Slide 1

Doosan Tier4-i Engine

Background

Date : 2012-04-25
EMEA Heavy line Training Team

Slide 2

INDEX
1. Development Background
2. Boring Parts & Lubrication
3. FIE system
4. Breather system
5. Cooling system
6. EGR system
7. Regeneration system
8. Forced Regeneration
9. Sensors & Actuators

Doosan Infracore

Slide 3

Development Background

Doosan has developed 2 types of engine for the Construction Equipment BG, the DL06 and DL08, in
response to Tier4 Interim exhaust requirements applied to the North American and European markets.
- Regulation were due to begin : DL08 2011 Jan, DL06 - 2012 Jan
(These dates have been delayed due to the global economic climate)

Needs

2008

2009

2010

2012

2011

2013

2014

< Emission Regulation >

DL06

Tier3

Industrial
DL08/DV11
Vehicle

Tier4 Interim

Tier3

Tier4 Interim

Euro4

ALL

Euro5

Tier4 Final
Tier4 Final
Euro6

Development

Affected Models & Engines

- Construction Equipment HEX, WL DL06, DL08

Technology

In order to reduce NOx and PM to correspond to the Tier-4 Interim regulations, certain post-process
technologies have to be used. In this case for Construction equipment Doosan Engine BG will apply
EGR+DPF, which precludes infrastructural limitations regarding the use of construction equipment.
For the Tier-4 Final regulations to be introduced in 2014, these regulations can be effectively met by
mounting additional SCR on the Tier-4 Interim engines.

Doosan Infracore

Slide 4

Development Background : Required Technology

Unlike the Euro-4 vehicles developed with SCR, the Tier-4 Interim has been developed with
EGR+DPF in consideration of each environment in which construction equipment is used.
Elements

Development Methods

Construction
Equipment Working
Environment

SCR
Features

It is possible that work is

undertaken in countries or
regions that do not have a
Urea supplying infrastructure
in place.
SCR type requires regular
injection of Urea into the
system (Failure to do this
may result in deterioration
of the fuel efficiency)
Future Environmental
Regulations
New Tier-4i engines have been
developed, with consideration
to meeting the Tier-4 Final and
Euro-6 regulations, due to take
effect in 2014.

Pros. &
Cons.

Applicati
on

Required to correspond with selective

catalytic restoration tools
Advantageous in fuel efficiency
Simple in architecture but equipped with
catalytic and Urea supplying units
Requires an infrastructure (supply
network) for supply of the elementary
component, Urea
Doosan Industrial Diesel Engine
Favored by European companies ( Benz,
IVECO)

EGR + DPF
Corresponding to regulations with an
exhaust gas recirculation system and
diesel particulate filtering unit.
No need of a device for regular refilling
of catalytic agents and no
environmental limitation
Fuel efficiency-competitiveness
weakened (about 5%)
In need of regular maintenance and
replacement of DPF
Favored by Northern American
Companies (CAT, Cummins)

Corresponding to Tier-4 Interim regulations with EGR + DPF in consideration of the

limitations with the use of equipment
In the future, correspond to Tier-4 Final regulations with Tier-4-Interim tech + SCR
* Tier-4(Stage4) is NOx 90% stronger regulation compared to Tier-3(Stage3A)

Doosan Infracore

Slide 5

Development Background : Required Technology

2. System Design Concept
With respect to Tier4 Interim solutions, we are applying higher combustion pressures than Tier3
engines; changing the charger system; augmenting the cooling volume; using EGR+DPF technology,
and additionally will add SCR for Tier-4 Final
Item

Tier3

Euro4

Tier4 Interim

Tier4 Final

Ignition Pressure (bar)

160

200

Turbo System

TC or WGT*

WGT

WGT or VGT

Piston

Al-Gallery

Al-Gallery
Material strength
increased

Cyl.Block

Cast Iron

Cyl.Head

Cast Iron

Con-rod

Steel

Strength increased

Crankshaft

Steel

Strength increased

Cooling System

Capacity increased

EGR

I-EGR***

No

20 ~ 25%

Yes

Yes

Yes

No

Yes

DPF
SCR

* WGT
: Waste Gate Turbocharger
** CGI
: Compact Graphite Iron
*** I-EGR : Internal Exhaust Gas Recirculation
Doosan Infracore

Slide 6

Key Changes
Components have been changed to meet Euro-4 standards and so are capable of being used for
both Tier-4 interim & Tier-4 final
Major Parts
Piston

DL08
- Material changed (M142 M174)
- Prevention of deterioration of oil due to Soot-in-oil
- Optimized profile to improve the life of the component

DL06
- Material changed (DM104 DM106)
- Prevention of deterioration of oil due to Soot-in-oil
- Optimized profile to improve the life of the component

- Application of the Inner Cut Top Ring

- Reduction in oil consumption by use of 2nd Reverse Inner
cut Ring

- Top ring: Outer circumference coated with Cr Ceramic. Inner Cut

-. 2nd ring: Increased durability and reduce oil consumption with
Reverse Inner cut and Cr coating of the outer circumference

Con Rod

- Reduction of the pressure on the Bush side by increasing the

bore of the small end
- Reduction of the pressure on the Bush side by applying Steptype method to the small end

- Reduce the pressure on the Bush side by applying Step-type

method to the small end

Con Rod
Bearing

- Boosting the safety by material change

- Augmentation of chamfer: corresponding to the tightened
standards on pin R

- Apply same components

(The safety factor proved under EURO-4 regulations)

- Complement the intensity by reinforcing the Pin R part

- Apply same components

(The safety factor proved under EURO-4 regulations)

- Remove the I-EGR (Extra Lobe)

- Improve the wear-resistance by improving the profile

- Remove the I-EGR (Extra Lobe)

- Improve the wear-resistance by improving the profile

- Increase the durability by applying the Fin Damper to reduce

the temperature .

- Apply same components

(The safety factor proved under EURO-4 regulations)

Piston Ring

Crank Shaft

Cam Shaft

Damper

Doosan Infracore

Slide 7

Tier 4 Interim Engine System

On the basis of Euro-4 engine model, apply higher-pressure injection, VGT, Cooled EGR, Hot side EGR
Valve, Inlet Throttle Valve, and DPF with a dosing unit as a post-treatment solution.

Charge Air Cooler

Throttle
Valve

EGR Cooler

Intake

EGR
Valve

Compressor
Turbine

Exhaust
DPF

Doosan Infracore

Slide 8

Tier 4 Interim Engine : Exterior (DL08)

Doosan Infracore

Slide 9

Tier 4 Interim Engine : Exterior (DL06)

Doosan Infracore

Slide 10

Development Background
3. Engine Installation Plan
Doosan Tier 4i engines to be mounted on a total of 13 types of Doosan construction equipment
(DL06 10 types, DL08 3 types)
Category

Crawler Excavator

DL06
Wheel Excavator

Wheel Loader

DL08

Crawler Excavator

Model

Power (PS/rpm)

Torque
(kg.m/rpm)

DX140LC-3

106/1850

46/1400

DX180LC-3

127/1950

47/1400

DX225LC-3

167/1800

70/1400

DX235NLC-3

169/1800

77/1350

DX255LC-3

188/1900

82/1400

DX140W-3

139/2000

60/1400

DX170W-3

154/2000

63/1400

DX190W-3

176/1900

77/1400

DL200-3

146/2100

63/1400

DL250-3

167/2100

76/1400

DX300LC-3

216/1800

99/1300

DX340LC-3

285/1800

130/1400

DX380LC-3

290/1800

130/1400

Remark

Doosan Infracore

Slide 11

- EOD -

Doosan Infracore