MTU 8V4000Mx4 User manual

Operating Instructions
Diesel Engine
8V4000Mx4
8V4000Mx4S
8V4000Mx4R
MS150109/01E

Engine model kW/cyl. Application group
8V4000M24S 111.9 kW/cyl. 3A, continuous operation, unlimited
8V4000M54 111.9 kW/cyl. 1A, continuous operation, unlimited
8V4000M54R 93.3 kW/cyl. 1A, continuous operation, unlimited
Table 1: Applicability overview
© 2015 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety
1.1 Correct use for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety regulations for startup and operation 8
1.5 Safety precautions when working on the
engine 10
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.7 Standards for safety notices in the text 15
2 General Information
2.1 Tightening specifications for screws, nuts
and bolts 16
2.2 Engine side and cylinder designations 29
2.3 Product description 30
2.4 Engine overview 38
2.5 Sensors and actuators – Overview 42
2.6 Engine wiring harness – Overview 52
3 Technical Data
3.1 Engine data 8V4000M24S, Marine EPA Tier
3, IMO Tier II 57
3.2 Engine data 8V4000M54, Marine EPA Tier
3, IMO Tier II 61
3.3 Engine data 8V4000M54R, Marine EPA Tier
3, IMO Tier II 65
3.4 Firing order 69
3.5 Main engine dimensions 70
4 Operation
4.1 LOP controls 72
4.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 73
4.3 Putting the engine into operation after
scheduled out-of-service-period 74
4.4 Starting the engine via the automation
system 75
4.5 Operational checks 76
4.6 Tasks after extended out-of-service periods
(>3 weeks) 77
4.7 Fuel treatment system control cabinet –
Controls 78
4.8 Checks prior to start-up 79
4.9 Fuel treatment system – Initial start-up 80
4.10 Fuel treatment system – Switching on 83
4.11 Emergency engine shutdown via
automation system 84
4.12 Engaging from LOP 85
4.13 Disengaging from LOP 86
4.14 Waterjet – Flushing from LOP (optional) 87
4.15 Engine shutdown via the automation
system 88
4.16 After stopping the engine 89
4.17 Fuel treatment system – Shutdown 90
4.18 Plant – Cleaning 91
5 Maintenance
5.1 Maintenance task reference table [QL1] 92
6 Troubleshooting
6.1 Troubleshooting 93
6.2 Control cabinet of fuel treatment system –
Troubleshooting 96
6.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application 97
6.4 Engine Control Unit ADEC (ECU 7) – Fault
codes 98
7 Task Description
7.1 SOLAS 163
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 163
7.1.2 SOLAS shielding – Installation 164
7.1.3 SOLAS shielding – Installation locations 165
7.2 Engine 172
7.2.1 Engine – Barring manually 172
7.2.2 Engine – Barring with starting system 174
7.3 Cylinder Liner 175
7.3.1 Cylinder liner – Endoscopic examination 175
7.3.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 177
7.4 Valve Drive 179
7.4.1 Cylinder head cover – Removal and
installation 179
7.4.2 Valve gear – Lubrication 180
7.4.3 Valve clearance – Check and adjustment 181
7.5 Injection Pump / HP Pump 184
7.5.1 HP pump – Filling with engine oil 184
7.5.2 HP pump – Relief bore check 185
7.6 Injector 186
7.6.1 Injector – Replacement 186
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7.6.2 Injector – Removal and installation 187
7.7 Fuel System 193
7.7.1 Fuel system – Venting 193
7.8 Fuel Filter 195
7.8.1 Additional fuel filter – Overview 195
7.8.2 Additional fuel filter – Replacement 196
7.8.3 Fuel filter – Replacement 198
7.8.4 Fuel prefilter – Differential pressure gage
check and adjustment of gage 200
7.8.5 Fuel prefilter – Draining 201
7.8.6 Fuel prefilter – Flushing 203
7.8.7 Fuel prefilter with water separator – Filter
element replacement 205
7.8.8 Fuel prefilter with water separator – O-ring
replacement in rotary slide valve 208
7.9 Exhaust Turbocharger 209
7.9.1 Compressor wheel – Cleaning 209
7.10 Charge-Air Cooling 214
7.10.1 Intercooler – Check water drain for coolant
leakage and obstruction 214
7.11 Air Filter 215
7.11.1 Air filter – Replacement 215
7.11.2 Air filter – Removal and installation 216
7.12 Air Intake 217
7.12.1 Service indicator – Signal ring position check 217
7.13 Starting Equipment 218
7.13.1 Starter – Condition check 218
7.14 Lube Oil System, Lube Oil Circuit 219
7.14.1 Engine oil – Level check 219
7.14.2 Oil indicator filter – Cleaning and check 220
7.14.3 Engine oil – Change 222
7.14.4 Engine oil – Sample extraction and analysis 224
7.15 Oil Filtration / Cooling 226
7.15.1 Engine oil filter ‒ Replacement 226
7.15.2 Automatic oil filter – Oil filter candles
replacement 228
7.15.3 Centrifugal oil filter – Cleaning and filter
sleeve replacement 231
7.16 Coolant Circuit, General, High-Temperature
Circuit 234
7.16.1 Engine coolant level – Check 234
7.16.2 Engine coolant – Change 235
7.16.3 Engine coolant – Draining 236
7.16.4 Engine coolant – Filling 237
7.16.5 HT coolant pump – Relief bore check 239
7.16.6 Engine coolant – Sample extraction and
analysis 240
7.16.7 Preheating unit 241
7.17 Raw Water Pump with Connections 244
7.17.1 Raw water pump – Relief bore check 244
7.18 Battery-Charging Generator 245
7.18.1 Battery-charging generator drive – Coupling
condition check 245
7.19 Engine Mounting / Support 246
7.19.1 Engine mounting – Check 246
7.20 Auxiliary PTO 247
7.20.1 Bilge pump – Relief bore check 247
7.21 Fuel Supply System 248
7.21.1 Water drain valve – Check 248
7.21.2 Differential pressure gauge – Check 249
7.21.3 Water level probe (3-in-1 rod electrode) –
Check 250
7.21.4 Pump capacity – Check 251
7.21.5 Coalescer filter element – Replacement 252
7.22 Wiring (General) for Engine/Gearbox/Unit 254
7.22.1 Engine cabling – Check 254
7.23 Accessories for (Electronic) Engine
Governor / Control System 255
7.23.1 Resetting CDC parameter and entering IIG
with DiaSys® 255
7.23.2 Limit switch for start interlock ‒ Check 256
7.23.3 Engine Control Unit ECU 7 – Checking plug
connections 257
7.23.4 Engine Monitoring Unit EMU 8 – Plug
connections check 258
7.23.5 Interface module EIM plug connections –
Check 259
7.23.6 Engine Control Unit ECU 7 – Removal and
installation 260
7.23.7 EMU 8 – Removal and installation 261
7.23.8 Engine Interface Module EIM – Removal and
installation 262
7.23.9 Diagnostic features on EIM 263
7.24 Emergency Instrumentation (Local
Operating Panel) 266
7.24.1 LOP and connectors – Cleaning 266
8 Appendix A
8.1 Abbreviations 267
8.2 MTU contact persons/service partners 269
9 Appendix B
9.1 Special Tools 270
9.2 Index 276
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1 Safety
1.1 Correct use for all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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1.2 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment
Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
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1.3 Transport
DANGER Suspended load
Danger to life
• Never stand under suspended loads!
• Wear appropriate personal protective equipment.
Transport
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta-
tion.
Only use the lifting eyes provided to transport the engine.
Use only suitable transport and lifting gear.
Take the engine's center of gravity into account.
Transport the engine only in installation position: max. permissible diagonal pull 10 degrees.
Remove any loose parts from the engine.
Lift/lower the engine slowly. Ensure that lifting cables/chains do not touch the engine or any of its compo-
nents. Readjust lifting tackle as necessary.
If the engine is supplied with special aluminum foil packing: Lift the engine at the lifting eyes of the bearing
pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta-
tion (if applicable).
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en-
gine must be secured against moving and tilting.
Setting down the engine following transportation
Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set down engines onto the oil pan unless expressly permitted by MTU on an engine-specific base.
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1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.
Operation of electrical equipment
Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.
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Follow the applicable warning instructions pertaining to such devices.
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1.5 Safety precautions when working on the engine
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work
Take special care when removing ventilation or plug screws from the product.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
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