Repair of the Cummins QSB6.7 Engine in the Grove RT540E Crane

Engine overhaul of Cummins QSB6.7 (Tier 3) in Grove RT540E rough terrain crane

In our WIBAKO service, we performed a comprehensive overhaul of the Cummins QSB6.7 engine installed in a Grove RT540E rough terrain crane. This machine, known for its excellent mobility and high load capacity, is often used on construction sites, in the petrochemical industry, and for the assembly of steel structures. The RT540E model, with a lifting capacity of 40 tons, is powered by a reliable Cummins QSB6.7 engine with an output of about 164 HP (Tier 3), which ensures smooth and economical operation.

The reason for the repair was a drop in oil pressure and the presence of metallic shavings in the filter, indicating wear of the crankshaft bearings. After conducting preliminary diagnostics, excessive wear of the crank-piston system was confirmed. Thanks to the experience of our mechanics and the full workshop facilities in Kojszówka, the engine was thoroughly verified, regenerated, and tested on a engine test bench before being reinstalled in the crane.

Engine disassembly

The disassembly of the power unit was carried out near Katowice by our WIBAKO mobile service. According to the procedure, the engine was disconnected from the power, cooling, and auxiliary hydraulic systems. The client's crane was used to safely lift the power unit from the machine's frame. All hoses, mounts, and equipment components were properly labeled and secured for reassembly.

Verification of components

After delivering the unit to our headquarters, we began a full verification. Preliminary inspections confirmed signs of overheating on the crankshaft journals. The pistons, connecting rods, and cylinder head were disassembled, and measurements of clearances, crankshaft runout, and cylinder head leak tests were performed. Shavings in the oil and scratches in the cylinder liners indicated the need for a complete overhaul of the crank-piston system.

Regeneration and repair

The repair process included grinding the crankshaft, replacing main and connecting rod bearings, regenerating pistons, liners, and rings. The cylinder head was machined, and guides and valves were replaced, along with a leak test in a water bath. The injection system was tested on a test bench, and the injection pump was sent for regeneration to a specialized facility. The turbocharger, after cleaning and measuring clearances, showed no abnormalities, so it was reinstalled after replacing the seals.

Engine installation

After completing all regeneration work and assembling the engine, the unit was reinstalled in the Grove RT540E crane. The installation included replacing air piping components, fuel and hydraulic hoses, and checking the tightness of the systems. All work was carried out in accordance with the manufacturer's service standards. After the engine was installed, a test run was performed in the presence of the operator, during which operating parameters, oil pressure, temperature, and absence of leaks were checked. After successful tests, an acceptance protocol for the installation was signed.

Testing on the engine test bench

Every engine after overhaul at WIBAKO undergoes detailed tests on the engine test bench. In the case of the Cummins QSB6.7, a 16-hour test cycle was conducted under increasing load conditions up to 100% of nominal power. The test bench allowed for monitoring parameters such as torque, effective power, boost pressure, and exhaust temperature. The test results confirmed the full efficiency of the lubrication and cooling systems, and the engine achieved parameters in line with the manufacturer's specifications. Thanks to these measurements, the client received a guarantee that the unit is fully ready for operation after installation.

Engine maintenance after overhaul

After the overhaul, we recommend performing the first inspection after 50 operating hours. During this, our mobile service checks the condition of filters, tightness of connections, proper operation of systems, and any leaks. Subsequent inspections are recommended every 250 operating hours or every 3 months. All our engines after regeneration are covered by WIBAKO service warranty.

Application of the Cummins QSB6.7 engine

The Cummins QSB6.7 engine is an extremely popular unit installed not only in Grove cranes but also in machines such as: Manitou telescopic loaders, Doosan DX190W excavators, Atlas 350 MH material handlers, and Bell B30D dumpers. Its durability and ease of maintenance make it one of the most frequently serviced engines in our company.

Summary

The completed overhaul of the Cummins QSB6.7 engine in the Grove RT540E crane restored the full efficiency and reliability of the machine. Thanks to detailed diagnostics, professional regeneration, and tests on the engine test bench, the client received assurance that the crane can safely return to work in the most challenging conditions. WIBAKO service guarantees the highest quality of service, comprehensive documentation, and technical support even after the repair is completed.

We invite you to contact us regarding Cummins engine overhauls and other brands – Deutz, Volvo, Perkins, Liebherr, Caterpillar. Our mobile service operates throughout Poland and in neighboring countries.