Diesel Engine Series 2000

for Petroleum Applications

DaimlerChryslerOff-Highway
Outstanding Durability,
Outstanding Power Ranges,
Market Leading Fuel Economy,
Over 8,500 Series 2000 Engines Built,
Over 14,000,000 Hours Of Operation.
 There Are Ordinary Engines
And There Are Extraordinary Engines.

The Difference Is The Details.

Ordinary Engines Provide...Horsepower.

A few years ago, horsepower was enough. Today, however, those

considering the purchase of a new machine, or new engines for existing machines,
demand much more:

■ Reliability
■ Maximum uptime
■ High output under all conditions
■ Low maintenance
■ Low cost of operation
■ Low fuel consumption
■ Long life to overhaul
■ Worldwide support
■ Attention to detail

With these thoughts in mind, Detroit Diesel Corporation and MTU Friedrichshafen
formed a global partnership for the development of an advanced series of high
output, four stroke cycle diesel engines. The partnership between MTU and DDC
combines the experience of two manufacturers who together have produced
over 4,000,000 engines. Today, both companies have become part of the newly
formed DaimlerChrysler Off-Highway business unit, and are combining
resources to become the world’s preeminent supplier of engines for
off-highway applications.
The Series 2000
Are Extraordinary Engines
■ Four Stroke Cycle
■ 8, 12, And 16 Cylinder Configuration

■ 605 - 1340 Horsepower Range

 From The Beginning, The Focus Has Been On The Details.
Cast in cooling channel
Oil cooling significantly reduces
piston temperatures.
The Series 2000 Is An ■ Ordinary engines use
Extraordinary Engine! cylinder heads with one
intake and one exhaust
Computer technology is often used valve. The Series 2000
during the design of modern engines. uses 4 valves per
When designing the Series 2000 cylinder,for maxi-
engines, our engineers used mum performance.
computer analysis, including the Cray
Supercomputer, to evaluate and ■ Ordinary engines use
design all elements of the engine. chrome faced piston
This “3-D solid modeling” technique rings. The Series 2000
uses the most
allowed the rapid development of a durable ring material
reliable, high output, compact and available, ceramic
easy to service engine. An engine chrome.The use of
designed from the beginning as a such a rugged
high output engine. material means long
By considering every detail, this life before overhaul.
design technique also refines the
manufacturing and assembly process, ■ Ordinary engines direct
improving both quality and reliability. an oil spray on the
underside of the piston to
High Performance carry away the heat
generated at high power
There is a difference between high levels. The Series 2000
horsepower and high performance. features cast-in-
Ordinary engines achieve high horse- channels in the
power by increasing the engine’s rate pistons through
of fuel usage and adding larger which high pressure
oil is accurately
turbochargers for increased airflow. directed, ensuring
Ordinary engines often suffer from proper cooling and
excessive smoke, poor cold weather significantlyreduced
starting and lackluster performance at piston ring temper-
low and medium speeds. Reliability is atures.The result is
frequently compromised. The Series long ring life.
2000 engines, benefiting from their
truly clean sheet design, overcome
these common problems with a
number of logical solutions:
And What Is Beyond The Details?
Are there innovations that further
separate the Series 2000 engines
from ordinary engines? Again, there
are many.
The Series 2000
Engine Features
Two main oil galleries in the block for
maximum piston cooling and bearing
lubrication under all conditions.
The block is a one-piece design to
eliminate leaks. The block is made
from super strong GG copper chrome
alloy for maximum strength and
rigidity at all power levels for long
bearing and piston ring life.
The cylinder bores feature tangential
flow to direct coolant flow around the
hottest part of the cylinder for long
piston ring life.
The crankshaft mains are induction
hardened to a maximum depth of
4.5mm for extreme durability (typical
crankshafts are hardened to 1.5mm).
Bolt-on counterweights allow for
complete static and dynamic
balancing throughout the RPM range.
Bearing loads are uniform for long life.
Cylinder liners feature 10.5mm wall
thickness for long life and resistance
to cavitation.
Liners are plateau honed to provide
a smooth, low friction surface
combined with excellent oil retention
characteristics. The result is low oil
consumption and long ring life even at
high load.
The connecting rod/piston bushing
are of a trapezoidal design for
maximum bearing area.
The top piston ring is located
18mm below the piston crown, away
from the maximum heat of
combustion for long life.
These rings, combined with the
non hardened cylinder liner surface,
provide exceptional life.
The Rings Are Also
Pressure Balanced
Cylinder pressure, during the
compression and power strokes,
forces the ring against the cylinder
wall for proper sealing. Traditional
straight face or barrel faced rings
have higher surface areas behind the
ring than on the ring face.
Traditional Barrel Faced Rings Are Symmetrical
This “unbalanced surface area”
results in significant pressure, forcing
the ring against the cylinder wall.
This high differential increases
friction, which in turn increases wear
and fuel consumption.
The Series 2000 Uses An Offset Barrel Design
Longer Life
Less Friction
The Series 2000 engines feature
pressure balanced rings. The surface
area of the face of the ring is
balanced with the surface area
behind the ring. The result is more
moderate force against the cylinder
wall for long life and improved fuel
consumption.
Hydraulically Expanded Front And
Rear Crankshaft Hubs On 8V
Front, 12V & 16V Models
Ordinary engines typically rely on a
number of closely spaced bolts to
attach power take off flanges and the
flywheel to the crankshaft. This type of
joint is susceptible to mechanical and
torsional fatigue.
The Series 2000 eliminates this
problem. The front and rear hubs are
expanded hydraulically, up to 40,000
psi and shrunk-fit to the crankshaft.
The resulting joint is 5X for crank
strength as strong as the crankshaft
itself. The flywheel, or front PTO, can
now be attached using a large
number of bolts, over a large
diameter.
Smoke Control
Smoke is often unavoidable with
ordinary engines. Either black smoke
occurs at full load or white smoke
occurs at start up, sometimes both.
Smoke is unacceptable in today’s
world. Smoke means wasted fuel.
Builders of ordinary engines are
always searching for one solution.
The Series 2000 engines offer many.
During cold start-up, the electronic
fuel injection system uses two smoke
reduction techniques:
1. Injection timing is automatically
adjusted to suit the conditions.
2. The engine idles on only half
the cylinders when cold. This
technique places enough load
on those cylinders to ensure
rapid warm up.Once warm, the
other cylinders are automati-
cally added, without fuel
wasting smoke.
Details That Make A Difference.
Maximum Performance, Maximum Fuel Economy...
Extreme Operating Conditions
Simple and rugged components
are key to withstanding the rigors of
severe heat, dust, cold and rain found
in the off-highway environment. One
standard cooling or air system can’t
provide optimal performance under
these wide ranging conditions. A “no
compromise” approach was used on
the Series 2000 to assure the highest
performance along with long trouble-
free life design. The exhaust manifold
illustrates just that. The Series 2000
engines use “tuned pulse” manifolds
Tuned Pulse Exhaust
to take advantage of the engines firing
order to further enhance turbocharger
performance.
Charge Air Cooling both engine and application
Turbocharged Power requirements. The Series 2000
The charge air cooler’s purpose is
features Separate Circuit Charge
All Series 2000 models feature twin to remove heat generated as the
Cooling (SCCC). Here a dedicated
turbos mounted above the flywheel on turbocharger compresses the
system, with separate water pump
the left and right banks, with a charge incoming air. Cooler, denser air
and radiator, provides coolant flow
air cooler fitted centrally between improves fuel efficiency, increases
through the charge air cooler. The
them. Easy maintenance access is power and helps reduce emissions.
SCCC system, without the burden of
assured and turbo boost is quickly Once again, the Series 2000
cooling the engine, can optimally cool
and efficiently directed through the demonstrates a tailored approach in
the incoming air and achieve the
charge air cooler. charge air cooling design, reflecting
highest performance levels possible.
Extraordinary
Maximum Power-All The Time
Managing Combustion Air
When developing a high performance
engine, managing intake air and
exhaust flow is one of the most
important factors.
“Managing airflow” requires more
sophistication than simply adding high
output turbochargers or intercoolers.
Managing airflow actually begins with
the design of the cylinder head.
Ordinary engines normally require
high air “swirl” within the cylinder to
ensure proper mixing of air and fuel.
Swirl is created by intake passages
which “twist” the flow of air as it enters
the cylinder. However, this technique
restricts maximum airflow through the
cylinder, limiting performance. The
Series 2000 is not handicapped by the
need for high “swirl.” It achieves the
proper mixing of fuel and air by using
specially developed intake port
geometry, an innovative injector tip
with two rows of holes and injection
pressures of more than 25,000 psi
(1724 bar). This low “swirl” design,
together with four valves per cylinder, Magnified (21X) injector tip
results in a free flowing cylinder head, staggered ports
maximum airflow and maximum fuel
economy.
Cooler Intake Air
The intake ports are also very short
which avoids reheating the incoming
charge air (the cool incoming air is
not exposed to long hot
metal passageways). This
cooler intake air provides
more power and reduces
stress on cylinder
components. Exhaust
passages are also short to
avoid losing heat into the
exhaust passages in the
head. Maximum exhaust
heat is retained for maximum
turbocharger
performance and
maximum output.
Electronic Engine Management
DDEC has been in production
since 1985 in over 700,000 Detroit
Diesel Engines.
DDEC Offers The Following:
■ Fewer Parts - Means higher
reliability
■ NoAdjustments - For reduced
downtime and maintenance
expense
■ Self
Monitoring - Protects the
engine from damage
■ Self
Diagnosing - Eliminates
guessworkif something goes
wrong
■ EasyTo Troubleshoot - Even
inremote locations
■ Modular Components Are
Easy To Replace - Mechanics
can perform this function with
minimal training
Engine Protection
n Using such a wide tolerance band can
result in a 120 HP variance on a 1200
These conditions are automatically HP engine.
monitored to avoid engine damage: Series 2000 engine horsepower is
■ Low Coolant Level guaranteed within a tolerance band of
minus 0% and plus 2%. Each
■ Low Coolant Pressure
electronic unit pump is individually
■ High
Engine Coolant calibrated and provides input to DDEC
Temperature for optimal performance. With the
■ Low Oil Pressure Series 2000 engines you receive all
the power you pay for. A detail that
■ High Oil Temperature makes a difference.
■ High Fuel Temperature Electronic engine controls also
permit technicians to use satellite
■ Low Fuel Pressure
telemetry to provide troubleshooting
■ Engine Overspeed Protection support and are supported by the
world’s most experienced Engine
In addition, electronic engine Service network.
controls also allow the precise
setting of the engine’s horsepower.
Ordinary engines are typically sold
with horsepower guaranteed within
a band of plus or minus 5%.

Series 2000 Electronic Engine Individually Calibrated Electronic Unit Injector Pumps
Controls Offer The Following
Benefits:
■ 1/2
Engine Idle - For rapid
warm-up
■ Acceleration Smoke Control
■ Cold Start Smoke Control
■ Self
Diagnostics of the
System and Controls - Easily
pinpoints problems
■ Automatic Adjustment for
Injector Variation - For
vibration free running
 The Series 2000 Engines Are Assembled And Tested
In Detroit, Michigan. Each Engine Is Dynamometer Tested
For Two Hours. Oil Samples From Each Engine Are
Analyzed To Further Verify The Integrity Of The Engine.

FACTORY 2000 PROGRAMMING MENU

ALT–E to Exit
Display Contents of ECM
Display Network Log File
Display
STATION MONITOR 01 2000 PROGRAMMING MENU
Update
EXIT ESC
SELECT OIL TYPE CYCLE Request
Program ECM F1
STATUS Injectors
Program Verify Injectors F2
ACCEPT Specify
TYPE "A" Station Test Menu
2000 Programming Menu
BATCH AMOUNT MODES Clear
PRESET DISPENSD

52.0 0.0 MANUAL Enter :

52

New At 1400 Hours

How Has Such A New
Product Gained
Acceptance Piston and Piston Rings

So Quickly?
It Was Designed Correctly And It
W as Tested Correctly.
Ordinary Engines Are Tested Cylinder Liner Surface Finish
Under Normal Conditions.Those
Tests Don’t Challenge The Series 1,000 Hour Standard Test✓
400 Hour Fuel Stop Test ✓
2000 Engines.
Different Tests Were Required.
1,000 Hour Navy
Endurance Test ✓
This engine was run on the Connecting Rod Bushings
dynamometer at full RPM, full load and full
power for 1400 hours. Dead Push Continuous
✓
This unretouched photo, using dry
dynoroom exhaust manifolds, speaks for Workboat Marine Test
the severity of the test. The result? Had it
300 Hour Probe Test
not been for dissecting these cylinder
liners, pistons and rings for examination, @ 30% Overload ✓
they could have easily been reused to
continue the test.

We Don’t Count On You To Do The Testing.

What Is Already Being Said About This New Engine?

“I Liked The Fuel Consumption And The Engine Was Really Quiet.”

“The High Horsepower Engines Provide The Best

Off-Road Performance.”

“We’ve Relied On Detroit Diesel Engines For Years Because

They Provide The Power, Service And Support Our
Customers Demand.”

“No Doubt They’re Much Faster.”

“We’re Definitely Looking Forward To The Increased Speed

And Durability.”

“As We Continue To Develop New And More Advanced

Systems, We Know DDC Engines Will Be There With New
Developments As Well.”

“It Has Plenty Of Horsepower And Speed.”

“We Are Always In The HP Race And Detroit Diesel

Has Traditionally Led In Horsepower.”

“After Four Years Of Service, It’s Exceeding Expectations And

Winning Repeat Buyers.”
The Series 2000 Is A Remarkable Engine.
Technical Support
Technical support for the Series 2000
begins long before your engine goes
into service.
It begins with a detailed analysis of
the installation by our Application
Engineering Department. When
necessary, a complete torsional
analysis of the driveline or driven
component is included.
After your engine goes into service
it’s backed up by our Worldwide
Parts and Service Network. Parts
and Service support is available 24
hours a day, 7 days a week, from a
distributor support network
dedicated to off-highway customers.
Service parts are available where
they are most needed…at the job
site, at the service center, at the
rebuild shop. Emergency parts

supplies are stored in our
warehouses in Canton, Ridderkirk
and Singapore. Expert technical
support is available virtually around
the clock from our offices in Detroit
and Friedrichshafen.
Training is available on site, at your
local distributor or dealer, or at our
own training center.
Our top technicians stay up to
date by achieving the status of Guild
Member. Only by ongoing study and
achievement on regular
examinations are they able to
maintain that status. Over 5000
technicians are qualified as
Guild Members.
If you want the most up-to-date
information on product updates,
simply visit the internet where
service information bulletins are
easily accessed.
detroitdiesel.com
mtu-online.com
Should You Consider A Series 2000?
Which Of These Benefits Are Important To You?

■ Unmatched fuel consumption for low cost of operation

■ Extended oil change intervals
■ Compact sizefor easy serviceability
■ Half engine idle for rapid warm-up and minimized white smoke
■ Training available at a number of locations
■ Worldwide parts and service support
■ Individual cylinder heads reduce thermal stress
and ensure long compression seal life
■ Ceramic chrome piston rings for long life at high loads
■ High capacity oil pump and twin oil galleries
for maximum piston cooling and bearing life
■ Endurance tested in heavy duty applications
■ Two hour production dyno test including oil analysis
■ DDEC engine control system manages both
the fuel and air systems for maximum output,
low smoke and precise control
■ Individually calibrated electronic unit injector pumps
for optimum combustion characteristics at all RPM’s
■ Electronic unit pump injection system for instant
response at all speeds
■ Four valve cylinder heads for high output
■ Powertuned performance - All Series 2000 engines produce
their rated power
■ Printed reportsfrom the electronic engine control system
verify the history of the engine

The Power You Pay For Is The Power You Get.

Why Should You Consider The Series 2000 Engine …
Why Would You Consider Anything Else?

WeInvite You To:

Contact Your Local Distributor
To Arrange A Plant Tour,
Watch Us Build Our Next Engine,
Find Out Why We Should Build…

…A Series 2000 Engine For You

For additional information, contact your local distributor or dealer

DaimlerChryslerOff-Highway
MTU Friedrichshafen GmbH Detroit Diesel Corporation DaimlerChrysler AG
88040 Friedrichshafen 13400 Outer Drive, West HPC P 304
Germany Detroit, Michigan 48239-4001, USA 70546 Stuttgart, Germany
Phone +49 7541 90-4495 Phone +1 313 592 5608 Phone +49 7111 72-3156
Fax +49 7541 90-3642 Fax +1 313 592 5625 Fax +49 7111 75-3711
powergen-systems@mtu-online.com powergen@detroitdiesel.com industrial@daimlerchrysler.com
www.mtu-online.com www.detroitdiesel.com www.mtu-online.com

For more information contact your

or Detroit Diesel Distributor or www.detroitdiesel.com

© Copyright 2003 Detroit Diesel Corporation. All rights reserved. Detroit Diesel® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.
Series 2000™ is a trademark of Detroit Diesel Corporation. MTU® is a registered trademark of MTU Motoren- und Turbinen-Union Friedrichshafen.
6$ As technical advancements continue, specifications will change. Printed in U.S.A.