Repair of Deutz TCD2013 L06 2V Engine in Dynapac F121C Asphalt Paver

Comprehensive repair of the Deutz TCD2013 L06 2V engine in the Dynapac F121C tracked asphalt paver (code 635)

Introduction

Our WIBAKO service received a tracked asphalt paver Dynapac F121C (code 635), operating on large road investments in the Małopolskie Voivodeship near the city of Kraków. The machine is equipped with a high-speed Deutz TCD2013 L06 2V engine, one of the most popular units used in road construction due to its work economy, high durability, and proven design.

The report concerned difficulties in starting the machine, lack of stability in revolutions, and a noticeable drop in power when laying heavy asphalt mixtures. The operator also observed periodic "popping" in the intake system. Preliminary diagnostics indicated the possibility of damage or burning of one of the valves in the engine head.

Preliminary diagnostics in the machine

Before proceeding with disassembly, our mobile service performed a complete engine diagnostics in the machine. We started with measuring compression – two cylinders showed significantly reduced values, confirming suspicions regarding problems with the valve system. A cylinder leak test and an endoscopic examination were also performed – the camera confirmed discolorations and damage on the surfaces of the exhaust valves.

To rule out other possible causes, an analysis of exhaust gases and boost pressure was performed, along with basic tests of the auxiliary equipment. All results indicated that the problem was a leak within the head. A complete disassembly of the engine and detailed verification in our workshop was necessary.

Disassembly of the engine from the paver

Disassembly of the Deutz TCD2013 L06 2V engine in Dynapac asphalt pavers requires precision and appropriate equipment. Our mobile service used a crane provided by the client to safely remove the unit from the engine compartment.

The process included disassembly of fuel lines, cooling system, air intake components, auxiliary equipment, and connections to the machine's hydraulic system. All elements were secured and labeled to avoid any mistakes during reassembly. After preparation, the engine was transported to our headquarters in Kojszówka.

Verification of the Deutz TCD2013 L06 2V engine

After disassembling the engine into parts, the results of the previous diagnostics were confirmed. Burned exhaust valves and damage to the valve seats were detected in the head. Additionally, leaks were noticed on the valve guides, leading to blow-by.

During verification, the following was performed:

- complete inspection of the crankshaft (measuring journals, runout, oil channels)
- inspection of the camshaft (measuring lobes and journals, visual inspection)
- examination of the turbocharger (axial and radial play)
- verification of connecting rods (tightening, bending, weight)
- leak test of the head in a water bath

Repair process

Crank-piston system

In the crank-piston system, a complete set of pistons, rings, connecting rod and main bearings were replaced. The cylinder liners were replaced with new ones. The crankshaft was measured and sent for grinding, followed by re-verification.

Engine head

The head underwent complete regeneration: planning, replacement of guides, installation of new valves, machining of seats, and replacement of seals. After the work was completed, the head was retested for leaks.

Fuel system

The injection pump was checked on an external test bench, and the injectors underwent a pressure opening and atomization test. Return lines were replaced, and the fuel system was cleaned.

Engine accessories

The turbocharger, starter, and alternator were regenerated. The intake system was sealed, and a detailed inspection of the electro-mechanical components responsible for engine control was performed.

Professional engine assembly

After completing all repair work, the engine was professionally assembled according to the documentation from Deutz. Each element was installed using new gaskets and bolts with appropriate parameters. During assembly, precise measuring tools were used to ensure proper tightening torques and full compliance with factory standards.

WIBAKO engine dynamometer test

The Deutz TCD2013 L06 2V engine was then placed on our engine dynamometer, which is one of the most important assets of WIBAKO service. We have a professional station for load testing high-speed units, allowing for full confirmation of engine efficiency even before installation in the machine.

The testing procedure lasted over 16 hours of operation under light load conditions, and then the engine was subjected to full loads multiple times to verify power parameters, oil pressure, operating temperatures, and stability. The dynamometer also allows monitoring of RPM graphs, fuel consumption, and analysis of the unit's behavior under sudden load changes.

As a result, the client receives assurance that the engine is fully operational, leak-free, and ready for work in the demanding conditions of road construction.

Engine installation in the Dynapac F121C paver

The installation in the machine took place again near Kraków. Our mobile service used a local crane from the client to precisely lower the unit into the frame of the paver. The installation included connecting the fuel system, cooling, auxiliary hydraulics, and electrical equipment.

Particular attention was paid to the tightness of the air intake and cooling system connections, as asphalt pavers often operate in elevated temperatures and dusty environments. Part of the piping was replaced, filters and lines were checked, the cooling system was flushed, and the machine was prepared for the first start-up.

Post-installation tests were conducted together with the operator. We checked hydraulic pressures, operating temperatures, and the engine's behavior under load while laying material. After positive tests, an installation protocol was signed.

Engine maintenance after repair

The engine is covered by WIBAKO's warranty. We recommend the first filter change after 50 operating hours and a full inspection of connections and tightness. Subsequent inspections should be performed every 250 operating hours, but no less than once every 3 months.

Where is the Deutz TCD2013 L06 2V engine installed?

Deutz TCD2013 L06 2V engines are found in machines such as:

- Dynapac pavers
- Terex wheel loaders
- Sennebogen handling machines
- Volvo and Atlas road machines
- various industrial applications in the off-highway sector

Summary

The repair of the engine in the Dynapac F121C paver restored the full efficiency of the machine. The replacement and regeneration of key components, a full load test on the dynamometer, and precise assembly guarantee long and trouble-free operation of the Deutz TCD2013 L06 2V unit. We recommend the next inspection after 50 operating hours of the engine.