Engine

Fact Sheet D12D500, EM-EC01

The D12D500 is a 500 hp, 12-litre, straight, six-cylinder

diesel engine with turbo, intercooler and turbo-compound.
The engine meets EU regulations regarding exhaust emissions
according to Euro 3
The D12D is a new generation of Volvo’s well-proven and sturdy
D12 engine. D12D is equipped with renewed fuel injection and
the Volvo EMS engine control system for optimal combustion.
The turbo-compound is an extra turbine placed behind the turbo
and recovers energy from the exhaust gases. The D12D500 is
fitted with a common cylinder head, four valves per cylinder,
overhead camshaft, two-part articulated piston and electronically
controlled unit injectors. Modified cooling of cylinder liners and
cylinder head provides improved heat dissipation. Engine
performance and exhaust emissions have been optimised through
extensive combustion development. The introduction of the
second-generation unit injectors with improved injection
characterise, combined with extensive improvement of the
combustion system, makes the D12D in the Euro 3 version still
highly competitive with regard to efficiency and with regard to
service intervals, now extended
.
The D12D500 is a very fuel-efficient engine with good drivability
developed for heavy, demanding driving for long-haul and
construction transport. The D12D500 in the Euro 3 version also
has long service intervals. The engine is equipped with VCB
(Volvo Compression Brake) with very good brake efficiency. The
following product features characterise the D12D500:
• The turbo-compound provides high engine power, low
fuel consumption and high efficiency, especially with regard
to heavy driving.
• Quick response and very good low-rpm characteristics
capability result in good starting and reversing capabilities.
• Electronic engine management, EMS, with precise fuel
injection results in efficient combustion with low emis-
sion values.
• Vertical centrally located unit injectors result in Power, kW
symmetrical distribution of the fuel.
• By means of a electronic sensor, the oil level can be read 360
on the driver’s graphic display. Net output
according to:
• Various power take-offs are available for a directly dri- 340
¥ ISO 1585
¥ Dir. 89/491/EEC
ven hydraulic pump (option). 368 kW 1600-1800 r/min
¥ ECE Reg 85
(500 hp metric)
320
Torque, Nm
2400 Nm
1000-1300 r/min
300 2400

Specifications 280 2200

Designation .................................. D12D500, EM-EC01 260 2000

Max output at 1600-1800 r/min ........ 368 kW (500 HP)

Max rpm ..................................................... 1900 r/min 240 1800

Max torque at 1000-1300 r/min ..................... 2400 Nm

1600
No. of cylinders .......................................................... 6 220

Bore ................................................................. 131 mm 200

Economy 1400
Stroke .............................................................. 150 mm
1000-1700 r/min

Displacement ..................................................12.1 dm3 180

Compression ratio ...............................................18.1:1 Spec. Fuel

consumption
g/kWh
Engine brake output (VCB) at 2300 r/min ....... 225 kW 160

Economy engine speeds ...................... 1000-1700 r/min 210

Engine oil capacity, including filter .................... 33-38 l

200
190
No. of oil filters ........................... 2 full-flow, 1 by-pass 186 g/kWh EC01 180
Cooling system, total volume ................................. 44 l
Weight .........................................................1170 kg 800 1000 1200 1400 1600 1800 2000 r/min

2004-11-05 ENG Version 02


Fact Sheet
Electronic engine management
integrated into the vehicle’s
electrical system
The D12D engine is fitted with Volvo
EMS (Engine Management System),
which means that the engine’s functions
are completely electronically
controlled. EMS provides efficient
engine management and advanced
capability for diagnostics and fault-
tracing. The engine’s control module
is connected to the vehicle’s electrical
system’s data links, and information is
presented in an easy-to-read display
on the instrument panel.
The engine control module is located
in an aluminium housing on the left
side of the engine, where the electronic
components are cooled by the fuel via
a built-in cooling coil. The engine’s
wiring has been gathered in one place
and is well-protected in a wiring ter-
minal located under the inlet manifold.
The graphical display inform the driver about
for example engine oil temperature
Electronically controlled fuel
injection gives low emission
values.
In order to allow operating data to be
registered, the engine is fitted with
several sensor functions.
The engine control module compares
current readings with stored data, and
regulates the amount of fuel and the
injection timing.
The entire combustion process is pre-
cision-controlled in all operating
situations, resulting in low fuel
consumption and a minimum of noise
and exhaust emissions.
The D12D500 meets EU regulations
regarding exhaust emissions according
to the requirements and additional
requirements for Euro 3.
Turbo-compound
provides extra power at heavy
load
The turbo-compound is an extra turbine
located behind the ordinary one and
recovers energy from the exhaust gases.
The extra power is transmitted through
a hydrodynamic coupling and a
gearwheel to the crankshaft. The turbo-
compound provides very good low-
rpm characteristics and quick response
combined with low fuel consumption
at heavy load.
Well-dimensioned
cooling system with high
efficiency
The thermostat is integrated in the
cylinder head, providing a compact
construction.
The engine has wet cylinder liners for
efficient heat dissipation.
They are exchangeable and are made
without a flame edge. D12D has
improved internal cooling for the cy-
linder head and for the oil system.
Inside the engine, all the calibrated
cooling channels co-operate in order
to bring about a balanced cooling pro-
cess. The cooling flow is distributed
between the lower and upper cooling
casing and the cylinder head.
The engine is equipped with piston
cooling. The upper section of the pis-
ton and the piston ring zone are cooled
efficiently as oil is sprayed underneath
the piston. Cooling is ensured even at
low idle.
Engine
D12D500, EM-EC01
Unit injectors with quick
injection provide efficient
combustion
The D12D500 is equipped with unit
injectors with a 17-mm pump stroke,
which results in high injection pressure.
The high pressure is created
mechanically through a rocker arm,
which is driven by the overhead
camshaft.
The centrally placed injector has been
renewed and provides quick and well-
controlled injection with symmetrical
distribution of the fuel in the
combustion chamber.
The cylinder head has only one common
fuel channel to the injectors and large-
diameter inlet channels and valves for
low pressure drop.
Designed for high reliability and
long
service life
The D12D engine is built for a long
and reliable service life. It is provided
with a common cylinder head with a
steel gasket and with induction-
hardened camshaft and crankshaft
induction. The camshaft is equipped
with a vibration damper to reduce
sound output.
The heavy-duty cylinder block is also
fitted with reinforcement ribs of
nodular iron, a design feature that also
offers lower noise levels and less vi-
bration. An engine-mounted fuel fil-
ter with water separator is available as
option.