Reconstruction of the Deutz TCD2013 L06 2V Engine in the Terex Fuchs MHL454 Machine

Engine overhaul of Deutz TCD2013 L06 2V in Terex Fuchs MHL454 wheeled material handler

The Terex Fuchs MHL454 material handler is a modern wheeled machine designed for intensive loading operations in ports, scrap sorting facilities, recycling plants, and logistics centers. The design of this machine combines high stability, a large lifting capacity, and precision in the operation of attachments, making it frequently used in multi-shift operations. The heart of the presented unit was a six-cylinder diesel engine Deutz TCD2013 L06 2V, known for its high work culture, good torque, and durability in off-highway applications.

A client from the Małopolskie Voivodeship, near Kraków, reported that their Terex Fuchs MHL454 machine began to show a decrease in power, increased smoke emissions, and higher engine oil consumption. Due to the machine's crucial role in loading processes, a comprehensive engine repair was decided upon. Our mobile service performed initial diagnostic procedures directly at the client's site, and then the engine was transported to our headquarters in Kojszówka, where we conducted a complete overhaul and testing on the engine dynamometer.

Preliminary diagnostics of the Deutz TCD2013 L06 2V engine in the machine

The preliminary diagnostics were performed on the Terex Fuchs MHL454 machine under normal operating conditions. The operator reported a noticeable drop in power when working at full reach and smoke emissions under load. Our mechanics conducted a compression pressure measurement, which showed significant differences between the cylinders. Additionally, a cylinder leak test and endoscopy of the combustion chambers were performed, which allowed for the preliminary identification of excessive wear on the cylinder liners and pistons.

Additionally, oil pressure was checked, and the oil filter was analyzed, revealing the presence of fine metal shavings. Based on these symptoms, the engine was classified for a major overhaul, and further diagnostics were to be performed after its disassembly in the workshop.

Disassembly of the engine from the Terex Fuchs MHL454 machine

The disassembly of the Deutz TCD2013 L06 2V engine was carried out by our mobile service at the client's facility. According to the manufacturer's procedure, the electrical system, fuel system, and intake and exhaust systems were disconnected first. Special attention was paid to securing the cooling system hoses and hydraulic components, which are very extensive in material handling machines.

The engine was removed from the machine using a crane provided by the client. After unbolting the engine mounts and the coupling, the power unit was safely removed from the machine frame and prepared for transport. The entire disassembly process concluded with the preparation of documentation and securing the machine until the engine was reassembled.

Verification of the Deutz engine in the workshop

After delivering the engine to our headquarters in Kojszówka, we began a detailed verification. The engine was disassembled down to the last component, and all parts were thoroughly cleaned and labeled. The verification confirmed the preliminary diagnosis - the cylinder liners and pistons showed significant wear, and the clearance on the piston rings exceeded permissible values.

The crankshaft underwent visual inspection and measurements of runout and journal diameters. Wear on the working surfaces was noted, qualifying the crankshaft for grinding. The engine head was checked for sealing and the condition of the valve seats. The leak test revealed leaks in the exhaust valves.

Repair process of the Deutz TCD2013 L06 2V engine

Crankshaft and piston system

As part of the overhaul of the crankshaft and piston system, the crankshaft was ground, and new main and connecting rod bearings were installed. The connecting rods were verified for twisting and bending, and then paired by weight. New cylinder liners, pistons, and piston rings were used, in accordance with the specifications of the Deutz engine.

Engine head

The regeneration of the head included surface planning, replacement of valve guides, and valves. The valve seats were machined, and the entire assembly underwent a leak test again. This ensured proper operating parameters and durability after the repair.

Fuel system and accessories

The injectors were tested on a test bench, and accessory components such as the turbocharger, starter, and alternator were checked for play and proper operation. If necessary, regeneration or replacement of worn components was performed.

Professional assembly of the engine

The assembly of the Deutz TCD2013 L06 2V engine was carried out according to the manufacturer's documentation and with strict cleanliness standards. Each tightening moment was controlled, and the valve clearance was set according to specifications. The engine was prepared for testing on the engine dynamometer.

Testing on the engine dynamometer

One of the key stages of the overhaul was the test on the engine dynamometer. As one of the few companies in the region, we have our own dynamometer, which allows for comprehensive testing of diesel engines before their installation in construction machines. The Deutz TCD2013 L06 2V engine was started and operated for several hours under controlled conditions, initially at a load of about 20-30% of nominal power.

During the tests, temperatures, oil pressure, combustion parameters, and the tightness of all systems were monitored. After the break-in phase, the engine was repeatedly loaded to nominal values, which confirmed its proper operation. The dynamometer test gives our clients confidence that the engine after the overhaul is fully operational and ready for intensive use.

Installation of the engine in the Terex Fuchs MHL454 machine

After the tests were completed, the engine was transported to the client and installed in the machine by our mobile service. The installation included precise seating of the engine in the frame, connecting all hoses, replacing the air intake piping components, and checking the tightness of the connections. After starting, machine operation tests were conducted with the operator's participation, and the entire process concluded with the signing of the installation protocol.

Summary and further service support

The comprehensive overhaul of the Deutz TCD2013 L06 2V engine in the Terex Fuchs MHL454 machine restored its full functionality and reliability. The client received the engine after complete testing on the dynamometer and with a warranty. According to recommendations, we will perform the first service inspection after 50 mth, and subsequent ones every 250 mth. Our construction machinery service and diesel engine service also provide ongoing operational support.