The Dieselmax Engine

Volvo Construction Equipment

History
JCB 4000 series Engine
Developed in the nineties
Not commercially viable

Volvo Construction Equipment

Engine Development
Specialist Design and Development team working over a 5 year
time span
3 iterations of prototypes
120,000 test hours
Collaboration with industry leading consultants
Ricardo Consulting
Cosworth Technologies

Volvo Construction Equipment

Partners
Ricardo
Leading power train and vehicle engineering
technology provider
Strategic consultant to the world automotive
industries
Provide research, design, development,
strategic services
Cosworth
World leader in integrated engine and power
train solutions
Clean sheet design concept through castings,
manufacture and vehicle installation
Calibration, onboard diagnostics and telemetry

Volvo Construction Equipment

Design Aims
Brand new clean-sheet design
Design specifically for off-highway markets
Robust construction
High torque at low revs
Low noise
Good cold start performance
Easy to service
Emission and noise compliant
Design for manufacture, assembly and cost
Volvo Construction Equipment

Competitive Advantages
Fundamental design is simple yet sophisticated
Reliability
Reduced warranty & prime life failures
Performance
Superior low speed torque & fuel consumption
Noise
3dBA to 6dBA quieter than previous engines
Cost of Ownership
500hr service intervals
Easily meets emissions
Engine designed for Tier 3+

Volvo Construction Equipment

Engine Features

Block
Construction
Grey iron
Integrated water pump and
alternator mounting
Integrated oil cooler
housing
Cylinder bores
Parent bore
Coolant circulation around
all cylinders

Volvo Construction Equipment

Bedplate
Construction
Grey iron
Simple casting core
structure
Integrated a/c compressor
mounting
Oil sealing
Front and rear oil seals
carried in block
No T joints

Volvo Construction Equipment

Cylinder Head
Construction
Grey iron
Simple casting core structure
Head simpler to cast more reliable process
Only 2 core plugs
No angle drillings/machining
Cross-flow
Optimum gas flow
Better breathing
Better conditioning of air into the cylinder
Four valves per cylinder
Parent metal valve guides
4 valves allow central placement of injector
more balanced heat distribution and dynamics

Volvo Construction Equipment

Cylinders and Block

Construction
SG iron, fillet rolled
Induction hardened bearing
surfaces
Strong and stiff
Minimises torsional
vibrations

Volvo Construction Equipment

Timing Gears
Rear Gear Train
Gears are positioned at the
node of torsional vibrations
of the crankshaft
Quieter
Smoother drive for fuel
pump
Gear teeth
High contact ratio spur
gears to give low noise,
particularly when at the rear
of the engine
Spur gears generate less
end thrust on crank and cam
shafts
Volvo Construction Equipment

Valve Train

Construction
Components generally steel
Bucket tappet, pushrod,
rocker, floating bridge piece
Splash lubrication
Interference thread screw
Easier to adjust

Volvo Construction Equipment

Pistons and Connecting Rods

Con-rods
Micro alloy steel
Fracture split
Pistons & Rings
Aluminium alloy pistons
Steel first ring carrier
3 rings

Volvo Construction Equipment

Fuel Injection Equipment

Delphi DP310 Fuel injection pump
JCB pump unique counter rotation due to rear drive
ESOS and cold start solenoids interchangeable
Pre-filter/water separator
Superior filtration system for reliability and low running costs
Electronic water sensor
5 Micron fuel filter
Pre filter changed at 500 hours
Main filter changed at 1000 hours
Volvo Construction Equipment

Other Systems
Lubrication system
G-rotor oil pump with integral relief valve
Integral oil cooler
Cooling system
Belt-driven pump with vane impeller and volute in block, full
flow through oil cooler

Volvo Construction Equipment

Other Components
Sealing
Multi-layer steel cylinder head gasket
Metal gaskets for manifolds
Moulded seals for covers
PTFE lip seals for crankshaft (front is cassette type direct mount into block)
Liquid sealant for bedplate, rear casings and sump
FEAD Belt
Long life Poly-vee FEAD drive belt
Automatic tension system
Belt change every 6000 hours
Flexible fan drive ratios and positions
Cold Start aid
Grid heater gives less compromise of combustion chamber design

Volvo Construction Equipment

 Robustness
Block, bedplate and head structure
Crankshaft dimensions
Gear train
Housings
Enclosed engine breathing
High low-speed torque output
Breathing 4 valves
Combustion system
FIE and turbo matching
Reliability and long life
Structures
Sealing technology
Rating capability
Fuel pre filtration
Water in fuel sensor
Low engine water sensor option
Low noise
Bedplate
Gear train at rear
Isolated covers
Oil pan material
Combustion system

Volvo Construction Equipment

Design Features

Power and Torque

Build

Power

Torque

KW

HP

rpm

Nm

lbf ft

rpm

SD

63

85

2200

362

267

1200

SD

68

92

2200

408

301

1200

SF

74

99

2200

440

325

1300

SF

85

114

2200

440

325

1300

Volvo Construction Equipment

SD Engines

Volvo Construction Equipment

SF Engines

Volvo Construction Equipment

22

Torque Back Up =

TBU =

(Maximum torque Torque at maximum power) x 100

Torque at maximum Power

425 Nm 325 Nm x 100

325 Nm

= 30.75%

425 Nm Torque
at maximum
torque

325 Nm Torque
at maximum
power

Volvo Construction Equipment

Service
Schedule

Volvo Construction Equipment

Engine Assembly
Custom built manufacturing facility
Failure mode effective analysis (FMEA)
Memory tag system
No faults forward computer controlled and monitored assembly
Lean manufacturing
Eliminate waste, maximize quality
Computerised engine parts testing
Clean room fuel system assembly and testing
Hot testing
Certified engines
Guaranteed quality

Volvo Construction Equipment

Volvo Construction Equipment

Engine Assembly

Volvo Construction Equipment

Working
With the
Engine

Volvo Construction Equipment

Volvo Construction Equipment

Tools Update
Double cranked spanner
892/01179

Templates made available through

JCB Service for:
Gear case to block 892/01176
Bedplate to block 892/01175
Flywheel to gear case 892/01177

Volvo Construction Equipment

Summary
Designed specifically for off-highway machines
High and low power take offs available on all engines
11.2kW (15hp) SAE A
60kW (80hp) SAE B
Robust construction bedplate design
High torque at low engine revs.
Good torque back up (TBU) characteristics
Low noise
Good cold start performance
State of the art design
Designed with full knowledge of impending emissions constraints.

Volvo Construction Equipment