Comprehensive Service of Deutz TCD2013 Engine in Sennebogen 830M E-Series Excavator

Complex Repair and Service of the Deutz TCD2013 L06 2V Engine in the Sennebogen 830M E-Series Material Handler - Professionalism and Engine Dynamometer Tests

At **WIBAKO**, we specialize in professional and comprehensive **construction machinery service** off-highway, as well as **diesel engine overhaul**. Our knowledge and experience cover a wide range of power units, including the popular and efficient **Deutz TCD2013 L06 2V** engine, which is often found in high-demand operational machines like material handlers. We are proud to announce the successfully completed **overhaul** of this unit, which powers the **Sennebogen 830M E-Series material handler**.

The service work for the client's machine, which required immediate intervention, began in the vicinity of **Łódź**, specifically in the dynamically developing agglomeration. Our mobile service reacted quickly, traveling to the machine's location. After preliminary diagnosis and disassembly, the engine was transported to our main headquarters in Kojszówka, where we have advanced workshop facilities and a unique **engine dynamometer**.

Sennebogen 830M E-Series Material Handler - Strength and Reliability

The **Sennebogen 830M E-Series** is a wheeled **material handler** designed for the heaviest tasks, such as handling scrap, bulk goods, wood, or materials in the recycling and port sector. It is characterized by a large operating weight (in the M-E version, it can be up to 43.5 tons) and an impressive working reach, extending up to 17 meters. This handler is known for its modular construction, which allows it to be adapted to individual client needs, including diesel, electric, or hybrid drive options.

Deutz TCD2013 L06 2V Engine - The Heart of the Machine

In the described case, power was provided by the reliable, 6-cylinder **Deutz TCD2013 L06 2V** engine with turbocharging and charge air cooling. It is an in-line unit with a displacement of 7.2 liters, meeting EU IIIA / US T3 emission standards. TCD 2013 series engines, utilizing the high-performance Deutz Common-Rail (DCR®) injection system and electronic engine control (EMR 3), ensure the best performance with optimal fuel consumption. This engine, in various power configurations (e.g., 185 kW at 2100 rpm), is frequently used in demanding construction and agricultural machinery.

Stages of Service Work - Comprehensive Diesel Engine Overhaul

Preliminary Diagnosis: Cause of Failure - Bearing Wear and Oil Pressure Drop

The failure report concerned serious, unusual **knocking noises** coming from the engine of the **Sennebogen 830M** machine and a significant **drop in oil pressure**, which clearly indicated a problem with the crankshaft-piston system, most often **crankshaft and connecting rod bearing wear**. Our mobile service in Łódź, upon arrival, conducted a basic diagnosis. This included a detailed measurement of engine oil pressure, which confirmed its critically low level. Furthermore, an oil sample and filter inspection revealed the presence of metallic shavings, which was an alarming sign requiring immediate disassembly.

Engine Removal from the Machine

After confirming the diagnosis, we proceeded with the removal of the **Deutz TCD2013 L06 2V** engine. At the client's location, with the help of a crane provided by the client, our mechanics safely lifted the engine out of the **Sennebogen 830M E-Series material handler** bay. The removal process required precise disconnection of all accessory components, removal of mounting bolts, disconnection of fuel and electrical lines, as well as securing the connections of the cooling and air intake systems. The engine was then prepared for transport and safely delivered to our central workshop in Kojszówka, where detailed verification and **rebuild** were to take place.

Component Verification in the Workshop

In the workshop, the engine was disassembled into parts, which were washed and subjected to detailed **verification**. The disassembly confirmed the preliminary diagnosis - significant wear, and in some places, destruction of the **crankshaft bearings** and connecting rods, which was the direct cause of the knocking noises and the drop in oil pressure. Verification included:

• Crankshaft Verification: Visual inspection revealed signs of overheating, which was confirmed by measuring the journals and runout.
• Connecting Rod Verification: Measurement of twist and longitudinal bend, as well as visual inspection, showed the necessity of their replacement or regeneration due to wear.
• Cylinder Head Verification: A leak test of the cylinder head was performed in a heated water bath, which confirmed its tightness, but regeneration was necessary due to wear of the valve seats and guides.
• Turbocharger Verification: Measurement of axial and radial clearances revealed excessive play, qualifying it for regeneration.

Regeneration and Repair - Rebuilding to Factory Condition

The **rebuild** process of the **Deutz TCD2013 L06 2V** engine was comprehensive and included the replacement and regeneration of key components in accordance with the manufacturer's technology:

Crankshaft-Piston System: The crankshaft underwent **regeneration**, meaning precise grinding of the crankshaft to the required oversize. All bearings (main and connecting rod), as well as pistons, piston rings, and cylinder liners, were replaced to restore nominal compression and sealing. The connecting rods were subjected to professional verification and machining.

Cylinder Head: A full **cylinder head regeneration** was performed. This included surface planning, replacement of valve guides, and the valves themselves. These works are crucial for the correct combustion process and chamber tightness.

Fuel System: The injection pump was disassembled and subjected to **verification on a test bench**, and then transferred to an external, specialized facility for **regeneration**. This guarantees precise fuel injection parameters, which are essential for achieving full power and optimal fuel consumption.

Accessories and Engine Assembly: The turbocharger was regenerated, and the other accessories (starter, alternator) were thoroughly verified and regenerated if necessary. The final stage was the professional engine assembly at our workshop, using new seals, filters, and operating fluids, strictly adhering to tightening torques.

Engine Dynamometer Test - Checking the Quality of the Overhaul

As one of the few companies in Poland possessing an advanced **engine dynamometer**, we can guarantee clients the highest quality of work performed. The **dynamometer test** is a crucial element of the **service** and **overhaul** process for **diesel engines**, including the **Deutz TCD2013 L06 2V** unit, allowing the engine to be loaded under controlled conditions before being installed in the machine.

The testing process lasted a minimum of 16 operating hours (mth). Initially, the engine was started and checked under light operating conditions, with a load of about 20-30% of the nominal power. Such a "running-in" in controlled conditions allows new components, such as piston rings and bearings, to settle correctly. During this time, basic operating parameters were monitored: oil pressure and temperature, coolant temperature, and the tightness of the systems was checked.

After successfully completing the light load stage, the engine was repeatedly subjected to full load, simulating the actual working conditions in the **Sennebogen 830M E-Series material handler**. The dynamometer allows for precise measurement of power and torque, which is necessary to confirm that the engine is achieving parameters close to factory specifications. This is our unique advantage – no client receives an engine that we are not 100% sure meets the highest standards of performance and reliability. Dynamometer tests are the final confirmation of the successful **rebuild** of the engine, and the client receives a full printout of the results, which builds immense trust and transparency in the process.

Engine Assembly in the Sennebogen 830M E-Series Excavator

Following successful dynamometer tests, the **Deutz TCD2013 L06 2V** engine was transported from Kojszówka back to Łódź, where the **Sennebogen 830M E-Series material handler** awaited. **Engine assembly** is a process as precise and critical as the overhaul itself, which is why our mobile mechanics approach it with the utmost care.

Installation in the machine, carried out with the help of the client and their crane, began with the careful placement of the engine into the bay, adhering to all service standards and precise centering. Next, meticulous assembly commenced: mounting feet, clutch, all lines - hydraulic, fuel, and electrical. Our service technicians paid particular attention to thoroughly checking and, if necessary, replacing the air intake piping and other flexible connections to eliminate the risk of leaks that could affect turbocharger operation and the purity of the air entering the combustion chamber.

As part of our comprehensive service, before the first start-up, all filters - oil, fuel, and air - were also replaced, which is a standard procedure after such a thorough **repair**. After connecting all components and preliminary filling with fluids, the first tests took place. Our service technicians always assist with the first start-up attempts, working closely with the machine operator to continuously monitor engine operation, temperature, oil pressure, and potential leaks. Positive tests confirming the correct operation of the engine and the absence of leaks conclude with the signing of a detailed assembly protocol. Thanks to this, the client has full documentation and assurance that the **Deutz TCD2013 L06 2V** is ready to return to heavy material handling work.

Engine Post-Overhaul Maintenance

All **diesel engines**, including the regenerated **Deutz TCD2013 L06 2V**, are covered by a full **WIBAKO** warranty. As part of our comprehensive service, the client was informed about the necessity of performing the first, crucial inspection. We always recommend replacing the filters and checking all connections between the engine and other components after the first **50 operating hours (mth)** of operation from start-up. This early **service**, performed by our mobile service at the client's location, is important not only for replacing filter elements but primarily for a general inspection of the accessories. This allows for the early detection and elimination of any minor leaks or play that may have arisen during normal operation after assembly. Subsequent regular inspections are recommended every 250 mth, but no less frequently than every 3 months.

Information on Machines Using the Deutz TCD2013 L06 2V Engine

The **Deutz TCD2013 L06 2V** engine is a highly versatile unit. Besides the **Sennebogen 830M E-Series material handler**, units from the TCD 2013 L6 2V series with power up to 200 kW are commonly used in many heavy off-highway **construction machinery**, agricultural machines, and in the recycling segment. It is found in crawler excavators, large wheel loaders, crushers, screeners, and specialized transport equipment. Our experience in **Deutz diesel engine service** covers all these applications.

Summary and Benefits

The comprehensive **repair** of the **Deutz TCD2013 L06 2V** engine for the **Sennebogen 830M E-Series material handler** is an example of **WIBAKO's** professional and precise approach to **construction machinery service**. Thanks to expert diagnosis, the use of genuine or high-quality replacement parts, and a rigorous **regeneration** process, the machine has regained full power and efficiency. The most important benefit for the client is the safety and assurance, confirmed by the **engine dynamometer test**, that the engine is fully operational before returning to work. This minimizes the risk of downtime and ensures maximum machine performance, which is crucial in demanding material handling tasks.

Trust our experience in **Deutz diesel engine overhaul**. Our mobile service is ready to operate in the **Łódź** region and throughout the country.

If your crawler excavator Liebherr, wheel loader Cat, or other material handler requires diagnosis, Deutz, Cummins, or Caterpillar diesel engine service, contact us. We offer full support and repairs, from mobile diagnostics to advanced rebuild at our workshop.