Renovation of the Mercedes OM906 Engine in the Grove GMK 2035 Crane

Engine overhaul of Mercedes OM906 in Grove GMK 2035 mobile crane

In our service WIBAKO, we carried out a comprehensive overhaul of the Mercedes OM906 engine installed in the Grove GMK 2035 mobile crane. It is a compact yet highly efficient mobile crane, known for its reliability in construction and assembly work. The order concerned a machine used in the Małopolskie Voivodeship, near Krakow. After identifying problems with starting and a noticeable drop in power, the client turned to us for help.

Preliminary diagnostics and cause of failure

After conducting preliminary tests on the machine, we determined that the cause of the failure was a drop in compression due to wear of the cylinders and pistons. The Mercedes OM906 engine exhibited symptoms of excessive smoking and increased oil consumption. As part of the diagnostics, a compression pressure measurement, cylinder leak test, and endoscopic inspection of the combustion chamber were performed. The results clearly indicated the need for a complete overhaul of the power unit.

Disassembly of the engine from the Grove GMK 2035 crane

The disassembly was carried out using a crane provided by the client. Our technicians disconnected the cooling system, hydraulic hoses, air intake components, and exhaust system. The engine was safely separated from the frame and transported to our headquarters in Kojszówka, where a detailed verification began. All components subject to disassembly were marked and secured, ensuring full control over the assembly process after the overhaul.

Verification and assessment of the technical condition of the engine

After disassembling the Mercedes OM906 engine, we proceeded to assess individual components. Excessive wear of the cylinder liners and piston rings was found, as well as local signs of overheating. The verification of the crankshaft included measuring runout, checking journals, and examining oil passages. The cylinder head was checked for tightness and micro-cracks in a water bath using compressed air. The injection pump and injectors were sent to the testing station, where their performance characteristics and tightness were assessed.

Regeneration and repair of the Mercedes OM906 engine

During the regeneration process, the complete crank-piston system was replaced – new liners, pistons, rings, bearings, and connecting rod bolts were used. The cylinder head was planed, valve guides, valves, and seals were replaced. The fuel system returned to full efficiency after thorough calibration. The turbocharger was regenerated – bearings and seals were replaced, restoring its nominal operating parameters. Everything was assembled according to the manufacturer's procedures using original tightening torques.

Engine testing on the dynamometer

After the overhaul, the Mercedes OM906 engine was started on our WIBAKO engine dynamometer. This allowed us to accurately check its performance under controlled load conditions. The test lasted over 16 hours, including 12 hours of operation under light load (20–30% of nominal power) and 4 hours at full load. Cooling liquid temperatures, oil pressure, and exhaust emissions were monitored. The test results confirmed correct power, stable RPM, and no disturbing vibrations. This is a stage that distinguishes our service – few companies in Poland have such technical facilities.

Installation of the engine in the Grove GMK 2035 crane

After the positive test, the engine was reinstalled in the Grove GMK 2035 crane. The installation included fitting the unit into the frame, connecting the hydraulic, intake, cooling, and exhaust systems. Fuel lines, cooling hoses, and air piping components were replaced to ensure full system tightness. Our team conducted thorough tests with the machine operator, checking the proper operation of the engine under load. After the installation was completed, a handover protocol was signed.

Engine maintenance after overhaul

The Mercedes OM906 engine was handed over with a full warranty. We recommended the first filter change and a maintenance check after 50 operating hours, which is performed by our WIBAKO mobile service. Subsequent inspections are recommended every 250 operating hours or every 3 months. This ensures the full efficiency of the power unit and extends its lifespan.

Mercedes OM906 engine – application

The Mercedes OM906 unit is a reliable six-cylinder diesel engine commonly found in Grove mobile cranes, Unimogs, as well as in municipal and construction vehicles. It is characterized by a high level of operational culture, economical fuel consumption, and high durability, making it a popular choice for off-road machines and lifting equipment.

Summary

The overhaul of the Mercedes OM906 engine in the Grove GMK 2035 crane restored the machine's full operational efficiency. Thanks to comprehensive service, dynamometer testing, and quality assurance from WIBAKO, the client can be confident in the reliability of their machine for thousands of operating hours to come. Our team pays attention to every detail – from diagnostics to final assembly – ensuring the highest standard of diesel engine service.