Engine overhaul of Deutz TCD2013 L06 2V in Terex Fuchs MHL460D wheeled material handler

Introduction

The material handler Terex Fuchs MHL460D is a modern and efficient machine used in recycling centers, ports, and industrial plants. Thanks to its design based on a robust wheeled frame and a long reach boom, the MHL460D provides precise material handling. In this case, our service WIBAKO carried out a comprehensive overhaul of the Deutz TCD2013 L06 2V engine, which failed due to worn cylinders and pistons. This engine is widely used in industrial and construction machinery, offering high reliability and low fuel consumption.

The Deutz TCD2013 L06 2V engine is a 6-cylinder, liquid-cooled unit equipped with a common rail injection system and a turbocharger. It features a power output ranging from 190 to 220 kW and meets Tier 3 emission standards. In our case, the client reported a problem with reduced power, increased oil consumption, and smoke from the exhaust system.

Preliminary diagnostics

The preliminary diagnostics performed at the client's site near Katowice revealed significant wear of the cylinders and pistons. The service team from WIBAKO conducted a compression pressure measurement, a cylinder leak test, and an endoscopic inspection of the combustion chambers. The results confirmed low compression values in three cylinders, indicating the need for a complete engine overhaul. The engine was disassembled using a crane provided by the client and then transported to our workshop in Kojszówka.

Engine disassembly

The disassembly process included disconnecting all fuel lines, the cooling system, the air intake, and removing engine accessories such as the turbocharger, alternator, and injection pump. Each component was properly labeled and secured. Special attention was paid to the condition of the cooling lines, which in this model often suffer from micro-cracks. After disassembly, the engine was thoroughly cleaned and prepared for verification in our mechanical diagnostics department.

Verification of components

In the workshop, a complete analysis of the engine's technical condition was performed. The measurement of the crankshaft showed that it exceeded permissible tolerances, so it was regenerated using grinding and oil channel inspection. The connecting rods were checked for twisting and bending, and the pistons and liners were replaced with new original Deutz parts. The engine head was machined and had its valve guides and valves replaced. The injection pump was sent to a specialized facility for testing and calibration. The turbocharger was regenerated and dynamically balanced.

Regeneration and repair

The regeneration of the crank-piston system included the replacement of the complete set of bearings, rings, pistons, and cylinder liners. All components were thoroughly cleaned and assembled with tightening torques in accordance with the manufacturer's documentation. After regeneration, the head underwent a leak test in a water bath under vacuum, confirming its full functionality. The fuel system was assembled and tested on a test bench. The entire engine was assembled in controlled workshop conditions.

Engine dynamometer test

After the assembly was completed, the Deutz TCD2013 L06 2V engine was moved to our engine dynamometer. WIBAKO has one of the most modern dynamometers in the region, allowing tests of units with power up to 700 kW. The engine was started and ran for 16 hours under partial load (20–30% of nominal power), which allowed the components of the crank-piston system to settle. Full load tests were then conducted, monitoring oil pressure, coolant temperature, and fuel consumption parameters. The test results confirmed correct performance and smooth operation of the engine. As a result, the client received assurance that the unit would be fully operational and ready for work after installation in the machine.

Engine installation in the machine

The installation of the engine in the Terex Fuchs MHL460D machine was carried out at the client's site with the support of our mobile service. The work included precisely seating the engine in the frame, connecting it to the hydrostatic transmission and cooling system. New air and fuel lines were installed, and after completing all connections, a leak test of the systems was performed. After filling the cooling and oil systems, the first start-up was conducted in the presence of the machine operator. Load tests of the loading arm were also performed to ensure that the engine's operating parameters met the manufacturer's requirements. After positive test results, a handover protocol was signed.

Engine maintenance after overhaul

After the overhaul, we recommend the first filter change and inspection after 50 operating hours, which is performed by our mobile service WIBAKO. Subsequent inspections should be carried out every 250 operating hours or at least once every three months. We also offer comprehensive after-sales service and supply of spare parts for Deutz engines and other brands.

Application of the Deutz TCD2013 L06 2V engine

The Deutz TCD2013 L06 2V engine is used not only in Terex Fuchs material handlers but also in Atlas loaders, Sennebogen cranes, and Liebherr industrial machines. Its popularity stems from excellent durability, high operational culture, and efficient combustion. Thanks to its universal design, this engine can be found in many industrial and construction applications.

Summary

The comprehensive overhaul of the Deutz TCD2013 L06 2V engine in the Terex Fuchs MHL460D machine restored its full operational efficiency. Thanks to the experience of our mechanics, the use of original parts, and dynamometer testing, the client received a fully verified power unit with a warranty. WIBAKO provides comprehensive diesel engine service and professional technical support for construction and industrial machinery. We invite you to contact us for the implementation of further repair and service projects.

Related topics:

Deutz engine service | Industrial engine overhaul | WIBAKO engine dynamometer