Overhaul of the Cummins QSB 4.5 Engine in a Bomag BW 213 DH-4 Vibratory Soil Roller
Bomag BW 213 DH-4 is a vibratory soil roller designed for intensive compaction of soil, aggregates and structural layers during road construction and other demanding building projects. Machines of this type often operate for many hours under heavy loads, which means that the condition of the power unit has a direct impact on the productivity of the entire machine. In the case described here, a comprehensive overhaul of the Cummins QSB 4.5 engine was required.
Cummins QSB 4.5 engines are used in many construction and off-highway machines where high durability, appropriate torque and stable operation under changing loads are required. The engine installed in the Bomag BW 213 DH-4 had been operating for an extended period under conditions typical of compaction machinery. Gradually developing signs of wear indicated that continued operation without detailed inspection could lead to more serious engine damage.
The engine removal was carried out by our mobile service mechanics in the Krakow area. After safely disconnecting the engine from the other machine systems, it was removed using a crane provided by the customer. The engine was then transported to the WIBAKO facility in Kojszówka, where detailed inspection and engine rebuilding could begin.
Initial diagnostics of the Cummins QSB 4.5 engine
The decision to overhaul the Cummins QSB 4.5 engine in the Bomag BW 213 DH-4 was made after analysing symptoms indicating natural engine wear resulting from intensive operation. In engines that have operated for many hours in construction machinery, wear does not always occur suddenly. The process often develops gradually, with the first symptoms initially being relatively minor.
The first step was a basic engine diagnosis. We checked the way the engine started, its behaviour during operation and the stability of its parameters. We paid attention to engine running characteristics, response to changes in load, unusual noises and the general condition of the engine accessories. Oil pressure and symptoms indicating wear of the crankshaft and piston assembly were also checked.
Further measurements were then performed to assess the actual technical condition of the engine. Pre-removal diagnostics are important because they allow our mechanics to connect the symptoms observed during operation with the condition of individual components identified later during dismantling. When an engine has been operating for a long time, it is not enough simply to replace randomly selected components. It is necessary to determine which parts can be reused after proper inspection and which require replacement or remanufacturing.
In cases of natural wear, the condition of the cylinders, pistons, piston rings, bearings and crankshaft is particularly important. Wear of these components can gradually lead to reduced performance, increased oil consumption, deterioration of combustion parameters and lower engine efficiency. For this reason, after the initial diagnostics, a decision was made to remove the engine and thoroughly inspect all major components.
Removal of the Cummins engine from the Bomag BW 213 DH-4
Removing an engine from construction machinery requires proper preparation. In the case of the Bomag BW 213 DH-4, WIBAKO mechanics began by securing the machine and preparing the work area for safe removal of the power unit. Before the engine was lifted out, the systems and components that could interfere with the removal process were disconnected.
The fuel system lines, electrical installation, cooling system components, intake system and exhaust system were disconnected. Particular attention was paid to protecting the ends of the lines so that they would not be damaged or contaminated during further transport. The engine mounting components were also disconnected.
The engine itself was removed from the machine using a crane provided by the customer. WIBAKO mechanics were responsible for preparing the engine for lifting, disconnecting the remaining connections and supervising the removal process. This solution allows the work to be carried out efficiently without requiring the service company to provide additional heavy lifting equipment.
After removal, all components requiring identification and later reinstallation were properly secured. The Cummins QSB 4.5 was then prepared for transport to the WIBAKO workshop in Kojszówka. There, the complete disassembly, measurements, remanufacturing work and subsequent engine test on the dynamometer could be carried out.
Inspection of the Cummins QSB 4.5 engine in the workshop
After the engine was delivered to the workshop, we began dismantling it. In the case of an engine where natural wear is the reason for the overhaul, it is particularly important to carefully inspect the components responsible for maintaining proper compression, lubrication and correct operation of the crankshaft and piston assembly.
The engine was dismantled into individual components. The parts were cleaned and inspected as they were removed. This made it possible to identify signs of wear, overheating, seizure or other irregularities that may have developed during operation. Each major component was assessed for its suitability for further use.
Inspection of the crankshaft included visual examination, measurement of runout, measurement of the journals and inspection of the oil passages. Our mechanics looked for excessive wear, overheating and possible damage to the surfaces cooperating with the bearings. If the measured values exceed the permissible limits, the component requires appropriate remanufacturing.
The connecting rods were also inspected in detail. Their visual condition, signs of overheating and wear, as well as their geometry, were checked. The inspection included connecting rod twist, longitudinal bending, weight and the condition of the connecting rod bolts. Such a detailed inspection is important because the connecting rods operate under significant loads and their improper condition can affect the durability of the entire engine.
The pistons, piston rings, cylinder liners and bearings were also inspected. In an engine with a high degree of wear, these components can contribute to reduced compression, increased oil consumption and deteriorated operating parameters. Measurements and visual inspection made it possible to determine the scope of the necessary engine rebuilding work.
Overhaul of the crankshaft and piston assembly
The most important stage of the Cummins QSB 4.5 rebuilding process involved work on the crankshaft and piston assembly. This group contains numerous components exposed to continuous mechanical and thermal loads during long-term engine operation. In the engine from the Bomag BW 213 DH-4, it was therefore necessary to accurately determine the degree of wear of all cooperating components.
After dismantling, the crankshaft was thoroughly cleaned and inspected. The working surfaces were measured and runout was checked. The oil passages were also inspected because their cleanliness and unrestricted flow are essential for proper lubrication of the bearings and other engine components.
The connecting rods were subjected to detailed inspection. In addition to visual examination, their geometry and the condition of the fastening components were checked. The pistons were assessed for wear on surfaces cooperating with the cylinders and for the condition of the piston ring grooves. The cylinder liners and sealing components were also inspected.
The scope of work on the crankshaft and piston assembly was determined on the basis of actual measurement results. This approach makes it possible to avoid both leaving excessively worn components in the engine and unnecessarily replacing parts that can still be safely used after proper inspection. The aim of the overhaul is to restore the appropriate operating parameters of the entire assembly rather than simply replace individual components.
After the work was completed, all components were prepared for reassembly. Particular attention was paid to the cleanliness of the working surfaces, correct matching of cooperating components and proper assembly sequence. The Cummins QSB 4.5 engine was then prepared for further work on the cylinder head, fuel system and accessories.
Inspection and remanufacturing of the engine cylinder head
The cylinder head of the Cummins QSB 4.5 was thoroughly cleaned and inspected. The inspection included the condition of the valve seats, valve guides and valves. An important part of the inspection was also a cylinder head leak test.
The leak test involves immersing the cylinder head in heated water and applying compressed air. By observing the component, it is possible to detect areas where escaping air indicates a potential crack or leak. This inspection allows the cylinder head to be properly assessed before it is reused in the engine.
Depending on the measurement results and degree of wear, the cylinder head may require machining, replacement of valve guides and valves. In the case of the overhaul described here, the scope of work was determined based on the actual condition of the components after disassembly. This made it possible to prepare the cylinder head for further reliable operation.
The camshaft was also inspected. The inspection included visual examination and measurements of the working surfaces, including the journals and cam lobes. The condition of the camshaft affects the correct operation of the valve train, which is why its inspection is an important part of a comprehensive engine overhaul.
Fuel system and Cummins QSB 4.5 engine accessories
During an engine overhaul, we do not limit our work to the components located inside the engine block. The inspection of the accessories is equally important because even a correctly rebuilt engine will not operate properly if its fuel system or other cooperating components are not functioning correctly.
The fuel system was inspected according to its design and required diagnostic procedures. Components requiring additional testing can be checked using specialist equipment, while parts requiring remanufacturing can be serviced by a specialised partner facility. This allows the condition of the system responsible for preparing fuel for combustion to be properly assessed.
The engine accessories were also inspected. The turbocharger was checked, with particular attention paid to axial and radial play. The starter motor, alternator and other electromechanical components were also inspected, as these components can affect engine starting and correct operation.
All components intended for reinstallation were properly prepared. The aim was to restore not only the engine block itself but the entire power unit to a condition suitable for subsequent load testing.
Professional assembly of the Cummins QSB 4.5 engine
After the inspection and remanufacturing of individual components had been completed, the engine assembly process began. This is a stage requiring a high level of accuracy because the correct operation of a rebuilt engine depends not only on the quality of the parts used, but also on the quality and correctness of the assembly.
The components of the crankshaft and piston assembly were installed in the correct sequence and in accordance with the required assembly procedures. During assembly, particular attention was paid to the cleanliness of cooperating surfaces, correct positioning of components and proper execution of all connections. All work was carried out by mechanics experienced in servicing diesel engines used in construction machinery.
After the main engine assemblies had been installed, the cylinder head and remaining components were fitted. The accessories required for engine start-up and testing were then installed. Before starting the engine, particular attention was paid to the correct preparation of the lubrication, cooling, fuel and intake systems.
A comprehensive overhaul of a Cummins QSB 4.5 engine therefore involves much more than simply replacing worn components. It is a process that includes diagnostics, disassembly, cleaning, measurements, remanufacturing, replacement of required parts, assembly and subsequent testing of the engine under load.
Testing the Cummins QSB 4.5 engine on the engine dynamometer
One of the most important stages of the work carried out on the engine from the Bomag BW 213 DH-4 was the test on the WIBAKO engine dynamometer. The ability to start and test an engine outside the machine provides a significant advantage during the overhaul process. The engine can be subjected to load before it is installed back into the roller, allowing its behaviour to be assessed under controlled conditions.
The engine dynamometer makes it possible to test the unit under conditions much closer to real operation than simply starting the engine at idle. During a conventional unloaded start, basic engine functions can be confirmed, but problems that only appear under increased load may remain undetected. For this reason, load testing is an important quality-control stage after a comprehensive overhaul.
After starting, the rebuilt Cummins QSB 4.5 operates on the dynamometer for a minimum of 16 hours during the initial test phase. The first stage is performed under relatively light load, approximately 20-30% of the nominal value. This period is used to check the stability of the engine after rebuilding and to observe its basic operating parameters.
During the test, engine operation, response to load changes and parameter stability are monitored. The mechanics can observe operating temperature, response to increasing load and any symptoms that could indicate an irregularity. The tightness of the systems and the general condition of the engine during operation are also checked.
If the engine maintains the correct parameters after the initial operating period, the load is gradually increased. The unit is then subjected to repeated higher-load tests to verify its behaviour under more demanding operating conditions. This makes it possible to check whether the crankshaft and piston assembly, cylinder head, fuel system, cooling system and accessories are operating correctly.
The dynamometer test also provides an opportunity to detect potential problems at an early stage. If unusual symptoms appear during testing, the mechanics can stop the test and inspect the relevant area of the engine again. This is significantly safer than waiting for a problem to occur after the engine has been installed in the machine and put into operation on a construction site.
In the case of rebuilt engines, the ability to perform testing under controlled conditions is particularly valuable. The engine can be gradually loaded while its response is monitored by the mechanics. This makes it possible to confirm the engine's ability to operate under load before it leaves the workshop.
The engine dynamometer is therefore not simply a device for measuring power. During the overhaul process, it is an important diagnostic and quality-control tool. It allows the rebuilt engine to be tested before it is returned to the machine. For the customer, this means an additional level of safety and a reduced risk that a potential problem will only become apparent while the roller is working.
The successful completion of the dynamometer test allowed the Cummins QSB 4.5 to be prepared for reinstallation in the Bomag BW 213 DH-4. Only after successfully passing the load tests was the engine prepared for transport and installation in the machine.
Installation of the engine in the Bomag BW 213 DH-4
After completing the overhaul and successfully passing the dynamometer test, the Cummins QSB 4.5 was prepared for reinstallation in the Bomag BW 213 DH-4. Engine installation is just as important as the overhaul itself. Even a correctly rebuilt engine must be installed properly to ensure safe and reliable operation in the machine.
The installation work was carried out by WIBAKO service technicians at the location where the engine had previously been removed, in the Krakow area. The crane provided by the customer was used again. The engine was properly prepared for lifting and carefully lowered into the engine compartment. During positioning, attention was paid to the correct alignment with the mounting points and other machine assemblies.
After positioning the engine, the mounts and components connecting the engine to the machine were installed. The individual systems were then connected. Particular attention was paid to the cooling system lines, fuel lines, intake system and exhaust system. The electrical connections and components responsible for proper engine control were also checked.
The condition of the piping was also inspected during installation. Air pipes and intake system components must be correctly installed and fully sealed. An intake system leak can affect engine operation, so all connections were carefully checked. Similar inspections were carried out on the cooling system and other lines connected to the engine.
After mechanically securing the engine and connecting the systems, the machine was prepared for the first start-up. The required filters were installed, fluid levels were checked and all connections were inspected. Before starting the engine, the mechanics checked for loose lines, incorrectly routed hoses or other elements that could affect the safety of the first test.
The first engine start after installation was carried out under the supervision of WIBAKO mechanics. The starting process, engine running characteristics and response to changes in load were checked. At the same time, the cooling, fuel, oil and intake systems were monitored for leaks. Particular attention was paid to connection points, which must remain fully sealed after reinstallation.
After the initial inspection, machine operating tests were performed. The roller operator participated in the tests because their experience is valuable when assessing machine behaviour under real operating conditions. The engine response to operator commands and its behaviour while the machine systems were operating were checked.
During the tests, the mechanics also monitored the machine for leaks, unusual noises, excessive vibration or other signs of irregular operation. Checking the connections after the first operating tests helps confirm that all components have been correctly installed and remain sealed during operation.
After the tests were successfully completed, the correct operation of the Cummins QSB 4.5 engine in the Bomag BW 213 DH-4 was confirmed. The installation process ended with a final machine inspection and preparation of the roller for further operation.
Engine servicing after the overhaul
An engine overhaul does not end when the engine is started in the machine. The first period of operation after rebuilding is very important for the future durability of the unit. WIBAKO therefore recommends carrying out the first inspection after 50 operating hours from the engine start-up.
The 50-hour inspection is performed by our mechanics at the machine's operating location. It is not limited to replacing filters. During the service visit, the general condition of the engine and its accessories, correct operation and the condition of connections made during installation are checked. Areas where leaks could appear during normal operation are also inspected.
After the first inspection, subsequent service inspections are recommended every 250 operating hours, but no less frequently than every 3 months. Regular inspections make it possible to detect irregularities at an early stage and reduce the risk of a serious failure. This is particularly important for machines that operate intensively, as the engine may work under high loads for many hours.
Machines using Cummins QSB 4.5 engines
Cummins QSB 4.5 engines are used in various machines operating in construction, road building and other off-highway applications. Engines from this family can be found in rollers, loaders, excavators, screens and other machines requiring a durable diesel power unit.
WIBAKO carries out overhauls and repairs of Cummins engines installed in construction machinery. The scope of work may include engine diagnostics, complete engine rebuilding, cylinder head remanufacturing, inspection of the crankshaft and piston assembly, accessory inspection and testing on the engine dynamometer.
Our service can handle Cummins engines installed in excavators, wheel loaders, rollers, screens, crushers and other working machines. Thanks to our mobile service, our mechanics can perform diagnostics as well as engine removal and installation directly at the customer's location. The removed engine can then be transported to the WIBAKO facility in Kojszówka, where further workshop work is carried out.
Summary of the Bomag BW 213 DH-4 engine overhaul
The overhaul of the Cummins QSB 4.5 engine from the Bomag BW 213 DH-4 included the complete process from diagnostics and removal, through detailed component inspection, remanufacturing and engine assembly, to dynamometer testing and reinstallation in the machine.
The reason for the overhaul was natural engine wear resulting from intensive operation. By dismantling the engine into individual components, it was possible to accurately determine the condition of the crankshaft and piston assembly, cylinder head, fuel system and accessories. This allowed the scope of work to be based on actual measurement results rather than only on the symptoms observed before the overhaul.
An important part of the entire process was the engine dynamometer test. The ability to operate the engine under controlled load for a minimum of 16 hours, followed by gradually increasing the load, allowed the rebuilt Cummins QSB 4.5 to be checked before it was installed back into the roller.
After successfully completing the tests, the engine was installed in the Bomag BW 213 DH-4. WIBAKO mechanics connected the systems, checked their tightness and carried out machine operating tests together with the operator. After 50 operating hours, another service inspection by our mechanics is recommended.
When an engine in construction machinery fails or becomes excessively worn, replacing the entire machine is not always necessary. Professional diagnostics, a properly performed overhaul and testing the engine before installation can restore machine performance and prepare it for further operation. WIBAKO performs this type of work both at our Kojszówka workshop and as part of our mobile service throughout Poland.
Cummins engine service includes diagnostics, repairs, comprehensive overhauls, component remanufacturing and engine dynamometer testing. If an engine installed in construction machinery shows reduced power, increased oil consumption, starting problems, uneven operation or other warning signs, it is worth carrying out diagnostics before minor wear develops into a major failure.
WIBAKO construction machinery service can include work performed directly at the machine, as well as engine removal and transport to our workshop. Diesel engine service is carried out using the experience of our mechanics and workshop facilities that allow engines to be comprehensively rebuilt and tested before reinstallation.
Do you need a Cummins QSB 4.5 engine overhaul or Bomag roller service?
WIBAKO performs comprehensive overhauls and repairs of Cummins engines used in construction machinery. We provide diagnostics, engine removal and installation, engine rebuilding and testing on an engine dynamometer. Contact us to ask about repairing your machine.
