Deutz D TD TCD 2011 w Workshop Manual 0312 3336 – PDF Download

Description

Deutz D TD TCD 2011 w Workshop Manual 0312 3336

This is the DEUTZ AG workshop manual for the D 2011 w, TD 2011 w and TCD 2011 w diesel engines. Published under Order No. 0312 3336 en in its 1st Edition, dated 12/2008, it is the same document DEUTZ service technicians use to strip, inspect, machine, reassemble and set up these 2011 w series engines. The manual is written for technicians who already know the contents of the operation manual and who now need the deeper repair, measurement and assembly data that only the workshop manual carries.

File Details

• Manual type: Workshop manual (repair and overhaul)
• Brand: DEUTZ AG
• Engines covered: D 2011 w, TD 2011 w, TCD 2011 w
• Order number: 0312 3336 en
• Edition / date: 1st Edition, 12/2008
• Language: English
• Pages: 544
• Format: PDF

Chapters Covered

• 1 Foreword
• 2 General
• 3 User notes
  • 3.1 General
  • 3.2 Specifications (accident prevention, cleanliness instructions for the DEUTZ Common Rail System, disposal regulations)
  • 3.3 Operation manual and workshop manual
  • 3.4 Job cards (numbering, structure)
  • 3.5 Explanation of symbols
• 4 Technical data
  • 4.1 Testing and setting data
  • 4.2 Tightening specifications
• 5 Job card overview
  • 5.1 Sorted alphabetically
  • 5.2 Sorted numerically
• 6 Job cards
  • 00 General / interdisciplinary activities
  • 01 Cylinder head
  • 02 Drive system
  • 03 Crankcase
  • 04 Engine control
  • 05 Speed governing
  • 06 Exhaust system / Charging
  • 07 Fuel system
  • 08 Lube oil system
  • 09 Cooling system
  • 11 Monitoring system
  • 12 Other components
  • 13 Electrical system
• 7 Commercial tools
• 8 Special tools

Within the job-card chapter the manual walks a technician through every major repair on these engines: checking compression pressure, mounting the engine on the assembly block, setting valve clearance, removing and installing the rocker arms and cylinder head, checking piston overhang and selecting the correct cylinder head gasket (1, 2 or 3 recesses), removing and installing the valves and checking valve lag, checking and renewing the crankshaft and its sealing rings, checking the con rod, removing and installing the small end bush, removing and installing the piston and con rod, renewing the piston rings and checking ring groove wear, removing and installing the piston cooling nozzles, checking the cylinder bore, removing and installing the front and rear covers, testing the camshaft bearings, renewing camshaft sealing rings, renewing the toothed belt and tensioning pulley, removing and installing the camshaft, removing and installing the control linkage and guide bushes, removing and installing the impulse transmitter, removing and installing the exhaust line, charge air line, turbocharger and intake manifold, servicing the exhaust gas recirculation system (return valve, return pipe, collection pipe, sensor, magnet clip), removing and installing the fuel injector pump and setting the start of injection, determining the correct shim thickness for the injector pump, servicing the fuel injectors (opening pressure, tightness, chatter test), servicing both lifting magnets, removing and installing fuel pipes and the fuel filter console, removing and installing the fuel supply pump, working on the lubricating oil pump, suction pipe, oil pan, oil cooler, oil pressure regulating valve, oil filter console, oil pressure switch, the lubricating-oil-cooler thermostat, the control line, the coolant pump, the thermostat and its housing, the temperature transmitter, the generator, the starter, the heating plugs and glow plugs, the V-belt pulley and V-belt tension, the flywheel and toothed starter ring, the hydraulic pump, and the hydraulic pump toothed belt and tensioning pulley.

What that means in practice is that the manual hands you the actual work sequence, the exact torque, the measuring points and the service limits for each of those jobs, rather than leaving you to guess. The job card structure used by DEUTZ (a “W” card for standard repairs and an “I” card for work that needs extra tooling or workshop conditions) is explained in section 3.4, and each card repeats the tools, auxiliary materials and cross-references so you can chain jobs together without flipping back and forth between chapters.

Testing, Setting and Tightening Data

Chapter 4 is the reference anchor of the whole manual. The testing and setting data list pulls together compression pressure (25 – 30 bar / 2500 – 3000 kPa), ignition sequence 1-3-4-2, valve stem diameters and clearances, valve edge thickness, valve plate diameters, valve lag wear limits, valve spring free length, valve clearance (inlet 0.3 mm / outlet 0.5 mm), rocker arm bore and pin dimensions, main and lifting journal diameters, underdimension stages, crankshaft axial clearance, con rod parallelism limits, small end bush and big end bearing shell dimensions, piston pin and piston dimensions per measuring point, piston overhang per cylinder head gasket recess count, piston ring joint and axial clearances, camshaft and camshaft bearing liner dimensions, cylinder bore standard and wear limits, minimum speed and adjusting capsule basic settings, injector nozzle opening pressure, oil pressure regulating valve opening pressures and spring lengths per colour code, thermostat opening temperature and stroke, V-belt tension values, and more.

The tightening specifications chapter then lists every screwed joint on the engine with its tightening torque, screw size, stage-by-stage angle, and any note such as “use new screws” or “replace sealing ring”. This includes the cylinder head staged sequence (30 Nm → 80 Nm → 160 Nm → 90°), main bearing covers (50 Nm → 60° → 45°), big end bearing covers (30 Nm → 60° → 60°), flywheel, toothed belt wheel on the crankshaft (130 Nm → 210°), toothed belt wheel on the camshaft (30 Nm → 210°), injector and injector line, injection pump, oil filter console, oil cooler, oil pressure switch, oil pan and locking screw, coolant pump, thermostat housing, temperature transmitter, generator and starter mounting, glow plugs, hydraulic pump, and the engine mounting feet — plus the general tolerance note that torque-wrench values have a ±10 % permissible variation.

What This Workshop Manual Enables

Because the D 2011 w, TD 2011 w and TCD 2011 w share the same workshop manual, this document gives you the full overhaul route for naturally aspirated, turbocharged and turbocharged/charge-cooled versions of the 2011 w series. You can time the engine using the adjustable bolt and degree scale procedure in job card W 07-06-01, set the injector pump start of injection correctly, select the right cylinder head gasket based on measured piston overhang, or determine the exact shim thickness under each injection pump from the depth measurement on the roller tappet. You can inspect the crankshaft, camshaft, con rods, pistons, liners and bearings against the printed wear limits, then assemble with the correct staged torques and angle turns.

For a workshop, fleet operator or serious owner, having the DEUTZ job cards and the testing and setting data on hand is what separates a correct repair from an expensive guess. Wrong cylinder head gasket, wrong shim, wrong valve clearance or a stretched fastener reused where a new one is specified — each of those is a specific, expensive failure mode the manual explicitly warns against, and the workshop manual is where you avoid them.

Delivery

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The manual is supplied as an instant-download PDF. There is no shipping and no waiting — the file is delivered immediately after payment and can be opened on a laptop, tablet or phone in the workshop, printed page by page, or kept on a memory stick next to the machine. Every job card, every diagram and every specification table is present in the same form as the original DEUTZ publication.