Renovation of the Deutz TCD2013 L06 2V Engine in the Sennebogen 835M Machine

Engine Overhaul of Deutz TCD2013 L06 2V in Sennebogen 835M Material Handler

Introduction – Sennebogen 835M service with Deutz diesel engine

WIBAKO was commissioned to carry out a comprehensive engine overhaul of a Sennebogen 835M material handler operating at a recycling facility near Katowice in the Silesian region. This wheeled material handler is designed for intensive loading operations involving scrap metal and bulk materials, often working in multi-shift conditions. The heart of this machine is the Deutz TCD2013 L06 2V – a six-cylinder inline diesel engine widely used in off-highway applications.

Sennebogen is a well-known manufacturer of material handlers, cranes, and specialized construction machinery. The 835M model combines mobility with high lifting performance, making it a popular choice in recycling and port operations. Deutz, as the engine manufacturer, is recognized worldwide for reliable and durable diesel engines used in construction, agricultural, and industrial equipment.

The customer reported power loss, increased oil consumption, and blue exhaust smoke. Additionally, hot starts were becoming increasingly difficult. Based on these symptoms, we suspected worn cylinders and piston assemblies leading to reduced compression.

Initial on-site diagnostics

Our mobile service team traveled to the customer’s location near Katowice. As part of the initial diagnostics of the Sennebogen 835M, we performed a compression pressure test on the Deutz TCD2013 L06 2V engine. The results showed significant deviations from nominal factory specifications.

We also carried out a cylinder leakage test and an endoscopic inspection of the combustion chambers. The inspection revealed visible wear on the cylinder liners and carbon deposits on the piston crowns. Blow-by gases were detected in the crankcase ventilation system. Based on these findings, we decided to remove the engine and transport it to our headquarters in Kojszówka for complete disassembly and verification as part of our professional diesel engine service for Deutz units.

Engine removal from the Sennebogen 835M

The engine removal was carried out by our technicians using a crane provided by the customer. The process began with disconnecting the electrical harness, fuel lines, air intake system, and cooling system components. Special attention was paid to securing hydraulic lines and the charge air cooler connections to prevent contamination or mechanical damage.

After disconnecting all auxiliary components and engine mounts, the Deutz TCD2013 L06 2V was carefully lifted out of the machine frame. All connections were labeled and documented to ensure precise reinstallation according to manufacturer standards. The engine was then transported to WIBAKO’s workshop facility.

Engine verification in the workshop

The verification process started with a controlled rotation of the crankshaft, followed by complete disassembly of the engine. Inspection confirmed severe wear of the cylinder liners and piston rings. Components of the crankshaft-piston assembly showed signs of operational wear consistent with long-term heavy-duty use.

We conducted a detailed crankshaft verification, including journal measurements, runout inspection, and oil passage checks. The crankshaft required grinding. Connecting rods were inspected for twist and bend, and their dimensions were measured. The cylinder head underwent a pressure test in a heated water bath to confirm structural integrity and sealing condition.

Engine rebuilding and repair process

Crankshaft-piston assembly

The engine block was machined and prepared for new cylinder liners. New pistons and piston rings compliant with Deutz specifications were installed. The crankshaft was reground and fitted with new main and connecting rod bearings. All components were assembled using manufacturer-specified torque values and procedures.

Cylinder head reconditioning

The cylinder head regeneration included surface machining, replacement of valve guides, and installation of new valves. Valve seats were machined and sealing surfaces restored. Valve clearances were adjusted according to Deutz technical documentation to ensure optimal combustion performance.

Fuel system and auxiliary components

Fuel injectors were tested on a dedicated test bench to verify spray pattern and injection pressure. The turbocharger underwent axial and radial clearance inspection. Seals and wear components were replaced where necessary. The starter motor and alternator were also tested to confirm correct electrical performance.

Engine testing on the dynamometer

Once fully assembled, the Deutz TCD2013 L06 2V engine was installed on our professional engine dynamometer test bench. WIBAKO is one of the few companies in the region equipped with a dedicated off-highway engine test facility, allowing us to verify engines under controlled load conditions before installation in the machine.

The engine was initially operated for a minimum of 16 engine hours under light load conditions, approximately 20-30% of nominal output. During this break-in phase, we continuously monitored oil pressure, coolant temperature, exhaust gas parameters, crankcase pressure, and overall engine stability.

After successful stabilization, the engine was subjected to repeated full-load cycles to verify power output, torque characteristics, and fuel system response. The dynamometer test allows us to detect even minor irregularities in fuel delivery, turbocharger performance, lubrication, or cooling systems. This step significantly reduces the risk of unexpected downtime once the engine is reinstalled in the Sennebogen 835M.

Comprehensive documentation of all operating parameters was prepared and archived. Thanks to this process, the customer received a fully tested and performance-verified engine, ensuring maximum reliability in demanding material handling operations.

Engine installation in the Sennebogen 835M

The engine installation was carried out on-site by our mobile service team. Using the customer’s crane, the rebuilt Deutz TCD2013 L06 2V was precisely positioned within the engine compartment and aligned with the mounting brackets. New vibration-damping elements were installed to ensure proper load distribution.

During installation, we replaced selected air intake piping components and verified the tightness of all boost air connections. The cooling system was reassembled with new seals, and all hose connections were pressure-checked. New oil and fuel filters were installed, and the engine was filled with fresh operating fluids meeting manufacturer specifications.

Each bolt connection was tightened according to specified torque values. Electrical connections were carefully reinstalled and verified. Before first start-up, we performed a pre-lubrication procedure to ensure correct oil distribution within the engine.

The first start-up took place in the presence of the machine operator. We monitored engine parameters at idle and under working load conditions. The Sennebogen 835M was tested in real operating cycles to confirm proper response and performance. After successful testing and leak inspection, a formal installation protocol was signed.

Post-overhaul service and maintenance

The overhauled engine is covered by warranty. We recommended the first service inspection after 50 engine hours. Our mobile service team will revisit the customer’s site to replace filters, check all connections, and verify overall engine performance. Subsequent maintenance intervals are scheduled every 250 engine hours, but not less frequently than every three months.

Applications of the Deutz TCD2013 L06 2V engine

The Deutz TCD2013 L06 2V engine is widely used not only in Sennebogen material handlers but also in wheel loaders, crawler excavators, crushers, screening plants, and industrial power units. Our extensive experience in construction machinery service and Deutz diesel engine overhaul enables us to provide comprehensive repair solutions across multiple machine brands.

Summary

The complete overhaul of the Deutz TCD2013 L06 2V engine restored full operational capability to the Sennebogen 835M material handler. By combining precise mechanical rebuilding with professional dynamometer testing, WIBAKO ensured reliable performance and minimized future downtime risks.

If you are looking for professional Deutz diesel engine service or comprehensive construction machinery service, contact WIBAKO. We provide mobile dismantling and installation as well as full engine testing on our dynamometer test bench.