Content W04C TI Marine WS 173pages
Content W04C TI Marine WS 173pages
Content W04C TI Marine WS 173pages
SPEC! Fl CATIONS
DIESEL ENGINE FOR MARINE USE
W04C·TI
3.839 liters, 4-cycle,
HIND 4-cyl., water~ooled,
turbocharged and intercooled
e ENGINE DESCRIPTION
1. Max. output, pleasure craft 157 kW (210 HP)/3,000 rpm
2. Max. output, work boat · 138 kW (185 HP)/3,000 rpm
(light duty)
3. Type Diesel, 4-cycle, 4-cyl., in-line, over-head valve, water-cooled
4. Aspiration Turbocharged and intercooled
5. Combustion system Direct injection
6. Cylinder
Bore x Stroke 104 x 113 mm (4.09 x 4.45 in.)
7. Piston displacement 3.839 liter (234.2 cu.in.)
8. Compression ratio 16.5
9. Direction of rotation Counter-clbckwise viewed from flywheel
10. Dimensions with marine
gear (L x W x H) Approx. 1,152 x 694 x 790 mm
(45.4 X 27.3 X 31.1 in.)
11. Dry weight with marine
gear Approx. 540 kg (1,1911b)
e FEATURES
1. Cylinder block Mono block cast iron with replaceable dry liner
2. Cylinder head Single piece cast iron
3. Crankshaft Induction hardened die forged special steel with counter
weights
4. Piston and rings Heat resistance aluminum alloy
Two compression rings, chrome plated
One oil ring, chrome plated with coil expander
5. Camshaft Induction hardened carbon steel
6. Valves Heat resistance steel
Gl-14 GENERAL INTRODUCTION
e EQUIPMENT
• ENGINE ~.
• INSTRUMENT PANEL
1. Battery switch
2. Starter switch with key
3. Instrument panel lamp switch
4. Tachometer (with hourmeter and trip meter)
5. Coolant temperature gauge
6. Oil pressure gauge
7. Fuel gauge
8. Volt meter
9. Pre-heater indicator lamp
10. Coolant temperature warning lamp
11. Charge warning lamp
12. Oil pressure warning lamp
GENERAL INTRODUCTION 01·3
09420·1442 - - - - - - P A R T NUMBER
REPAIR PROCEDURES
Repair procedures which are self-explanatory such as simple
installation and removal of parts have been omitted. lllustra·
tions such as the one below have been provided to make such
simple procedures clear. Only essential procedures requiring
directions have been dealt with explicitly.
14
T • Tightening torque kg-em (lb.ft)
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBERS
Please quote these numbers when ordering spare parts or
reporting technical matter as they will give you prompt service
anent ion.
The engine serial number is engraved on the engine cylinder
block.
GENERAL INTRODUCTION Gl-5
SPECIFICATIONS
DIESEL ENGINE FOR MARINE USE
e ENGINE DESCRIPTION
1. Max. output, pleasure craft 82 kW ( 110HP)/3,000 rpm
2. Max. output, work boat 69 kW (92 HP)/3,000 rpm
(light duty)
3. Type Diesel, 4-cycle, 4-cyl., in-line, over-head valve, water-cooled
4. Aspiration Natural aspirate
5. Combustion system Direct injection
6. Cylinder
Bore x Stroke 104 x 118 mm (4.09 x 4.65 in.)
7. Piston displacement 4.009 liter (244.6 cu.in.)
8. Compression ratio 17.9
9. Direction of rotation Counter-clockwise viewed from flywheel
10. Dimensions without marine
gear ( L x W x H) Approx. 1,026 x 691 x 790 mm
(40.4 X 27.2 X 31.1 in.)
11. Dry weight without marine
gear Approx. 385 kg (850 lb)
e FEATURES
1. Cylinder block Mono block cast iron with replaceable dry liner
2. Cylinder head Single piece cast iron
3. Crankshaft Induction hardened die forged special steel with counter
weights
4. Piston and rings Heat resistance aluminum alloy
Two compression rings, chrome plated
One oil ring, chrome plated with coil expander
5. Camshaft Induction hardened carbon steel
6. Valves Heat resistance steel
Gl-6 GENERAL INTRODUCTION
•• ENGINE
EQUIPMENT
• INSTRUMENT PANEL
1. Battery switch
2. Starter switch with key
3. Instrument panel lamp switch
4. Tachometer (with hourmeter and trip meter)
5. Coolant temperature gauge
6. Oil pressure gauge
7. Fuel gauge
8. Volt meter
9. Pre-heater indicator lamp
10. Coolant temperature warning lamp
11. Charge warning lamp
12. Oil pressure warning lamp
GENERAL INTRODUCTION Gl-9.
SPECIFICATIONS
DIESEL ENGINE FOR MARINE USE
• ENGINE DESCRIPTION
1. Max. output, pleasure craft 112 kW (150 HP)/3,000 rpm
2. Max. output, work boat 93 kW (125 HP)/3,000 rpm
(light duty)
3. Type Diesel, 4-cycle, 4-cyl., in-line, over-head valve, water-cooled
4. Aspiration Turbocharged
5. Combustion system Direct injection
6. Cylinder
Bore x Stroke 104 x 113 mm (4.09 x 4.45 in.)
7. Piston displacement 3.839 liter (234.2 cu.in.)
8. Compression ratio 17.9
9. Direction of rotation Counter-clockwise viewed from flywheel
10. Dimensions with marine
~'
gear (L x W x H) Approx. 1,134 x 661 x 790 mm
(44.6 X 26.0 X 31.1 in.)
11. Dry weight with marine
gear Approx. 465 kg ( 1,025 Ib)
• FEATURES
1. Cylinder block Mono block cast iron with replaceable dry liner ,
2. Cylinder head Single piece cast iron
3. Crankshaft Induction hardened die forged special steel with counter
weights
4. Piston and rings Heat resistance aluminum alloy
Two compression rings, chrome plated
One oil ring, chrome plated with coil expander
5. Camshaft Induction hardened carbon steel
6. Valves Heat resistance steel
GJ-10 GENERAL INTRODUCTION
e EQUIPMENT
• ENGINE
1. Flywheel housing SAE No.3
2. Flywheel SAE 11%
3. Fuel injection pump BOSCH "A" type with all speed governor
4. Fuel filter Paper element type
5. Water separator Equipped
6. Lube oil pump Full forced pressure feed by gear pump
7. Lube oil filter Paper element type (Full flow)
8. Lube oil cooler Multi plate type, Fresh water cooled
9. Fresh water pump Forced-circulation by volute pump
10. Raw water pump Self priming, Rubber impeller type
11. Intake manifold Inlet position at rear
12. Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat
exchanger with expansion tank
13. Turbocharger Cooled by fresh water, with air cleaner
14. Starter 12V, 2.5 KW
15. Alternator 12V, SOA, with built-in voltage regulator
16. Engine stop solenoid Equipped
17. Emergency stop relay Equipped
18. Starter block relay Equipped
19. Grow plug Equipped
20. Rigid mount bracket Equipped
21. Exhaust riser Cooled by raw water ·~
• INSTRUMENT PANEL
1. Battery switch
2. Starter switch with key
3. Instrument panel lamp switch
4. Tachometer (with hourmeter and trip meter)
5. Coolant temperature gauge
6. Oil pressure gauge
7. Fuel gauge
8. Volt meter
9. Pre-heater indicator lamp
10. Coolant temperature warning lamp
11. Charge warning lamp
12. Oil pressure warning lamp
GENERAL INTRODUCTION Gl-11
F226
FRONT VIEW
F227
LEFT SIDE VIEW
F228
FRONT VIEW
F229
,- ------···········-~··----------------------~-----
....
1:')
en
TIGHTENING TORQUE OF STANDARD BOLT
Unit: kg·cm (lb.ft)
~
Bolt
identific•
tion 4 6 8 10 12 14 16 18 20 22 24
0
Optimum conditions. z
-1
:::D
Cast iron or aluminum tightening 0
22-32 75- 110 183- 270 364-533 636-932 1,020 - 1 ,500 1 ,590 - 2 .330 2,180- 3,200 3,100-4,550 4,250- 6.210 5.360- 7,850 0
surface. Washars. (1.6- 2.3) (55- 7.91 (14- 19) (27- 381 (47- 67) (74- 1081 j116- 168) 1158- 231 I (225- 3291 (308- 4491 (388 .. 5671 c:
~·" Medium conditions. n
L J ::!
·- 7 Tightening area having black
coarse surface. Rusty. Naked
bolt or lubricant unavailable.
Poor tightening conditions.
27-40
(2.0- 2.81
94- 138
(6.8- 9.9)
229- 336
(17- 24)
455-667
(33- 481
795-1,165
(58- 84)
1,270-1,870
(92-135)
1,990- 2,920
(144- 211)
2.730- 4,000
(198- 289)
3,870 - 5.680
(280- 4101
5,310 - 7 .BOO
(385- 5641
6.700- 9.850
(48~- 712)
0
z
C~'J ~
Evan tightening area. Bolt nut,
coating, naked bolt, lubricant, etc.
Optimum conditions.
24-32
(1.8- 2.3)
82- 110
(6.0- 7.91
200-267
(15- 19)
397-574
(29 -41)
694-925
(51- 66)
1,010-1.480
(74- 107)
1,730- 2,310
(126 -167)
2,380-3,170
(173- 229)
3.380 - 4,510
(244- 3261
4,630-6,170
(335- 4461
5,850- 7.790
(424- 563)
NOTE: The torque values given in this table should be applied where bolt torque is not specified.
) ) )
n ) ) )
ATMOS-
LUBRICANTS POSITIONS S.A.E.
PHERIC BP CALTEX CASTROL ESSO GULF MOBIL SHELL TOTAL
NO.
TEMP.
RPM DELO •oo ();I Castrot or Deusot MyriNI 0.1 olO, TOTAL
Above Essolube Mobil Oelvec 1340
Vanellus C-3 SAE 40 Of 15W/40 CRO 40, Turboma-.: GuH Super Duty 20W·•O. 15W-•O Rubia S 40
32'C •o 0·3 40. Mobil Oelvec SUI*
I9D'FI 40 RPM DELO 300 ();I Caatrof or Deusot Motor 0•1 olO. 15W-ol0 Rimula X Oil 40 TOTAL
XD·3 40 15W·40
SA£ •o AX Super 40. 15W/40 R1mula CT 40 Rube TM 15W40
ENGINE OIL
Mvnna Oil 30.
--
lA PI COl RPM DELO 400 ();I Cntrot or Deusot TOTAL
hsolube Mobil Oetvec 1330 2ow-•o.1sw-•o
Previous Classification 32' o·c JO
Venellus C-3 SA£ 30 or 15W/•O CRO 30
0·3 30.
Gulf Super Duty
Mobil Defvec Super Rtmula X Oil 30.
RubeS 30
lA PI DSI 190' 32'FI 30 RPM DELO 300 ();I Castro! or Deusot Motor 011 30,15W-40 TOTAL
XD-3 30 15W·40 10W-30
IMIL·L-2104CI SAE 30 AX Super 30. 15Wt40 Rubia TM 15W40
Aimuta CTJO
IMIL-l-4519981
Castro! or Deusot
RPM DELO 400 ();I Mvrint Oil 20. TOTAL
o· 12'C CRD 20Wt20 Essolube Mob! De1voc: 1310
Vanellus C-3 SA£ 20/20W,15W/•O Castro! or Deusof
Gutf Super Duty Mobil Oetwc Supai' 20W-40. 15W·•O RutNS 20
132' 10'FI 20 RPM DELO 300 ();I 0·3 20W. Motor 0.1 20, 15W-ol0 Rimut1 X Oil 20 TOTAL
20W X0-3 15W-40 15W-40
AX Super 20W/20. Rimuta CT20 Rubi1 TM 15W40
Cvtinder Block SA£ 20120W 15Wr40 C)
lnjectton Pump
Air Cleanet" RPM DELO 200 ();1 Cntrot or Oeusol
m
Above
Vanellus M SA£ 40 CRX 40
Essotube
Gulflube Motor ()tl Mobtl Oelvac 1240
RoteHa TX40,20W-50
TOTAl z
32'C
I90'FI
40
40 RPM DELO 100 ();I Castro! or Oeusol
HDX 40,
HOX Plus 40
XHO 40.15W-40 Mobol Delvac 1140
Rotella SX 0.1 40.
20W-40
Rubia H 40 m
SA£ 40 AX Super 40, 15W/40
-- :a
ENGINE OIL
lA PI CCI
Previous Clanificatton 32' o-c 30
Vanellus M
RPM OELO 200 Oil
SA£ 30
Casttot or Deusol
CRX 30
Essotube
HDX 30.
Gulflube Motor Oil Mobtl Oetvac 1230
Rotella TX30.20W-50
Rotella SX Oil 30.
TOTAL
,...:J:Io
lAP 1 OMI 190. 32'FI 30 RPM OElO 100 Oil Cestrof or Oeusol XHO 30, 15W-40 Mobtl Oetvac 1130 Rubia H 30
IM1L·L·461521 SAE 30 AX Super 30. 15W140
---------
HDX Plus 30 20W·40
z
IMIL-l-210481 .~---- ~--
-f
o- 12'C Vanellus M
RPM DELO 200 ();1
SA£ 20/20W
Castro! or Oeusol
CRX 20Wr20 Essotube
Gulflube Motor ()tl Mobil Oetvac 1220
Rotella TX20,20W-50
TOTAL
:a
20 Cattrot or Deusol HOX 20. Rotetla SX Oil Q
132' 10'FI RPM DELO 100 ();I Mobil Oefvac 1120 Ruboa H 20
20W
SAE 20t20W
AX Super 20W 1 20. HOX Plus 20W- 20
XHD 20.15W-40
20/20W.20W·40 c
-------- -· -- -- 15W,40
~- c:
COOLANT PUMP Marfak
Esso
n
~
Energrease Multtpurpose 2 CastrollM Mobtlgrease Retina.. A TOTAl
BEARING GREASE Coolant Pump Beartng
L·2 or Marfak Grease
Multtpurpose Gulfh~JC Polv
MP. 77 .MS Alvania Grease A2 MULTIS 2
IMIL·G · 1092 461 Grease Q
All PiJtpose 2
Bushing, Clutch,
- - - - - - --------- z
Drive Shah, Molyle• --- --- ---
STARTER GREASE Ptllton Shth lever
--- --~
Mobllgreese 29 Aero Shell Grease 17
Grease EP2
& R:eductton Gear
---~~- - - - - - -; - - - - - - - - - -
GENERATOR & STARTER
BEARING GREASE
Generator Beanng
Staner Bean"Q
Energrease
LT2
RPM Grease
SR12
---- --- --- MotJ;Igrease 28 Aero Shell Grease 1 ---
Marfak
-~------ -~--~----~
r---·--· -- - - - - - - -
INJECTION PUMP Energrease Multtpurpose 2 Castrof LM
Esso Mobllgrease Rettna• A TOTAl
TIMER GREASE lntectton Pump Ttmer
L·2 or Marfak Grease
Multipurpose Gulfle• Poly
MP. 77.MS Alvanta Grease R2 Multts EP 1
IMIL-G-109248) Grease
.. __ All Purpotft 2
- -~
------- --
ShellzoneiU.S A. I
Crutse Master Glycoshefl Plus
Castrot Antt-Freeze Esso Mobil IEuropian Countnes) TOTAl
AF Eng.ne An(lfreeze
ANTI FREEZE Engtne. Radtator
Anlt Frost Castrot long l•fe Ant• freere
And Summl!f Permazone Shellsafe ANl'IGEl
(MIL·H·5559AI Cootant Coolant
Coolant At1t1-Freeze P281
Coolant
Cooloua•d
Note: lubtic8nts ~ lfTMnded KCOrding to rww c:leaific:ltion by A. P.l tAmericlln Petroteum lnttituteJ '62·12-2001T S DHlll'l
.
.....
.....
ENGINE EN·DS7A·1
ModeiW04D
PERFORMANCE CURVE
:f :f
£
I A: SHAFT
BRAKE HOSe PoweR
B: HOSE POWER
)E.
ii:' !00
ii:'
100
f--.=c_:_TY_P..,.IC_AI._P_R_O_Pe,...L_LE_R_L_OAO...,....:I-EX_P_ON_ENT..---J.O..;.I___,---i
;_
120
80
'~[ I
80~--~-----r----~---~--~----;
100 100
I
!
r- eo 60 r- eo t 60 1--+-----i---1-'t--:::>::::s-1'"--+t---;
60 ~ 40~--t---7'T-~
::l ::l
0.. 0..
l
r- r-
::l ::l
0 0
•ot 20f--+----t-:~~
•o
20
~
20 r I
! I a 0f ;::
~
0
z 20 I ~ 0z
0
..J ;::
oL 0 50 ~ 0.. ol 0~1----4-----~--~-----+----,_-- ;t 0..
12. :::: i \2. ::::
40 ::l 40 ,10 ::l
10 (/) (/)
z a z
JO e 0 JO 0
6
u u
20 ...J 20 ...J
w w
10 ::l 10 ::l
2 II.. II..
0 0
NOTE:
Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro-
metric pressure), 25°C (77°F) air intake temperature, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2
diesel fuel wll be within 5% of that shown at the time of engine shipment. Actual performance may vary with
different ambient conditions.
ENGINE EN-DS7A-3
·~
\
Model W04C-T
PERFORMANCE CURVE
.,...,-
·'~
A: LTEDJ 140
140
v I
100 100
A: RATEDBHP
1-
:;,
a..
120
/~
1-
:;,
a..
120
\,.;: ~
10
v 10
iY
~
1/
1- 100 1-
:;, :;, 100
0 /.
/7 r\a: 0
/
v
RATED SHP/
10 10 80 80
~
/ ~ 80
I\ a: RATED SHP/
7 ~
~ I ~
~
10
40 "'t: z 40
0
=-
~ C: POWER·PROPEU.ER LOAD i=
.... a.. /
~ ~
40
FUEl CONSUMPTION
50 <
!2. :::E
:;,
•o
20
v \ C : POWER·PROPEllER LOAD 50
40 ~
-
20 40
20
~l-~LOAD \ 30
10
8
C/)
z
0
20 7 FUEl CONSUMPTION
30
10
8 ~
FUEL·PROPElLER LOAD
~ / s 0 .l- 0
20 ...1
0 0
~ ~
20
10
•
...1
w
:;,
0 0
L..---1-- ::...> 10 2
w
~
2 II.. ~
~
~
0
I-- 0
1,.00 1,800 2.200 2.800 3,000 1••oo 1,800 2.200 2,&00 3.000
NOTE:
Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg) baro-
metric pressure), 25°C (77°F) air intake temperature, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2
diesel fuel wll be within 5% of that shown at the time of engine shipment. Actual performance may vary with
different ambient conditions.
DESCRIPTION
~\
DHF-226 DHF-227
r
EN-DS7A-4 ENGINE
Model W04C-TI /~
I
PERFORMANCE CURVE
250 250
180 180
A: RATED BHP
160 160
200 )..: ~ 200
1•0 1•0 A: RATED BHP
/.V"" / r-. .... ~ ~
1-
:::l 150
c..
1-
120
100
<I~B:
.?
RATEDSHPI'
v 1-
:::l 150
c..
1-
:::l
120
100
,As:
£
RATED SH~7
7
:::l
0 100
80
/ v f
0 100
80
,f / f
60
~ / C : POWER-PROPELLER LOAD
...;;;.~
g
60
v .A ~ ~
50 •o
20
./
:;1
Q. z
0
50 40
50
u ~
~ 12 :::E I 12 :::E
FUEL CONSUMPTION
.o 10
:::l
en •o 10 iil
..........- ~ / z 5 f----7 z
./ ./
30 8 0
u ~ v 30 8 0
u
~
20
10
•
2
..J
LIJ
:::l
u.
v ~
v 20
1
•
2
..J
LIJ
:::l
u.
!----" \ FUEL·PROPEL.LER LOAD 1----- FUEL-PROPELLER LOAD
1,.00 1.800 2.200 2,600 3,000 1.•oo 1.soo 2.200 2.600 3,000
NOTE:
Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro-
metric pressure), 25°C (77° F) air intake temperature, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2
diesel fuel wll be within 5% of that shown at the time of engine shipment. Actual performance may vary with
different ambient conditions.
DESCRIPTION
DHF-228 DHF-229
ENGINE EN·TS1B·1
TROUBLESHOOTING
PottlbleCMtM Remedy/Prevention
Abnormal combustion
Other problems