Repair of the Cummins QSB4.5 Engine in the Badger CD4415 Crane

Engine Overhaul of Cummins QSB4.5 (Tier 3) in Badger CD4415 Rough Terrain Crane

Introduction

The Badger CD4415 rough terrain crane is a compact yet extremely robust lifting machine used primarily in the construction and industrial sectors. The machine is designed for operation in challenging environments, providing stability and precision in lifting. In this case, a crane with a Cummins QSB4.5 engine in the Tier 3 version was brought to our WIBAKO service for a comprehensive rebuild after a failure of the crank-piston system. The engine manufacturer, Cummins, is renowned for durable and efficient power units used in off-highway machines, and our team has the complete facilities for their professional repair and testing on the engine dynamometer.

The reason for the overhaul request was a failure due to worn crankshaft bearings, which manifested as a drop in oil pressure and a characteristic metallic noise in the lower parts of the engine. After analyzing the oil, the presence of metal shavings was confirmed, indicating the need for disassembly and verification of components.

Engine Disassembly

The disassembly of the power unit was carried out by our WIBAKO mobile service in the vicinity of Katowice. On-site, in cooperation with the crane operator provided by the client, the engine was disconnected from the frame and auxiliary systems. First, the equipment, intake system, cooling hoses, and electrical connections were removed. All components were secured against contamination and labeled for later reassembly. After preparing the unit, the engine was transported to our headquarters in Kojszówka for complete workshop diagnostics.

Component Verification

During the verification stage, significant wear of the main and connecting rod bearings was confirmed, as well as visible scratches on the crankshaft journals. As part of the procedure, a verification of the crankshaft was performed – measuring the journals, checking for runout, and cleaning the oil passages. The connecting rods were also examined for twisting and bending. The cylinder head underwent a leak test in a water bath, and no cracks were found. The injection pump and injectors were sent to an external facility for verification on a test bench. The turbocharger had significant radial play, requiring a complete rebuild.

Rebuilding and Repair

As part of the repair of the Cummins QSB4.5 engine, a comprehensive overhaul of the crank-piston system was performed. The crankshaft was ground, the main and connecting rod bearings were replaced, and the pistons and rings were substituted with new OEM parts. The cylinder liners were re-ground and re-fitted. After machining, the cylinder head received new valve guides and valves. The fuel system rebuild included testing and calibrating the pump and injectors, while the turbocharger underwent complete cleaning, bearing, and seal replacement. The entire assembly was completed according to the manufacturer's technical documentation, adhering to the tightening torques recommended by Cummins.

Testing on the Engine Dynamometer

After assembly, the power unit was directed to our engine dynamometer. This is a crucial verification stage that distinguishes WIBAKO from the competition. The Cummins QSB4.5 engine underwent a full test cycle lasting 16 hours with gradually increasing load. Initially, testing was conducted at 20-30% of nominal power, monitoring oil pressure, temperature parameters, and operational stability. The engine was then loaded to 100% of nominal power. Thanks to a modern measurement system, the dynamometer allows for recording torque, power, liquid and exhaust gas temperatures, as well as analyzing the engine's response dynamics. After the test, a leak check was performed, and oil and filters were replaced. The unit achieved results fully compliant with the factory parameters of Cummins Tier 3.

The dynamometer at WIBAKO not only guarantees the quality of the repair but also serves as a safety element – through testing, we can ensure that the engine does not require additional adjustments after installation in the machine. The client receives test documentation with load progress, power graphs, and confirmation of parameter compliance.

Engine Installation

After successful tests, the power unit was transported to the client and installed in the Badger CD4415 crane. The installation was carried out according to Cummins service standards, maintaining complete cleanliness of the fuel and cooling systems. New air intake piping and oil and cooling hoses were installed. All connections were checked for leaks. After starting the machine, joint tests were conducted with the crane operator, monitoring the smooth operation, absence of vibrations, and proper response to load. Upon completion of the trials, an installation protocol was signed, and recommendations for post-repair operation were provided.

Engine Maintenance After Repair

The engine after repair is covered by a warranty and full service support. We recommend the first oil and filter change after 50 operating hours. Our WIBAKO mobile service conducts a leak check and overall condition assessment of connections and potential leaks. Subsequent inspections should be performed every 250 operating hours or every 3 months, depending on the intensity of machine use.

Machines Equipped with Cummins QSB4.5 Engine

The Cummins QSB4.5 (Tier 3) unit is found not only in Badger cranes but also in wheel loaders, excavators, and agricultural machines from brands such as Case, JCB, Komatsu, and New Holland. This engine is known for being economical and durable with a high level of operational culture, which, with proper servicing, can run for thousands of hours without serious failures.

Summary

The comprehensive overhaul of the Cummins QSB4.5 engine in the Badger CD4415 rough terrain crane performed by WIBAKO restored the machine's full functionality. Thanks to testing on the dynamometer and precise assembly, the client received a guarantee of reliable operation and safety during use. Our experience in diesel engine service and technical facilities allow us to effectively carry out repairs even for the most demanding power units used in off-highway machines.

We invite you to contact our Cummins engine service and construction machinery diagnostics department – we perform both stationary and mobile repairs throughout Poland.