Renovation of the Deutz TCD2013 L06 2V Engine in the Dynapac DF125P/D Asphalt Paver

Overhaul of Deutz TCD2013 L06 2V Engine in Dynapac DF125P/D Asphalt Paver (Code 34)

The Dynapac DF125P/D asphalt paver (code 34) is a high-performance wheeled machine used in road construction projects, parking lots, and maneuvering yards. For years, the Dynapac brand has been associated with reliable solutions for the road industry, and the DF125P/D model is valued for its precision in laying mineral-bituminous mixtures and stable operation in varying terrain conditions. The heart of this machine is the Deutz TCD2013 L06 2V engine – a six-cylinder diesel unit used in many off-highway machines, known for its durability and high operating culture.

Our company, WIBAKO, received an order for a comprehensive overhaul of this power unit. The machine was working on a road investment project in the Lesser Poland Voivodeship, near Krakow. The operator reported increased oil consumption, a drop in power, and heavy smoking under load. Our construction machinery service conducted initial diagnostics at the client's site, then organized the engine's disassembly and transport to our headquarters in Kojszówka, where we performed a full verification and rebuild of the unit.

Initial Diagnostics and Engine Disassembly

The first stage involved detailed diagnostics within the machine. Due to symptoms such as a drop in compression, increased oil consumption, and bluish smoke from the exhaust system, wear of the cylinders and pistons was suspected. We performed a compression pressure measurement on all cylinders and a leak test. The results indicated uneven compression values and blow-by into the crankcase. Additionally, we conducted an endoscopic inspection of the cylinder interiors, which confirmed visible scratches and signs of wear on the cylinder liners.

After confirming the necessity of an overhaul, we proceeded with the engine disassembly. The engine removal was performed using a crane provided by the client. Our mechanics disconnected the fuel system, electrical system, cooling system hoses, and air intake. We paid special attention to securing the accessories and labeling all connections to ensure that subsequent assembly would be efficient and compliant with the manufacturer's documentation. Once removed, the power unit was properly secured and transported to our workshop.

Verification of the Deutz TCD2013 L06 2V Engine

In the workshop, we began the verification process by attempting to rotate the engine and conducting an initial assessment of the component conditions. Subsequently, the unit was completely stripped down. All parts were subjected to cleaning in industrial washers, followed by detailed measurement inspections.

Verification of the crank-piston system included measuring cylinder diameters, checking piston clearances, and assessing the condition of the rings. We found excessive wear on the cylinder liners and piston rings, confirming earlier suspicions. Verification of the crankshaft included measuring the main and rod journals, checking for shaft runout, and inspecting oil passages. The shaft was suitable for grinding.

The engine head underwent a leak test in a water bath using compressed air. We checked the valve seats, guides, and the condition of the valves. Verification of the turbocharger included checking the axial and radial clearances of the rotor. The fuel system, including the injectors, was tested on a test bench.

Regeneration and Repair of Components

The scope of work included a comprehensive regeneration of the crank-piston system. We performed a crankshaft grind and used new bearings selected according to the repair dimensions. The cylinder liners were replaced with new ones, as were the pistons and rings. The connecting rods underwent inspection for twisting and longitudinal bending.

The engine head was surfaced (planed), and we replaced the valve guides and valves. The valve seats were machined to ensure proper sealing. After testing, the injectors were regenerated, and the injection pump was checked at a specialized facility. The turbocharger underwent regeneration with the replacement of wear parts.

Following the machining of all components, we proceeded with the professional assembly of the engine under workshop conditions, maintaining tightening torques in accordance with Deutz documentation.

Dyno Testing

One of the key stages was the test on our engine dynamometer (dyno). As one of the few companies in Poland, we offer the possibility of checking the engine before it is installed in the machine. The test began by starting the unit under light load conditions, at approximately 20-30% of nominal power. The engine ran in this mode for over 16 engine hours, allowing for the initial break-in of components and monitoring of parameters such as oil pressure, coolant temperature, and combustion parameters.

Next, we proceeded to full engine loading across various RPM ranges. The dyno allows us to simulate the real working conditions of the Dynapac DF125P/D asphalt paver, including dynamic load changes. We monitored operational stability, reaction to sudden load increases, and the tightness of all systems. Exhaust gas analysis confirmed the correct operation of the injection system. Consequently, the client received an engine that was tested and verified before installation in the machine.

Engine Installation in the Dynapac DF125P/D Paver

After testing was completed, the engine was transported back to the client near Krakow. Installing the engine in the asphalt paver was a multi-stage process that required close cooperation with the machine operator. Using a crane provided by the client, the unit was seated in the engine compartment. We then proceeded to the precise connection of all fuel lines, intake, exhaust, and cooling systems.

We replaced the fuel, oil, and air filters and checked the condition of the piping and flexible hoses. Every connection was verified for tightness. After filling with fresh fluids, we performed initial startup tests. The first start took place in the presence of the operator. We monitored operating parameters and checked for leaks. Following positive tests, we prepared an installation protocol.

Post-Overhaul Maintenance and Unit Applications

The Deutz TCD2013 L06 2V engine is covered by a warranty after the overhaul. We recommended the first filter change after 50 engine hours, along with an inspection of the connections between the engine and its accessories. Every subsequent service should occur every 250 engine hours, and no less frequently than every 3 months. Our mobile service performs such inspections directly at the client's location.

The Deutz TCD2013 L06 2V unit is used not only in Dynapac asphalt pavers but also in wheel loaders, crushers, screeners, and material handlers. Thanks to its design, it is valued in the industry as a durable and efficient diesel engine.

Summary

The comprehensive overhaul of the Deutz TCD2013 L06 2V engine in the Dynapac DF125P/D machine restored the asphalt paver to full technical efficiency. Thanks to detailed diagnostics, professional regeneration, and dyno testing, the client received a verified unit ready for work. WIBAKO offers a comprehensive Deutz diesel engine service and construction machinery repairs with on-site travel to the client.

If you are interested in Deutz engine service or construction machinery service, contact our team. We perform overhauls, regenerations, and dyno tests for road and construction machinery throughout Poland.