • Ample torque rise as required by application

• Configured for the demanding heavy-duty applications in construction, earthmoving and mining equipment.

• Smooth, direct throttle response for maximum operability and maximum operator satisfaction and efficienty

• Providing outstanding performance, reliability and durability.

• Low fuel consumption

• Manufactured with world-leading engine production and assembly technology.

• Low exhaust emission levels

• Complies with US (EPA) Tier 3 and EU Stage IIIA exhaust emission standards.

VOLVO D16E DIESEL ENGINE WITH V-ACT

• A new flexible, high-pressure fuel injection system with latest-generation unit injectors;

As one of the leading diesel engine manufacturers in the world, Volvo possesses extensive, advanced engine research & development and manufacturing resources.

You will find Volvo diesel engines at work all over the world, in all climates and conditions.

VOLVO CONSTRUCTION EQUIPMENT

V-ACT is the acronym for Volvo Advanced Combustion Technology. It embodies the unique technology specifically developed by Volvo for its heavy- and medium-duty diesel engines that power Volvo construction equipment. V-ACT represents new achievements in the areas of combustion efficiency, emissions reduction and overall engine performance. Major V-ACT features include:

• Low noise levels

All products are not available in all markets. Under our policy of continuous improvement, we reserve the right to change specifications and design without prior notice. The illustrations do not necessarily show the standard version of the machine.

MORE CARE. BUILT IN. Ref. No. 22 A 100 3523 Printed in USA 2007.07 – 2

English

US (EPA) TIER 3 / EU STAGE IIIA

For many years, Volvo has been one of the world leaders in heavy-duty diesel engine development. All Volvo heavy-duty diesel engines share the same basic state-of-the-art technology. The result – unprecedented confidence in the best engines in the world for your business.

20 3

NUMBER OF UNITS PRODUCED

1

2

3

4

One-piece cylinder head of cast iron, providing stable bearings for the overhead camshaft for precise valve actuation. The cylinder head features an intermediate deck that promotes sturdiness and enhances cooling. The inlet and outlet ports are optimized for low pressure drop. There is one common fuel channel to the injectors. The cylinder head gasket is of steel, with integrated rubber seals for water and oil ports, providing heat resistance and durability. Induction-hardened, overhead camshaft with seven bearing trestles and removable bearing shells. The camshaft is provided with carefully shaped lobes for valve control and with a cam profile adapted to the unit injectors. The exhaust rocker arm has a switchable ‘double rocker’ device, an unique feature instrumental to Volvo’s patented I-EGR solution (see paragraph on I-EGR below). An extra rocker arm is fitted in parallel to the exhaust rocker arm; simply put, one rocker arm for the ordinary exhaust lift event and one for the I-EGR activation.

5

6

High pressure, flexible fuel injection system with centrally located, camshaft-driven, electronicallycontrolled, dual solenoid unit injectors for precise fuel injection timing, optimum pressure and exact fuel quantity required in each instance. The unit injectors are vertically installed for optimal distribution of the fuel in the combustion chamber.

10

Sturdy cylinder block, made of cast iron and provided with wet, replaceable cylinder liners. To withstand the very high firing pressures of the modern diesel engine, the sides of the block have a curved shape at the level of each cylinder in order to produce high stiffness and good sound reduction. A ‘ladder frame,’ consisting of a sturdy steel plate, is bolted onto the bottom of the block for extra rigidity and durability.

SPECIFICATIONS The new heavy-duty, Tier-3/StageIIIA-compliant Volvo D16E featuring V-ACT, is a 16.1 liter, in-line, four-stroke, water-cooled, six-cylinder diesel engine with turbo and intercooler. It features an integrated single cylinder head, four valves per cylinder, overhead camshaft, electronically-controlled unit injectors and Volvo’s enhanced electronic engine management system, EMS-2.

Displacement

9

The pistons, made of steel, are provided with jet spray oil cooling (cavity cooling) for uniform piston temperature. The oil cooling also encompasses the piston ring zone and the combustion chamber, all contributing to sustained efficient combustion and lower oil consumption. There are two compression rings and one oil ring. The connecting rod is of forged steel.

7

Base engine configuration

8

Valve mechanism with four-valve technology • cross-flow configuration of the inlet and exhaust ports for efficient gas flow • fully symmetrical combustion chamber enhances air/fuel swirl control for highly efficient combustion • replaceable alloy steel valve guides and steel valve seats • all valve guides have oil seals for low oil consumption

11

Drop-forged, inductionhardened crankshaft, provided with a vibration damper of the viscous type.

2

21

The flywheel is secured to the crankshaft by through-bolts in a large diameter bolt pattern for strength and durability. The flywheel ring gear is replaceable. The generous radius of the flywheel serrations allows high accuracy of engine speed sensoring for maximum fuel injector control and performance.

18

9

The engine timing gear train is fitted on a sturdy steel plate that is bolted on to the rear end of the cylinder block. It incorporates a hydraulic damper on the camshaft gear for minimized vibrations and noise. The rear end location of the timing gear means fewer moving parts and contributes to a very high precision of valve motion and injection timing, and to a virtually vibration-free running of the engine and a reduced sound level.

6

12

The enhanced engine cooling system, including a new type of radiator provides effective heat dissipation which, together with the electronically-controlled cooling fan (except excavators) for minimized energy losses, contributes to the engine´s high efficiency rating. Inside the engine, calibrated cooling ducts interact to provide balanced cooling. The coolant flow is distributed between the cylinder liners´ upper and lower coolant jackets and the cylinder head. A coolant thermostat is integrated in the cylinder head.

13

14

Turbocharged/air-to-air

Bore

144 mm

4.75 in.

Stroke

165 mm

5.4 in.

Cam/valve configuration

SOHC/4 valves per cylinder

12

3

Torque 895 ft.lbs. – 1254 ft.lbs. 2420 Nm – 2550 Nm

For specific engine output data by product application, see machine brochures. Information presented in this guide is current at time of printing.

5

2

EPG (Exhaust Pressure Governor)/ Engine brake. Exclusive, patented Volvo technology for use on Volvo trucks, buses and articulated haulers. An efficient exhaust retarder fitted on the turbocharger’s exhaust outlet restricts the exhaust gas flow, thus increasing engine backpressure which results in a braking effect. A pulse width modulated (PWM) control valve allows variable control of the EPG for variable braking effect. Extra braking power at no extra cost. Main PTO (power take-off) integrated in the flywheel housing (artic.haulers). Specifically designed for the high output requirements of the articulated hauler application. Engine side-mounted PTO available as required by application. Force-fed lubrication system ensures sufficient oil supply, also at cold starts.

16

The efficient oil cooler, integrated in the cylinder block, assures full oil temperature control. An oil cooler bypass valve ensures lubrication of the engine at cold starts.

17 Power 346 kW – 397 kW 471 hp – 540 hp

Switchable I-EGR (Internal Exhaust Gas Recirculation) system. Exhaust emissions reduction achieved by the application of the patented ‘double rocker’ device, an integral element of V-ACT, whereby at high engine speeds and loads a controlled portion of exhaust gases is fed back into the cylinder during the inlet stroke by a short, second exhaust valve lift event. (see 2 lower left) The I-EGR system is electronically-controlled by the EMS based on machine and engine operating conditions.

15

4

Power and torque range (in Volvo construction equipment, at varying engine speeds depending on applications)

7

183000

DaimlerChrysler

170000

Oil filtration system Two full-flow and one bypass oil filter for maximum filtration efficiency, long change intervals and engine reliability and durability. The filters are either enginemounted or chassis-mounted and are strategically located in order to enhance serviceability.

• Inlet air filtration system in three steps for efficient, reliable air cleaning, low maintenance costs and longer service life • pre-cleaner • main filter with replaceable insert • safety filter

146000

Weichai Power

134000

Cummins Scania MAN KamAZ

72000 67000 52000

The chart reflects production of diesel engines in 2006 in the 9-18 liter size class.

• Oil-bath filter, fitted in series with and ahead of the dry type filters, is optional (for particularly severe operating conditions).

8

12

18.1:1

19

10

The oil sump is designed in order to ensure reliable oil supply in non-road operations. A rubber gasket is positioned in a groove in the sump. The sump is fastened to the cylinder block by means of spring-loaded bolts; this constitutes a tight seal and reduces noise.

200000

Volvo

Caterpillar

Other Significant Features

Four cycle/inline six cylinder

Compression ratio

13

11

16.1 liter

Aspiration/intercooler

1

16

Sensors A number of engine parameters are continuosly sensed for precision control of engine performance. (For further details, see separate EMS box).

14 17 18

19

20

15

The fuel filtration system, more efficient in view of additional requirements on fuel cleanliness stemming from the new fuel injection system, consists of a 10 micron pre-filter, including a water separator with a sensor that monitors the level of condensate, and a main 5 micron filter for maximum protection of the fuel injection system. A new type of fuel filter housing, with automatic air bleeding, incorporates non-return valves in the filter nipples which prevent leakage at fuel filter exhange. A fuel tank breather filter is an additional feature.

• The air-to-air intercooler, specifically designed for demanding non-road applications, cools the inlet air by up to 150 degrees C ( 300 degrees F), for increased fuel efficiency and reduced exhaust emissions, nitrogen oxides (NOx) in particular. The colder air also reduces stresses on valves and pistons for extended engine service life. • High-capacity batteries and starter motor, tested in cold climates for reliability of operation. • An engine pre-heater warms the air in the inlet manifold to assure fast, gentle cold starts at ambient temperatures as low as –25 deg. C (— 15 deg. F). Its activation duration is regulated by the coolant temperature. • Electric transmission of the throttle application provides precise throttle control.

State-of-the-art Computer Aided Design (CAD) plays an essential role in the engineering of the Volvo diesel engines and also, as these Volvo D16E CAD creations show, in facilitating the engineering work required to optimally install the engine and its ancillaries into the machine.

A turbocharger of the standard fixed-geometry type for simplicity and reliability features improved flow characteristics and higher charge air pressure capability. Enhances engine efficiency and contributes to lower emission levels. In order to cope with the high turbo speeds and to achieve the required efficiency, the specially designed compressor wheel is milled from a solid, forged piece of high strength aluminum. Total Electronic Control and Diagnostics The E-ECU controls combustion to optimize output and minimize fuel consumption and emissions. The system also eliminates the risk of engine shock loads and protects the engine from over-speeding. A malfunction is immediately indicated in the Contronic monitoring system. At engine start-up, the electronic system automatically diagnoses all machine functions, including the engine. A separate, Volvo-unique PC-based diagnostic tool, VCADS Pro, is used by the Volvo service technician for in-depth performance analysis, fault-tracing, diagnostics and programming, if necessary. In addition, the engine´s (and the machine´s) operational history, including engine speed and fuel consumption data, is registered and stored, and can be retrieved from the electronic control system for analysis.

FEATURES

BENEFITS

Performance High efficiency • Ample power and torque • Excellent low end torque • High torque across a wide engine speed range with peak torque at modest engine speed • Fast engine response One engine, different layouts • Optimum engine/equipment match–performance characteristics optimally adapted and fine-tuned to the requirements of each application

High Productivity

Reliability and Durability; Availability A proven Volvo base engine with the highest quality of material and constituent parts, manufactured to the most exacting standards Constant electronic control and monitoring of the operation of the engine for optimal performance Effective and highly reliable air, fuel and lubrication systems, including very efficient filtering systems Powerful diagnostic tool (VCADS Pro) for quick fault analysis. Service of the engine greatly facilitated CareTrack telematic remote machine tracking and operating control system, including engine monitoring

High operational availability Productivity

High availability; productivity Enhanced availability Maximum operational control and up-time

Operator efficiency and convenience Excellent engine response • power and torque when and where needed for the application • high performance also at low engine speeds • ample torque rise as required by application Smooth, precise throttle control Low noise and vibration levels

Sustained high productivity and competitive fuel economy

Convenience and comfort Convenience and comfort

Low operating costs Electronic control of the combustion process and high thermal efficiency rating Simplified service and maintenance work and long service intervals • oil change at 500 hour intervals (normal operating conditions) • filters regrouped for ease of service and maintenance • easy access to engine installation for service and maintenance

21

Competitive fuel economy Low maintenance and service costs

Environmental Care Enhanced, latest-generation EMS (Engine Management System), EMS 2, whereby the E-ECU (Engine Electronic Control Unit) is integrated with the machine´s other electronic control units to form a highly efficient, interactive, real-time electronic communication system for optimum engine/machine performance, whatever the application and operating conditions. 21

CAD representation of overhead camshaft and valve actuation mechanism

Low exhaust emissions • meets current exhaust emission legislation (US Tier 3/EU Stage IIIA) Low noise levels Fuel filter housing anti-spill non-return valves and anti-spill oil drainage device

Tier 3/Stage IIIA-compliance

Minimum impact on the environment Minimum impact on the environment