WS3 BFM-1013-MVS

Workshop Manual
competence level 3
Solenoid Valve System (MVS)

BFM 1013
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This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
Regarding copyright questions and licensing agreements
please contact : VS-DI, Mr. Sonntag
Phone.: + 49 (0) 221 822-3053
E-Mail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostraße 1
D-51149 Köln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-Mail: info@deutz.com
Printed in Germany
All rights reserved
1st Edition © 10/2007
The engine company. Order No. 0312 3294 en
DEUTZ engines Table of contents
1 Foreword
2 General
3 User notes
3.1 General
3.2 Specifications
3.3 Operating manual and workshop manual
3.4 Job cards
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
7 Commercial tools
8 Special tools
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Table of contents DEUTZ engines
© 01/2008 2/2 14754-001

DEUTZ engines Foreword
1 Foreword
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Foreword DEUTZ engines
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DEUTZ engines Foreword
z Read and observe the information in this docu- z Repair of the engine must correspond to its use
mentation. You will avoid accidents, retain the for the intended purpose. Only parts released by 1
manufacturer's warranty and possess a fully the manufacturer for the respective purpose may
functional and ready to operate engine. be used for conversion work. Unauthorised mod-
z This engine is built exclusively for purpose ac- ifications to the engine exclude manufacturer lia-
cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe
equipment manufacturer (use for the intended this will void the warranty!
purpose). Any use above and beyond this is con- z The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications. A wide range of var-
be liable for damages resulting from this. The iants ensures that the respective special require-
user bears the sole risk. ments are met.
z Use for the intended purpose also includes ob- z The engine is equipped according to the installa-
servance of the operating, maintenance and re- tion case, i.e. not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this z We have done our best to highlight the differenc-
and are aware of the risks involved. es so that you can easily find the operating, main-
z Make sure that this documentation is available to tenance and repair instructions relevant to your
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
z Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
z Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
z Engine parts such as springs, clamps, elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
z The pertinent rules for the prevention of acci-
dents and other generally recognised health and
We are at your service for any questions you may
safety regulations must be observed.
have in this matter.
z Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
Your DEUTZ AG
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Foreword DEUTZ engines
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DEUTZ engines General
2 General
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General DEUTZ engines
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DEUTZ engines General
DEUTZ engines are the product of years of re-

search and development. The profound expertise
gained through this, in combination with high de-
mands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability 2
and low fuel consumption. It goes without saying
that the high environmental protection requirements
are also met.
Maintenance and care are the only way the engine

can satisfy the demands you make on it. Compli-
ance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular-
ly heeded.
Please consult one of our service representatives

responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
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General DEUTZ engines
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DEUTZ engines User notes
3 User notes
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User notes DEUTZ engines
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3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety regu-
been created based on the engine available at the lations
time of going to press.
The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra-
cidents must be observed. These are available from
tions and parts due to further developments.
professional associations or from dealers. These
The maintenance work described in the operation are dependent on the application site, operating
3
manual and in the workshop manual must be carried mode and the operating and auxiliary materials be-
out on schedule and completely. The maintenance ing used.
personnel must have the necessary technical
Special protection measures are specified depend-
knowledge to perform the work. Safety and protec-
ing on the work being carried out, and are identified
tion devices which are removed during maintenance
in the job description.
work must be replaced again afterwards.
Among other things it generally applies that:
Caution!
z for the personnel:
The rules for the prevention of accidents and the
safety regulations must be observed during mainte- – Only briefed personnel may operate or main-
nance work. tain the engine. Unauthorised persons are
prohibited access to the machine room.
Reference is made in the workshop manual job
cards to the regulations in chapter 3.2. These must – Wear close-fitting clothing and ear protectors
be read before working on the engine and must be in the machine room when the engine is in op-
strictly followed. eration.
The maintenance intervals and the work to be per- – Only deploy trained personnel to do repairs
formed are specified in the maintenance schedule and maintenance work.
of the operation manual. The job cards contain tech- – Do not work on the fuel system when the en-
nical documentation on the execution of mainte- gine is running. The fuel system is under high
nance work. pressure - danger of death.
– Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
– Ensure adequate ventilation (do not cover air
shafts).
– Provide first aid kit and suitable fire extinguish-
ers. Check the filling and readiness for opera-
tion regularly.
– Only store inflammable materials in the ma-
chine room if they are essential for operation
of the system.
– Smoking and naked flames are prohibited in
the machine room.
z for operation, maintenance and repairs on the
engine:
– Wait 30 seconds after switching off the engine
before working on the fuel sytem.
– After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6.2 Fuel system“.
– Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
– Cleaning, maintenance and repair work may
only be performed with the engine at a stand-
still and secured against starting.
– Injection lines and high pressure pipes must
not be deformed.
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– Damaged injection lines and high-pressure z Remove loose parts (for example paint chips
pipes must be renewed. from assembly work) with an industrial vacuum
– Injection lines and high pressure fuel lines cleaner or other suction device. Only suction may
must never be connected when the engine is be used in assembly work on the open fuel sys-
running. tem.
– Do not place hands near to a leak in the high z Only work on the fuel system in a clean environ-
ment (no dust, no grinding or welding). Avoid
3 pressure fuel system.
draughts (dust). Clean the workshop floor regu-
– Also carefully check all high pressure compo-
larly. No brake or performance test benches may
nents visually before performing tests on the
be kept or operated in the same room.
running engine. Wear suitable protective
clothing (for example protective glasses). z Air currents which kick up dust, such as those
Leaks are a potential source of danger for caused by brake repairs or the starting of en-
workshop personnel. gines, should be avoided.
– Even if no leaks are discernible on the high z For work such as removal and installation on de-
pressure fuel system, the workshop personnel fective hydraulic components on the Common
should avoid the immediate danger zone or Rail System it is recommended to partition off a
wear suitable protective clothing (such as pro- separate workshop area in the factory. This must
tective glasses) when performing tests on the be separate from other areas in which general
running engine and during the first trial run. vehicle repairs such as brake repairs are carried
out.
– Always stay out of range of a fuel jet, as it
could cause severe injury. z No general machine tools may be operated in
this room.
– Smoking is strictly prohibited when working on
the fuel system. z Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
– Do not work near to sparks and flames.
fans should be minimised.
– Never disconnect an injector when the engine
z Areas of the engine room from which particles of
is running.
dirt could be loosened (for example the bottom
3.2.2 Cleanliness instructions and meas- part of the tipped driver cab) must be covered
ures for handling the DEUTZ Com- with fresh clean film.
mon Rail System z Working materials and tools must be cleaned be-
The DEUTZ Common Rail system used in the fore work. Only use tools without damage to the
DEUTZ engines consists of high-precision compo- chrome plating or tools which are not chrome-
nents which are exposed to extreme stress. Great plated.
attention must be paid to cleanliness when working Notes and measures to be observed during work
on the fuel system due to the high precision technol- on the fuel system or with the fuel system open.
ogy.
z Only work in clean overalls.
Notes and measures to be observed before
z Only lint-free cleaning cloths may be used for
starting work on the fuel system
work on the fuel system.
z The fuel system must be closed. Make a visual z Remove loose parts (for example paint chips
inspection for leaks / damage to the fuel system. from assembly work) with an industrial vacuum
z Clean the whole engine and engine room with the cleaner or other suction device. Only suction may
system closed before starting work on the fuel be used in assembly work on the open fuel sys-
system. tem.
z The engine must be dry when you start working z Working materials and tools must be cleaned be-
on the fuel system. fore work. Only use tools without damage to the
z Blowing (dry) with compressed air is only permis- chrome plating or tools which are not chrome-
sible with the fuel system closed. plated.
z When using a steam jet, first cover up the control z Do not use used cleaning fluid or test fluid for
unit, the cable plugs, all other electrical plug con- cleaning.
nections and the generator. Also, the steam jet z Compressed air must not be used for cleaning on
may not be pointed directly at them. the open fuel system.
z Electrical plug connections must be plugged z Work on removed components may only be per-
when spraying. formed at a suitably equipped workbench.
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z When removing and installing components, no operating materials among other things. The re-
materials which can leave behind particles or fi- newed parts / operating materials must be stored,
bres (cardboard, wood, cloths) may be used. transported and disposed of according to regula-
z Removed parts may only be rubbed down with tions. The owner himself is responsible for this.
clean, lint-free cloths. No dirt particles may be Disposal includes recycling and the scrapping of
rubbed into the components. parts / operating materials, although recycling has
z Openings on the components and on the engine priority.
3
must be closed immediately with suitable stop- Details of disposal and their monitoring are gov-
pers/caps. erned by regional, national and international laws
z The stoppers/caps may only be removed imme- and directives which the system operator must ob-
diately before installing. serve on his own responsibility.
z Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
z Only remove new parts from the original packag-
ing just before installation.
z Removed components must be kept in new, seal-
able bags or - if available - in the packaging of the
new parts.
z Always use the original packaging of the new part
to send back the removed components.
Notes and measures for the vehicle workshop
area
z For work such as removal and installation on de-
fective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
z The workshop floor is sealed or tiled.
z No welding gear, grinders, general machine
tools, brakes or performance test benches may
be operated in this room.
z Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
fans should be minimised.
Notes and measures for workbench and tools in
the vehicle hall
z A special workbench must be set up for work on
removed components.
z Clean the removal and installation tools regularly
and keep them in a closed tool cabinet.
z Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device.
z Working materials and tools must be cleaned be-
fore work. Only use tools without damage to the
chrome plating or tools which are not chrome-
plated.
3.2.3 Disposal regulations
The work described in the operation manual and
workshop manual necessitates renewal of parts and
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3.3 Operation manual and workshop 3.4 Job cards

manual The job cards are divided in the workshop manual
To structure the information to suit the user, the into "W" and "I" job cards.
service documentation is divided into operation The "W" job card documents standard repairs on the
manual and workshop manual. engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
The operation manual contains a general descrip-
3 tion and instructions for all other maintenance work.
card.
The "I" job card additionally documents the appro-
It contains the following chapters: priate work procedures for repairing the engine and/
1. Contents, General or its components. The workshop must satisfy spe-
2. Engine description cial conditions to perform these work procedures.
Special tools and machine tools must be available,
3. Operation
for example.
4. Operating media
3.4.1 Numbering of job cards
5. Maintenance
6. Care and maintenance work The job card numbers follow the pattern W 02-04-
01. The individual parts of this pattern are explained
7. Faults, causes and remedies below:
8. Engine conservation z W 02-04-01: Documentation type
9. Technical data – W.... Workshop manual
10.Service – I ...... Repair instructions
The workshop manual assumes knowledge of the z W 02-04-01: Maintenance group
contents of the operation manual. This applies es-
pecially for the safety regulations. The workshop – 00 ... General / interdisciplinary activities
manual describes repairs to the engine and compo- – 01 ... Cylinder head
nents for which more effort and appropriately quali- – 02 ... Drive system
fied technicians are required. – 03 ... Crankcase
– 04 ... Engine control system
– 05 ... Speed governing
– 06 ... Exhaust system / Charging
– 07 ... Fuel system
– 08 ... Lube oil system
– 09 ... Cooling system
– 10 ... Compressed air system
– 11 ... Monitoring system
– 12 ... Other components
– 13 ... Electrical system
z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number
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3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
1 2 3
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
Triebwerk injury.
W 02-04-01 4
Caution! 3
5
Danger to the component/engine. Non-
16
6 compliance can lead to destruction of the
component/engine.
15
6 7 Must be observed!
14
Note
General notes on assembly, environmental
8 protection etc. No potential danger for man
13 or machine.
Tool
Conventional and special tools required for
12
the work.
8
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
11 10 9 References
to important documents or job cards for the
1. DEUTZ AG, work process.
publisher of service documentation For example: Job card W 04-05-05
2. Engine type (e.g. TCD 2013 4V) Reference
3. Maintenance group to a document or a job card within the work
process.
4. Job card number or topic
5. Title of job card Test and setting data
The necessary values are specified here.
6. Reference to other job cards If several values are necessary, a cross re-
7. Chapter ference is given to the Test and Setting Va-
8. Graphic or photo lues table.
9. DEUTZ internal creation number For example:
ID no. P01 61 = valve clearance, inlet
10.Page number
Tightening specification
11.Date of issue of job card
The necessary values are specified here.
12.Note If several values are necessary, a cross re-
13.Danger / Important ference is given to the Tightening Specifi-
14.Work sequence cations table.
For example:
15.Special tools; auxiliary materials
ID no. A01 001 = cylinder head screws
16.Conventional tools
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MVS Technical data
BFM 1013 Testing and setting data
4 Technical data
4.1 Testing and setting data
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Technical data MVS
Testing and setting data BFM 1013
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© 10/2007
ID no. Name Information Series Value Unit

Camshaft
P04 35 Camshaft, axial clearance BFM 1013 0,1 - 0,5 mm
Speed governing
BFM 1013
MVS
Gap dimension between speed governor + 0,1
P05 91 Dimension "X" BFM 1013 0,6 mm
(crankshaft) and toothed washer
Distance between speed governor (camshaft)
P05 92 BFM 1013 0,20 - 1,00 mm
and camshaft toothed wheel
Length dimension (a) = 27.85-27.95
7,1 mm
spacing disc (1) =
Selection of spacing disc depending on length of Length dimension (a) = 27.96-28.05
P05 94 BFM 1013 7,2 mm
the speed governor (camshaft) spacing disc (2) =
Length dimension (a) = 28.06-28.15
7,3 mm
spacing disc (3) =
3/8
Testing and setting data

Technical data
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4
Technical data MVS
Testing and setting data BFM 1013
4
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MVS Technical data
BFM 1013 Tightening specifications
4.2 Tightening specifications
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Technical data MVS
Tightening specifications BFM 1013
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© 10/2007
Pre-ten- Post-ten-
ID no. Name Screw type Notes / Remarks Series sioning va- sioning
lue value
Cylinder head cover on cylinder head Collared screw BFM 1013 13 Nm
A01 004
Screw with washer BFM 1013 11 Nm
BFM 1013
MVS
Insert screws with
A03 091 Gear case on crankcase M8x55 BFM 1013 30 Nm
DEUTZ DW 75.
A03 092 Turning gear on gear case/crankcase M8x70 BFM 1013 30 Nm
A04 022 Locking cap on gear case M8x60 BFM 1013 21 Nm
Insert screws with
A05 011 Speed governor (crankshaft) on holder M6x16 BFM 1013 9 Nm
DEUTZ DW 72.
Insert screws with
A05 012 Speed governor (camshaft) on gear case M6x20 BFM 1013 9 Nm
DEUTZ DW 72.
Holder speed governor (crankshaft) on front co- Insert screws with
7/8
A05 013 M8x45 BFM 1013 30 Nm

ver DEUTZ DW 72.
Union nutInsert new injection
A07 003 Injection line on fuel injector/injection pump BFM 1013 5 Nm 25 Nm
line!
A07 012 Injection pump on crankcase M8x60 12-sided collared head screw BFM 1013 5 Nm 30 Nm
Hollow screw (chroma-
Tightening specifications
A07 015 Fuel line on injection pumps M12x1.5 ted).Replaces hollow screw BFM 1013 45 Nm
(bare)!
Temperature transmitter (fuel) and connection
A07 023 BFM 1013 20 Nm
piece
A08 091 Oil pressure switch M14x1.5 BFM 1013 45 Nm
Technical data
Adapter (temperature transmitter) on cylinder
A09 012 M26x1.5 BFM 1013 110 Nm
head
Temperature transmitter (coolant) on cylinder
A09 031 M14x1.5 BFM 1013 20 Nm
head
14342-001
A12 090 Fuel hose on connection piece (fuel pipe) M14x1.5 Hollow screw BFM 1013 39 Nm
4
4
© 10/2007
Tightening specifications
Technical data
Pre-ten- Post-ten-
ID no. Name Screw type Notes / Remarks Series sioning va- sioning
lue value
Temperature transmitter (charge air) on charge
air line
A13 046 M6 Insert with DEUTZ DW 72. BFM 1013 9 Nm
Pressure transmitter (charge air) on charge air
line
A13 054 Cable connection to injection pump SW 5 BFM 1013 1 Nm
A13 064 Pin housing on holder Plastic nut BFM 1013 7 Nm
8/8
BFM 1013
MVS
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MVS Job card overview
BFM 1013 Sorted alphabetically
5
5 Job card overview
5.1 Sorted alphabetically
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Job card overview MVS
Sorted alphabetically BFM 1013
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MVS Job card overview
BFM 1013 Sorted alphabetically
Activity Job card Maintenance group

Installing and removing turning gear W 04-06-03 Engine control
Removing and installing the cable harness (MVS) W 13-01-02 Electrical system
Removing and installing the fuel injector pump W 07-04-01 Fuel system
Removing and installing the impulse transmitter
W 05-07-03 Speed governing
(camshaft)
(crankshaft)
Removing and installing the oil pressure switch W 08-11-08 Lube oil system 5
Removing and installing the pressure transmitter
W 13-08-01 Electrical system
(charge air)
Removing and installing the temperature transmitter
W 06-14-01 Exhaust system / Charging
(charge air)
W 09-12-01 Cooling system
(coolant)
W 07-09-01 Fuel system
(fuel)
Renewing the injection lines W 07-03-01 Fuel system
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Job card overview MVS
Sorted alphabetically BFM 1013
© 10/2007 4/8 14338-001

MVS Sorted numerically
BFM 1013 Job card overview
5
5.2 Sorted numerically
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Sorted numerically MVS
Job card overview BFM 1013
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MVS Sorted numerically
BFM 1013 Job card overview
Job card Activity Maintenance group

W 04-06-03 Installing and removing turning gear Engine control
(crankshaft)
(camshaft)
W 06-14-01 Exhaust system / Charging
(charge air)
W 07-03-01 Renewing the injection lines Fuel system
5
W 07-04-01 Removing and installing the fuel injector pump Fuel system
W 07-09-01 Fuel system
(fuel)
W 08-11-08 Removing and installing the oil pressure switch Lube oil system
W 09-12-01 Cooling system
(coolant)
W 13-01-02 Removing and installing the cable harness (MVS) Electrical system
W 13-08-01 Electrical system
(charge air)
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Sorted numerically MVS
Job card overview BFM 1013
© 10/2007 8/8 14338-001

DEUTZ engines Job cards
6 Job cards
6
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Job cards DEUTZ engines
© 11/2005 2/2 14755-001

MVS Engine control
BFM 1013 W 04-06-03
Installing and removing turning gear

Commercial available tools
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100320
– Disassembly tool. . . . . . . . . . . . . 110901
– Fitting compound
DEUTZ AP1908
– Locking agent
DEUTZ DW 75
Attaching turning gear

z Unscrew screws (1).
z Remove cover (2).
1
2
© 46066-0
z Remove the O-ring (1) with the disassembly tool.
© 46043-0
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Engine control MVS
W 04-06-03 BFM 1013
z Insert turn-over gear (1).

The toothed gear of the turn-over gear
must grip into the teeth of the camshaft
wheel.
1
6
© 46041-1
z Tighten screws (1).

30 Nm
© 46042-0
Removing turning gear

z Remove turn-over gear.
© 46042-0
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MVS Engine control
BFM 1013 W 04-06-03
z Clean sealing surfaces.

z Mount new O-ring (1).
z Lightly coat O-ring with fitting compound.
1
6
© 46043-0
z Press in the cover (3) to the stop.

z Insert screws (1) with locking agent.
Screws:
M8 x 55 mm
z Fasten screw (2). 1

Screw:
M8 x 60 mm 3
© 46101-0

21 Nm
z Tighten screw (2).
30 Nm
1
© 46065-0
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Engine control MVS
W 04-06-03 BFM 1013
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MVS Speed control
BFM 1013 W 05-07-01

(crankshaft)
Commercial available tools: Read out error memory of the motor con-
– Feeler gauges trol timer with SERDIA.
– Locking agent
DEUTZ DW 72
Removing the impulse transmitter

z Unlock cable plug (1) and disconnect.
z Remove cable tie (2).
1
© 46049-0
z Remove cable tie (1).
© 46050-0
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Speed control MVS
W 05-07-01 BFM 1013

z Remove holder (2).
1
2
6
© 46051-0
z Unscrew screw (1).

z Remove impulse transmitter (2).
© 46052-0
z Visually inspect the components.
© 46053-0
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MVS Speed control
BFM 1013 W 05-07-01
Installing the impulse transmitter

z Clean thread of screw and bore.
z Insert impulse transmitter (2).
Attention!
Do not damage the component.
z Insert screw (1) with locking agent.

1
2
6
© 46052-0

9 Nm
© 46054-0

z Mount holder (1).
z Fasten screws.
© 46093-0
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Speed control MVS
W 05-07-01 BFM 1013
z Push feeler gauge blade between toothed washer (1)

and speed governor (2).
z Press the impulse transmitter lightly against the feel-
er gauge blade.
6
© 46094-0
– Nominal dimension "X"

+ 0,1
0,6 mm
© 46091-0
z Hold position of the speed governor.

30 Nm
© 46095-0
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MVS Speed control
BFM 1013 W 05-07-01
z Check gap dimension with feeler gauge blade again.

+ 0,1
0,6 mm
The feeler gauge blade must fit between
the tooth lock washer and impulse trans-
mitter (crankshaft) with low resistance.
6
© 46057-0
z Fix cable tie (1).
© 46050-0
z Plug cable plugs (1) together.

Ensure that the connection is perfect.
z Fix cable tie (2). 1

Delete error entry in the error memory of
the motor control timer with SERDIA.
© 46049-0
© 10/2007 5/6 14344-001

Speed control MVS
W 05-07-01 BFM 1013
© 10/2007 6/6 14344-001

MVS Speed control
BFM 1013 W 05-07-03

(camshaft)
Commercial available tools Read out error memory of the motor con-
trol timer with SERDIA.
– Locking agent
DEUTZ DW 72
– Packing compound
DEUTZ DW 76
Removing the impulse transmitter

© 46058-0

z Remove impulse transmitter (2).
z Remove spacing disc.
z Remove seals.
© 46059-0
© 10/2007 1/4 14345-001

Speed control MVS
W 05-07-03 BFM 1013

z Clean components.
6
© 46060-0
Installing the impulse transmitter

z Measure distance, dimension (a)
z Select spacing disc.
a
Dimension "a" Identification Thickness
27.85 - 27.95 mm 1 7.1 mm
27.96 - 28.05 mm 2 7.2 mm
28.06 - 28.15 mm 3 7.3 mm
© 46103-0
z Coat the hollow throat (arrow) thinly with sealing

compound.
© 46069-0
© 10/2007 2/4 14345-001

MVS Speed control
BFM 1013 W 05-07-03
z Mount new gasket (1).

z Coat new spacing disc (2) thinly with sealing com-
pound on both sides.
z Fit spacing disc (2).
2
1 6
3
© 46104-0

z Press in impulse transmitter (2).
Attention!

1
9 Nm
© 46059-0

1
© 46058-0
© 10/2007 3/4 14345-001

Speed control MVS
W 05-07-03 BFM 1013
© 10/2007 4/4 14345-001

MVS Exhaust system/Charging
BFM 1013 W 06-14-01

(charge air)
Special tools:
DEUTZ AP1908
– Locking agent
DEUTZ DW 75
Removing temperaure transmitter

z Unlock cable plug (1) and remove.
1
© 46082-0

z Remove heat shield (2).
z Remove temperature transmitter (3).
3
1
© 46084-1
© 10/2007 1/4 14346-001

Exhaust system/Charging MVS
W 06-14-01 BFM 1013

6
© 46016-0
Installing temperature transmitter

1
© 46016-0
z Insert temperature transmitter (3).

Attention!
3
1
z Mount heat shield (2).
9 Nm
© 46084-1
© 10/2007 2/4 14346-001

MVS Exhaust system/Charging
BFM 1013 W 06-14-01
z Plug in the cable plug (1).

Delete error entry in the error memory of 1
6
© 46082-0
© 10/2007 3/4 14346-001

Exhaust system/Charging MVS
W 06-14-01 BFM 1013
© 10/2007 4/4 14346-001

MVS Fuel system
BFM 1013 W 07-03-01
Renewing the injection lines

Commercial available tools – User notes
Special tools:
– Special wrench . . . . . . . . . . . . . . 110500
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
6
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Injection pipes may not be bent.
Removing injection pipes

z Loosen screws (1).
z Pull off cables (2).
Mark assignment of cables/connections
before removing. 2
© 46028-0
© 10/2007 1/8 14347-001

Fuel system MVS
W 07-03-01 BFM 1013

1
6
© 46017-0
© 46029-0

z Place cover plate (2) on one side.
© 46073-0
© 10/2007 2/8 14347-001

MVS Fuel system
BFM 1013 W 07-03-01
z Pull off bleeding hose (1).
6
© 46031-0
z Unscrew all screws (1).

z Remove cylinder head cowling (2).
z Remove gasket.
1
© 46074-0
z Unscrew lock nuts (1) with special wrench.

z Remove injection line.
Lay out components in the order in which 1
they should be installed.
Note assignment!
© 46032-0
© 10/2007 3/8 14347-001

Fuel system MVS
W 07-03-01 BFM 1013

z Renew damaged profile washers.
6
© 46107-0
Installing injection pipes

z Mount new injection pipe.
z Screw on union nuts (1). 1
Attention!
Install injection line without tension.
Note installation position.

1
© 46032-0
z Position profile washer (1).

The profile seal must touch the cylinder
head (arrow). 1
© 46034-0
© 10/2007 4/8 14347-001

MVS Fuel system
BFM 1013 W 07-03-01
z Tighten union nuts (1) with special wrench.

– Pre-tensioning value:
5 Nm
– Post-tensioning value:
25 Nm
1
6
© 46035-0

© 46036-0
z Mount cylinder head cover (1).

Note installation position of the profile
seals (2). 1
© 46067-0
© 10/2007 5/8 14347-001

Fuel system MVS
W 07-03-01 BFM 1013
z Mount cover (2).

z Tighten all screws (1).
13 Nm
1 2
6
© 46100-0
z Fit on the venting hose (1).
© 46031-0

© 46029-0
© 10/2007 6/8 14347-001

MVS Fuel system
BFM 1013 W 07-03-01

z Plug together the cable plugs (2).
Ensure that the connection is perfect. 1
6
© 46017-0
z Plug cables to all injection pumps.

– Assignment of cable plugs to the injection pumps

Injection pump Identification
1 Y15.1
2 Y15.2
3 Y15.3
4 Y15.4
5 Y15.5
6 Y15.6
5 6
4
2 3
1
© 46088-0
Attention!
Note assignment and polarity of the electri-
cal connections!
Connect cables according to marks made

before removing.

1 Nm
© 46021-0
© 10/2007 7/8 14347-001

Fuel system MVS
W 07-03-01 BFM 1013
© 10/2007 8/8 14347-001

MVS Fuel system
BFM 1013 W 07-04-01
Removing and installing the fuel injector pump

Commercial available tools: – User notes
– Socket wrench insert, – W 04-06-03
10 mm, 12-edge . . . . . . . . . . . . . . . 8135 – W 07-03-01
Special tools:
– Special pliers. . . . . . . . . . . . . . . . 103220 Attention!
– Disassembly tool. . . . . . . . . . . . . 110901 Pay attention to utmost cleanliness when
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 working on the fuel system.
– Fitting compound before removing.
DEUTZ AP1908 Clean the respective affected parts care-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels. 6
to regulations.
Read out error memory of the motor con-

Removing the fuel injector pump

z Remove injection lines.
W 07-03-01
© 46075-0
© 10/2007 1/10 14348-001

Fuel system MVS
W 07-04-01 BFM 1013
z Hold connector (1).

z Unscrew hollow screw (3).
z Remove sealing rings.
z Place fuel hose (2) to one side.
3
2
6
© 46108-0
z Unscrew hollow screws (1).

z Remove fuel pipe (2).
z Remove sealing rings.
z Attach turning gear.
W 04-06-03 1
© 46077-0
z Turn over crankshaft until the valve overlap is

achieved on cylinder 1.
Valve overlap means:
The inlet valve starts opening,exhaust
valve closes.

4-cylinder
Ignition
1-3-4-2
sequence:
Valves Cylinders
overlap 1 3 4 2
set to 4 2 1 3
© 46078-0
© 10/2007 2/10 14348-001

MVS Fuel system
BFM 1013 W 07-04-01

6-cylinder
Ignition
1-5-3-6-2-4
sequence:
Valves Cylinders
overlap 1 5 3 6 2 4
set to 6 2 4 1 5 3
6
© 46078-0
z Turn crankshaft with turning gear by 90 ° against the

engine direction of rotation.
© 46044-0
z Tighten screws (1) with the socket wrench insert al-

ternately.
Loosen screws evenly to avoid jamming
the injection pump. 1
z Remove fuel injector pump(2).

z Put aside components in the order in which they were
removed.
Note assignment!
2
© 46045-0
© 10/2007 3/10 14348-001

Fuel system MVS
W 07-04-01 BFM 1013
z Remove shim (1).

removed.
Note assignment!
1
6
© 46079-0
z Pull out roller tappet (1) with special pliers.

Attention!
Do not damage the roller tappet!

removed.
Note assignment!
1
© 46080-0
z Remove the O-rings (1) with the disassembly tool.
© 46063-0
© 10/2007 4/10 14348-001

MVS Fuel system
BFM 1013 W 07-04-01
6
© 46046-0
Installing the fuel injector pump

removed.
Note assignment!
© 46081-0
z Turn camshaft with turning gear until the cam for the
injection pump is on the base circle (arrow).
© 46048-0
© 10/2007 5/10 14348-001

Fuel system MVS
W 07-04-01 BFM 1013
z Oil the roller tappet lightly.

z Insert roller tappet (1) with special pliers.
Note assignment!
The pilot pin (1) must lock in
groove (arrow).
6
© 46068-0
z Insert shim (1).

Attention!
Renew components if worn.
Note assignment! 1
© 46079-0
z Coat chamfers (1) and locating hole with mounting

compound.
© 46062-0
© 10/2007 6/10 14348-001

MVS Fuel system
BFM 1013 W 07-04-01
z Mount new O-rings (1).

z Coat the O-rings with fitting compound.
6
© 46063-0
z Insert injection pump (1).

Note assignment!
2
z Lightly oil screws (2).
Renew damaged screws.
z Tighten screws (2) with the socket wrench insert al-

ternately. 1
– Pre-tensioning value:
5 Nm
– Post-tensioning value:
30 Nm
© 46102-0
z Mount new sealing rings.

Note assignment!
Sealing ring thickness:
2.5 mm (1)
4
1.1 mm (4) 3
z Mount fuel pipe (2).

z Turn in new hollow screws (3).
Attention!
1
Replace hollow screw (bare) with hollow
screw (chromated)!
© 46109-0
© 10/2007 7/10 14348-001

Fuel system MVS
W 07-04-01 BFM 1013
z Tighten hollow screws (1).

45 Nm
Attention!
Install fuel pipe tension free.
1
6
© 46085-0
z Mount sealing rings (3).

z Position fuel hose (1).
z Screw on hollow screw (2).
3 1
2
© 46110-0
z Hold connector (1).

z Tighten hollow screw (2).
39 Nm
Attention!
Lay the hose pipe free from chafing and
tension. 1
© 46111-0
© 10/2007 8/10 14348-001

MVS Fuel system
BFM 1013 W 07-04-01
z Install injection lines.

W 07-03-01
z Remove turning gear.
W 04-06-03
6
© 46064-0
© 10/2007 9/10 14348-001

Fuel system MVS
W 07-04-01 BFM 1013
© 10/2007 10/10 14348-001

MVS Fuel system
BFM 1013 W 07-09-01

(fuel)
Commercial available tools: – User notes
– Socket wrench insert,
size 19 . . . . . . . . . . . . . . . . . . . . . . 8017
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
before removing.
Clean the respective affected parts care-
sed air.
Observe the safety regulations and natio- 6
nal specifications for handling fuels.
to regulations.


© 46000-0
© 10/2007 1/4 14349-001

Fuel system MVS
W 07-09-01 BFM 1013
z Unscrew the temperature transmitter (1) with the

socket wrench insert.
6
© 46001-0
© 46002-0

z Mount new sealing ring.
z Tighten the temperature transmitter (1) with the
socket wrench insert.
1
20 Nm
© 46001-0
© 10/2007 2/4 14349-001

MVS Fuel system
BFM 1013 W 07-09-01

1
6
© 46000-0
© 10/2007 3/4 14349-001

Fuel system MVS
W 07-09-01 BFM 1013
© 10/2007 4/4 14349-001

MVS Lube oil system
BFM 1013 W 08-11-08
Removing and installing the oil pressure switch

Commercial available tools Collect leaking operating substances in
Special tools: to regulations.
– Socket wrench insert . . . . . . . . . 110700
Removing the oil pressure switch

© 46003-0
z Unscrew the oil pressure switch (1) with the socket

wrench insert.
© 46004-0
© 10/2007 1/2 14350-001

Lube oil system MVS
W 08-11-08 BFM 1013
6
© 46005-0
Installing the oil pressure switch

z Tighten the oil pressure switch (1) with the socket
wrench insert.
1
45 Nm
© 46004-0

© 46003-0
© 10/2007 2/2 14350-001

MVS Cooling system
BFM 1013 W 09-12-01

(coolant)
Commercial available tools: Collect leaking operating substances in
– Socket wrench insert, suitable vessels and dispose of according
size 19 . . . . . . . . . . . . . . . . . . . . . . 8017 to regulations.
– Socket wrench insert, Read out error memory of the motor con-
size 22 . . . . . . . . . . . . . . . . . . . . . . 8035 trol timer with SERDIA.

© 46006-0
z Unscrew temperature transmitter (1).
© 46007-0
© 10/2007 1/4 14351-001

Cooling system MVS
W 09-12-01 BFM 1013
6
© 46008-0
z Unscrew the adapter (1) with the socket wrench in-

sert 8035.
© 46071-0
z Remove sealing ring.

© 46072-0
© 10/2007 2/4 14351-001

MVS Cooling system
BFM 1013 W 09-12-01

z Tighten the adapter (1) with the socket wrench insert
8035.
110 Nm
6
© 46071-0

Mount the new sealing ring additionally to
the captive sealing ring.
z Tighten temperature transmitter (1).

20 Nm 1
© 46007-0

© 46006-0
© 10/2007 3/4 14351-001

Cooling system MVS
W 09-12-01 BFM 1013
© 10/2007 4/4 14351-001

MVS Electrical system
BFM 1013 W 13-01-02
Removing and installing the cable harness

(MVS)
Commercial available tools Attention!
cal connections!
Removing the cable harness

z Disconnect the battery's negative terminal.
z Unlock cable plug (1) and remove. 1
© 46082-0

1
© 46019-0
© 10/2007 1/8 14352-001

Electrical system MVS
W 13-01-02 BFM 1013
6
© 46020-0
z Loosen screws (1).

z Pull cables off all injection pumps.
Mark assignment of cables/connections
before removing.
© 46021-0
© 46006-0
© 10/2007 2/8 14352-001

BFM 1013 W 13-01-02

1 2
6
© 46022-0
z Unscrew nut (1).
© 46023-0
z Pull out pin housing (1).
© 46024-0
© 10/2007 3/8 14352-001

W 13-01-02 BFM 1013
z Remove all cable ties(1).

z Remove cable harness.
6
© 46025-0
© 46026-0
Installing the cable harness

z Lay the cable plugs to the individual components. 1

2 3
Position Connection
1 Temperature transmitter (coolant) 9
2 Pressure transmitter (charge air)
Temperature transmitter (charge
3
air)
4 Speed governor (crankshaft)
5 Oil pressure switch 8
6 Temperature transmitter (fuel)
7 Injection pumps
8 Pin housing 7
9 Speed governor (camshaft)
6 4
5
© 46092-0
© 10/2007 4/8 14352-001

BFM 1013 W 13-01-02
z Position cable harness on the cover plate and fix with

cable ties (arrows).
1
2
6
© 46106-0
z Push pin housing (1) up to stop.

© 46027-0
z Tighten nut (1).

7 Nm
© 46023-0
© 10/2007 5/8 14352-001

W 13-01-02 BFM 1013

1 2
6
© 46022-0
© 46006-0
z Plug cables to all injection pumps.

– Assignment of cable plugs to the injection pumps

Injection pump Identification
1 Y15.1
2 Y15.2
3 Y15.3
4 Y15.4
5 Y15.5
6 Y15.6
5 6
4
2 3
1
© 46088-0
© 10/2007 6/8 14352-001

BFM 1013 W 13-01-02
Attention!
cal connections!
Connect cables according to marks made

before removing.

1 Nm
6
© 46021-0
© 46020-0

1
© 46019-0
© 10/2007 7/8 14352-001

W 13-01-02 BFM 1013

z Connect the battery's negative terminal.
1
6
© 46082-0
© 10/2007 8/8 14352-001

BFM 1013 W 13-08-01

(charge air)
Special tools:
DEUTZ AP1908
– Locking agent
DEUTZ DW 75
Removing the pressure transmitter

© 46009-0

z Remove spacing sleeves (1).
z Remove washers.
z Remove shielding plate (3). 1
3
© 46105-0
© 10/2007 1/4 14353-001

W 13-08-01 BFM 1013
z Remove pressure transmitter (1).
6
© 46011-0

© 46012-0
Installing the pressure transmitter

© 46012-0
© 10/2007 2/4 14353-001

BFM 1013 W 13-08-01
z Insert pressure transmitter (1) carefully.

Attention!
Do not damage the component. 1
6
© 46011-0
z Mount shielding plate (3).

z Insert spacing sleeves (1).
z Mount washers. 1
3
9 Nm
© 46105-0

© 46009-0
© 10/2007 3/4 14353-001

W 13-08-01 BFM 1013
© 10/2007 4/4 14353-001

MVS
BFM 1013 Standard tools
7 Standard tools
© 10/2007 1/4 14354-001

Handelsübliche Werkzeuge
Commercially available tools
Outils usuels
Herramientas comerciales
Bestellungen
Werkstatthandbuch BFM 2012 No. Deutsch English Français Español
Handelsübliche Werkzeuge /
Spezialwerkzeuge:
Diese sind mit Angabe der Bestellnummer
wie ein normales DEUTZ-Ersatzteil zu
bestellen.
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
Commandes
Outils habituels /
Outils spéciaux :
Ils doivent être commandés en indiquant la
référence selon la même procédure que
pour la commande de pièces de rechange
DEUTZ standard.
Pedidos
Herramientas habituales /
Herramientas especiales:
Se deben solicitar indicando el número de
pedido como una pieza de repuesto normal
de DEUTZ.
© 2002 / 0312 0361

6
MVS
BFM 1013 Standard tools
8017
Socket wrench insert
Size 19, long version
© 43198-1
7
8035
reinforced, size 22
© 37504-2
8135
size 10, 12-edge
© 46096-0
© 10/2007 3/4 14354-001

MVS
Standard tools BFM 1013
© 10/2007 4/4 14354-001

MVS
BFM 1013 Special tools
8 Special tools
© 10/2007 1/4 14355-001

Handelsübliche Werkzeuge
Commercially available tools
Outils usuels
Herramientas comerciales
Bestellungen
Werkstatthandbuch BFM 2012 No. Deutsch English Français Español
Handelsübliche Werkzeuge /
Spezialwerkzeuge:
Diese sind mit Angabe der Bestellnummer
wie ein normales DEUTZ-Ersatzteil zu
bestellen.
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
Commandes
Outils habituels /
Outils spéciaux :
Ils doivent être commandés en indiquant la
référence selon la même procédure que
pour la commande de pièces de rechange
DEUTZ standard.
Pedidos
Herramientas habituales /
Herramientas especiales:
Se deben solicitar indicando el número de
pedido como una pieza de repuesto normal
de DEUTZ.
© 2002 / 0312 0361

6
MVS
BFM 1013 Special tools
100320
Turning gear
flywheel side
© 35422-1
103220
Special pliers 8
for removing the roller tappet
© 43175-0
110500
Special wrench
Size 17
Removing and installing injection pipes
© 35436-1
© 10/2007 3/4 14355-001

MVS
Special tools BFM 1013
110700
long version
© 43198-2
110901
8 Disassembly tool
Removing and installing the O-rings
© 45950-1
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
© 10/2007 4/4 14355-001

WS3 BFM-1013-MVS

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Workshop Manual

Solenoid Valve System (MVS)

5 Job card overview

© 01/2008 1/2 14754-001

© 01/2008 2/2 14754-001

© 05/2005 1/4 14339-001

© 05/2005 2/4 14339-001

© 05/2005 3/4 14339-001

© 05/2005 4/4 14339-001

© 11/2005 1/4 14340-001

© 11/2005 2/4 14340-001

DEUTZ engines are the product of years of re-

Maintenance and care are the only way the engine

Please consult one of our service representatives

© 11/2005 3/4 14340-001

© 11/2005 4/4 14340-001

© 12/2005 1/8 14341-001

© 12/2005 2/8 14341-001

3.1 General 3.2 Specifications

© 12/2005 3/8 14341-001

© 12/2005 4/8 14341-001

© 12/2005 5/8 14341-001

3.3 Operation manual and workshop 3.4 Job cards

© 12/2005 6/8 14341-001

3.4.2 Structure of a job card 3.5 Explanation of symbols

© 12/2005 7/8 14341-001

© 12/2005 8/8 14341-001

© 10/2007 1/8 14342-001

© 10/2007 2/8 14342-001

ID no. Name Information Series Value Unit

Testing and setting data

4.2 Tightening specifications

© 10/2007 5/8 14342-001

© 10/2007 6/8 14342-001

A05 013 M8x45 BFM 1013 30 Nm

© 10/2007 1/8 14338-001

© 10/2007 2/8 14338-001

Activity Job card Maintenance group

© 10/2007 3/8 14338-001

© 10/2007 4/8 14338-001

© 10/2007 5/8 14338-001

© 10/2007 6/8 14338-001

Job card Activity Maintenance group

© 10/2007 7/8 14338-001

© 10/2007 8/8 14338-001

© 11/2005 1/2 14755-001

© 11/2005 2/2 14755-001

Installing and removing turning gear

Attaching turning gear

z Remove the O-ring (1) with the disassembly tool.

© 10/2007 1/4 14343-001

z Insert turn-over gear (1).

z Tighten screws (1).

Removing turning gear

© 10/2007 2/4 14343-001

z Clean sealing surfaces.

z Press in the cover (3) to the stop.

z Fasten screw (2). 1

z Tighten screws (1).

© 10/2007 3/4 14343-001

© 10/2007 4/4 14343-001

Removing and installing the impulse transmitter

Removing the impulse transmitter