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MTU Series 4000. Legendary. Since 1996.

In 1996 we presented the Series 4000 to the public for the first time. Even then it was clear: These engines are something really special. As the very first large diesel engines, they were equipped as standard with the common-rail injection system – and as a result, were ten years ahead of the current status of development. Right at the start we specifically designed the engines to be powerful, universally deployable and yet efficient. That’s how you can still recognize a Series 4000 even today. Because we strive continuously to convert our customers' requirements into reliable, clean and durable technology. As a result the Series 4000 engines will also stand the test in future in the toughest applications: in boats, rail vehicles, industrial and mining vehicles, in energy systems as well as pump drives for the oil and gas industry.

The Series 4000. The most important facts.

Regardless of what you are driving: Our Series 4000 engines accomplish every task supremely. Because they are one of the best engines in the world.

Technology, that has proven reliable thousands of times
The Series 4000 is our most successful product range. Since its introduction, more than 37,000 of these engines have proven how efficient and reliable they are. In the toughest applications, together they have accumulated about 180,000,000 hours of operation. With planned scheduled service intervals, numerous engines have been able to demonstrate more than 60,000 hours of operation.

Emission-optimized for every deployment location
Our Series 4000 engines are efficient and powerful, but nonetheless always satisfy the valid emission directives, whether on rails, in water, industrial applications or power generation. For this we rely on purely engine-internal measures, that we combine with aftertreatment technologies according to application and requirements.

Less fuel, more efficiency
We focus consistently on further developing our key technologies of combustion design, turbocharging, electronic engine management and common rail injection. This way we ensure that the engines of the Series 4000 are not only clean, but also extremely economical. No wonder that they are one of the most efficient in their performance class.

High performance with low weight
The engines of the Series 4000 are distinguished above all by their outstanding power to weight ratio and high power density. As a result they provide the necessary power reserves in order to drive heavy vehicles, boats or generators – without taking up a lot of unnecessary installation space.

Powerful at high altitudes
Full power, even where the air gets thin: This is ensured by suitably adapted turbochargers, that MTU develops and produces itself. These are coordinated to the engine, so that it safely delivers its high output over the entire range of the engine specification – on the ground as well as at an altitude of 4,000 meters.

Quiet and with low vibration when off-road
In the driver's cab of an excavator, while generating back-up power in a hospital or on the sun deck of a luxury yacht, one thing counts above all: quiet running. Special sound-reduction measures from pre-injection through to elastic bearings and special sound-insulation enclosures ensure that with Series 4000 engines the environment remains as quiet as possible.

The largest yachts.

The majority of the 100 largest yachts in the world are powered by a 12-, 16- or 20-cylinder engine of the Series 4000.

The most exclusive yachts.

The Series 4000 yacht engines have gained the highest reputation in the world of style, luxury and top performance. At the World Superyacht Awards, in the Displacement Motor Yacht category, luxury boats with this propulsion are therefore among the winners again and again.

The fastest workboats.

She is not only the largest, but also the fastest crew transport boats working in the oil and gas industry: With her four powerful 2,880 kW 16-cylinder engines, the 70 meter long "Muslim Magomayev" reaches speeds of up to 74 km/h (40 knots).

The most efficient workboats.

In 2009, the American marine magazine "American Ship Review" awarded the title of Ship of the Year to the Seacor "Cheetah". Justifiably so: It could accommodate almost twice as many passengers as the usual crew boats up until then and was also almost 30 kilometers per hour (more than 15 knots) faster – that was ensured by four of the specially developed engines of the "IRONMEN" prototype. As a result the operator was able to save between 30 and 40 percent of the costs per passenger in comparison to helicopter transport.

The most modern research boats.

The Series 4000 can be found in research boats belonging to university facilities – such as the ice-going "Sikuliaq". Here the Series 4000 supplies all boat systems as well as the electric drive motors with power.

The latest submarines.

The MTU engines also prove themselves under water. The latest submarines are powered by a battery charging generator set, which is based on the 12V 4000 engine.

The fastest train.

With a top speed of 256 km/h, the Spanish express train "Talgo" is the fastest diesel-powered rail vehicle in the world. The drive is provided by two 1,500 kW 12-cylinder Series 4000 diesel engines, that are installed in two driving units at both ends of the train.

The biggest dump truck.

The biggest and heaviest of the gigantic mining vehicles is the Belaz 75710. As the first dump truck in the world with a dual-engine system (two 16-cylinder Series 4000 engines, each with 1,715 kW), the truck from the Belarusian manufacturer can load 450 tons. With that it replaces the previous largest dump truck, the Liebherr T284. The latter is also powered by an MTU Series 4000 engine.

The most environmentally friendly mining vehicles.

In 2012, readers of the trade magazine "Mining Magazine" honored the Series 4000 mining engines with the "Mining Magazine Award". Despite tightened regulations, they observe the Emission Standard Tier 4 final with purely engine-internal measures and thereby consume up to five percent less fuel than the Tier 2 engines. As a result it was able to win through against the projects of competitors in the category "Environmental Excellence".

The safest power supply.

Supplying hospitals, data centers, nuclear power plants and other mission-critical applications with power, even when the earth quakes:
That is ensured by diesel generator sets of the Series 4000.
In extensive tests they have proven that they are still able to function even after an earthquake, with all essential components intact. With that they satisfy the IBC 2009, a strict US requirement for earthquake safety, and therefore may be deployed in all seismically active zones.

Technological Development

First standard implementation of common rail
The Series 4000 was the logical development from the very successful Series 396. At the beginning of the 1990s, ...
The Series 4000 was the logical development from the very successful Series 396. At the beginning of the 1990s, together with Detroit Diesel we began working on a successor engine model. Contrary to the original plan, which was to equip the 90°V engine with pump-nozzle line for lower power outputs, right at the start the complete series was given an electronically controlled common-rail injection system. We developed the technology for this in-house, together with our subsidiary L’Orange. We were therefore the first manufacturer of large diesel engines to implement the common rail injection technology as standard – and also remained the only one for the next ten years. A decisive factor thereby was also the in-house development and production of the essentially indispensable electronic engine management.
Improved injection technology
Due to the new common rail technology we were able to improve the control of the combustion – and in such a way, that ...
Due to the new common rail technology we were able to improve the control of the combustion – and in such a way, that the developers were able to set ideal conditions in the entire engine map. As a result a far more open approach to many design aspects could be adopted: injection start, -volume and -process, and above all the injection pressure could now be controlled with the electronic engine control system. These factors decisively influence how much fuel an engine consumes and how many pollutants it emits. In comparison with previous systems, considerably higher injection pressures could be worked with, specifically at low speeds. Soot particles could consequently be considerably reduced. Since the first generation of the series, we have continuously increased the pressure, from 1,200 bar to currently 2,500 bar. During the same period the system was made more robust and maintenance-friendly; the accompanying, systematic further development of a fuel filter concept was a decisive factor for this.
Higher displacements for higher power
To be able to remain competitive over the long term, the Series 4000 was designed right at the start to enable further ...
To be able to remain competitive over the long term, the Series 4000 was designed right at the start to enable further increases in power. In the last 20 years we have implemented this by enlarging the combustion chamber. In its first version the Series 4000 engines had a bore of 165 mm and a stroke of 190 mm. That produced the eponymous displacement of 4.06 liters per cylinder. With the prototype 4000-03 for the high performance marine engines, the bore was enlarged to 170 mm, for a swept volume of 4.31 liters per cylinder. In combination with redesigned turbocharging, a higher swept volume could be realized –the current 20-cylinder boat engines achieve 50 kW/l. Also further developed were the Series 4000 engines for power generation, in railway vehicles, construction- and mining machines, in the oil and gas industry as well as in the workboat engines of the "IRONMEN" series. Here, besides the 170 mm bore, the stroke was also increased to 210 mm. For these applications that produces a swept volume of 4.77 liters per cylinder.
Appropriate turbocharging for every application
No other element characterizes the Series 4000 engines like its turbocharging. Traditionally, we have the know-how to ...
No other element characterizes the Series 4000 engines like its turbocharging. Traditionally, we have the know-how to develop and produce this key technology in-house. In the past 20 years the conditions under which the Series 4000 engines are used have become stricter – which has a direct effect on the service life of the turbocharger. We have taken these changes into account: The time between overhaul (TBO) has been continuously optimized and coordinated to that of the engines. This way the complex technology remains robust and durable. For example in the case of the Series 4000 rail engine: Here the TBO of the turbocharger is up to 15,000 hours, depending on the number of load changes per hour. The charger is coordinated according to where the engine will subsequently be used. The Series 4000 that generates power and always runs at the same speed requires a different turbocharger than a vehicle with variable engine speed. For this reason, in the rail engine we rely on two-stage regulated turbocharging for the first time. This is also planned for other mobile applications, for example in the mining sector. For stationary applications, such as power generation with diesel or gas (e.g. natural gas, biogas and other special gases), the more cost-effective single-stage turbocharging will also continue to be used.
Successful on water and on land
Thanks to its first class consumption values – up to ten percent less than the competition – the series was able to ...
Thanks to its first class consumption values – up to ten percent less than the competition – the series was able to quickly become established in the boat market; by the end of 1997 the series launch for the two other applications, rail, mining and power generation was also concluded. The basis of the success was and still is a common basic design for the entire engine family and an engine concept that is based on a uniform platform. In all applications in which the Series 4000 is deployed, the following points are decisive above all: high outputs, low life cycle costs and the observance of current emission directives. This is a challenge that MTU meets head-on, despite ever higher demands to manufacture engines that have these characteristics while still being robust and reliable. For 20 years the Series 4000 has kept pace with these market developments. Today, it is available in 8-, 10-, 12-, 16- and 20-cylinder versions. That is therefore the perfect basis, in order to perpetuate the story of success.
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