Reconstruction of the Cummins QSB4.5 Engine in the Dressta 510G Wheel Loader

Engine Overhaul of Cummins QSB4.5 in Dressta 510G Wheel Loader

The Dressta 510G wheel loader is a machine widely used in construction, material transport, and aggregate management. Its solid construction and efficiency make this model highly regarded in the industry. The power unit in this machine is the Cummins QSB4.5 diesel engine, known for its high operational culture and reliability in difficult conditions. In the case of the unit delivered to our WIBAKO service, a comprehensive overhaul of the power unit was necessary.

Diagnostics and Cause of Overhaul

The machine was reported to our service, where the operator noticed a drop in power, excessive smoking, and increased oil consumption. After performing basic compression measurements and a cylinder leak test, wear of the sleeves and pistons was confirmed. Endoscopy revealed excessive scratches in the cylinder walls, indicating the need for a complete overhaul.

Engine Disassembly

The disassembly of the Cummins QSB4.5 engine was carried out near Katowice by our mobile service. With the support of a crane provided by the client, the power unit was safely removed from the machine's compartment. The auxiliary equipment, cooling system, and air intake were disassembled, and all components were properly secured and labeled to avoid mistakes during reassembly.

Verification and Breakdown

After delivering the engine to the WIBAKO headquarters in Kojszówka, the process of complete disassembly began. During verification, significant wear of the pistons, rings, and cylinder sleeves was confirmed. The measurement of the crankshaft indicated the need for grinding. The cylinder head required regeneration, including planning, replacement of guides, and valves. The fuel system along with the injection pump was tested on a test bench. The turbocharger also required checking for clearances and replacing worn components.

Regeneration and Repair Process

As part of the overhaul, we performed regeneration of the crankshaft-piston system – the sleeves were replaced, and the pistons along with the rings were matched to the new walls. The crankshaft, after grinding and replacing the bearings, returned to full functionality. The cylinder head underwent complete regeneration after a leak test. The injection pump and injectors were set according to the parameters of the manufacturer Cummins. Additionally, the alternator, starter, and electro-mechanical components were checked.

Engine Assembly

After completing the regeneration work, the engine was professionally assembled. Gaskets, O-rings, and all consumable parts were replaced. During assembly in the machine, special attention was paid to the correct connection of the intake and cooling systems, the air piping was replaced, and all connections were checked for tightness. During the first start-up, our mechanics collaborated with the machine operator to conduct thorough functional tests. After their successful completion, an assembly protocol was drawn up.

Engine Dyno Test

One of the greatest advantages of our service is having our own engine dynamometer. The Cummins QSB4.5 engine was started on the test stand and operated under controlled load conditions for several hours. Initially, light loads (20-30% of nominal power) were applied, and then the unit was subjected to full load multiple times. The tests allowed verification of operating parameters, stability of the fuel system, oil pressure, and operating temperature. As a result, the client received assurance that the engine installed in the loader would operate reliably.

Post-Overhaul Service

Every engine rebuilt at WIBAKO is covered by a warranty and a service maintenance program. After 50 operating hours, our mobile service comes to the site to replace filters and check the condition of connections. Subsequent inspections are recommended every 250 operating hours or every 3 months. This way, the user of the Dressta 510G loader can be sure that the Cummins QSB4.5 engine will operate for a long time and reliably.

Application of Cummins QSB4.5 Engine

Cummins QSB4.5 engines are used in many construction and industrial machines. In addition to Dressta loaders, they can also be found in tracked excavators, telescopic loaders, and handling machines. The popularity of this unit stems from its durability and the availability of spare parts.

Summary

The comprehensive overhaul of the Cummins QSB4.5 engine in the Dressta 510G loader was a complete success. Thanks to precise work, dynamometer tests, and professional assembly, the client gained a reliable power unit ready for many years of operation. The construction machinery service offered by WIBAKO guarantees quality and safety of operation in the most challenging conditions.

What we do as part of the service

What the repair process looks like