Cummins B3.9, B4.5, B4.5 RGT, B5.9 Engines Service Repair Manual

Service Manual B3.9, B4.5, B4.5 RGT, and B5.9 Series Engines Volume 1

Foreword This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be contacted directly for any information not covered in this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction. The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures. The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair) are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in Service Literature (Section L). Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.

Table of Contents Section Introduction .............................................................................................................................................. i Engine Identification ................................................................................................................................ E Familiarization .......................................................................................................................................... F Troubleshooting Symptoms ..................................................................................................................... TS Complete Engine - Group 00 .................................................................................................................... 0 Engine Disassembly - Group 00 ............................................................................................................... DS Engine Assembly - Group 00 ................................................................................................................... AS Cylinder Block - Group 01 ........................................................................................................................ 1 Cylinder Head - Group 02 ......................................................................................................................... 2 Rocker Levers - Group 03 ........................................................................................................................ 3 Cam Followers/Tappets - Group 04 ......................................................................................................... 4 Fuel System - Group 05 ........................................................................................................................... 5

B Series Section i - Introduction Page i-a Section i - Introduction Section Contents Page About the Manual ...............................................................................................................................................i-1 General Information...........................................................................................................................................i-1 Acronyms and Abbreviations ...........................................................................................................................i-12 General Information..........................................................................................................................................i-12 General Cleaning Instructions ...........................................................................................................................i-8 Abrasive Pads and Abrasive Paper.....................................................................................................................i-8 Definition of Clean..............................................................................................................................................i-8 Gasket Surfaces.................................................................................................................................................i-9 Plastic Bead Cleaning......................................................................................................................................i-10 Solvent and Acid Cleaning.................................................................................................................................i-9 Steam Cleaning................................................................................................................................................i-10 General Repair Instructions ...............................................................................................................................i-7 General Information...........................................................................................................................................i-7 Welding on a Vehicle with an Electronic Controlled Fuel System........................................................................i-7 General Safety Instructions ...............................................................................................................................i-5 Important Safety Notice......................................................................................................................................i-5 How to Use the Manual ......................................................................................................................................i-2 General Information...........................................................................................................................................i-2 Illustrations .........................................................................................................................................................i-4 General Information...........................................................................................................................................i-4 Symbols ..............................................................................................................................................................i-3 General Information...........................................................................................................................................i-3

B Series About the Manual Section i - Introduction Page i-1 About the Manual General Information This Service Manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures. Additionally the manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and assembly of components. The manual is divided into sections. Each section is equivalent to a group used in Cummins' filmcard system. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting the problem and describe specific rebuild procedures. This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual, if there are no electronic fault codes. This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the back of the manual to locate specific topics when not using the troubleshooting trees.

How to Use the Manual B Series Page i-2 Section i - Introduction How to Use the Manual General Information The troubleshooting and repair section of this manual is organized to provide an easy system installation and flow from problem identification to problem correction. System Installation The installation guidelines section has been designed to provide instructions for installing the system. A technician should read the instruction, learn the intent of the step, and install the component in a fashion that will comply to the vehicle's configuration. Each deviation from the specific instructions provided in this procedure should be noted. Refer to the OEM service manual for OEM specifications. A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms, Section (TS). The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair. Complete the following steps to locate and correct the problem. (Step 1) Locate the symptom on the Section Contents pages of Section TS. Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title. (Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a probable cause of the problem, starting at the top with the simplest and easiest to repair, and continuing downward to the most difficult. The right column of boxes provides a brief description of the corrective action with a reference number to the correct procedure used to make the repair. (Step 3) Locate the probable cause in the left column then turn to the procedure referenced in the right column. (Step 4) The Troubleshooting Symptom Charts are based on the following assumptions: • The engine has been installed according to the manufacturer's specifications. • The easiest repairs are done first. • "Generic" solutions to cover problems with the most common applications and Original Equipment Manufacturer (OEM). The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals and the Cummins' filmcard system. Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical sequence. Reger to the Table of Contents at the front of the book to determine the section that details the desired information. Each section contains the following in sequence: Table of Contents Required Service Tool Listings General Information containing the basic service, maintenance, design and revision information necessary to assist in the rebuild of an engine or a component Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included. These procedures depend on the length of time an engine has been in service and the conditions of the parts. All the procedures are identified with a name and a number. Each digit in the procedure number has a specific meaning. The first three digits of the number refer to the specific section that the procedure can be found within the manual. In this example, “001” represents Section 01 — Cylinder Block. This number will range from 000 to 022. The second three digits of the number are unique and refer to a specific subject. In this example, “028” represents Cylinder Liner. This number will range from 001 to 999. Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications and torque values for each engine system are given in that section. NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject to a penalty of various monetary charges. Dispose of these substances in accordance with standard set by the EPA.

B Series Symbols Section i - Introduction Page i-3 Symbols General Information The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below:

Illustrations B Series Page i-4 Section i - Introduction Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.

B Series General Safety Instructions Section i - Introduction Page i-5 General Safety Instructions Important Safety Notice WARNING Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death. Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. • Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. • Always wear protective glasses and protective shoes when working. • Rotating parts can cause cuts, mutilation or strangulation. • Do not wear loose-fitting or torn clothing. Remove all jewelry when working. • Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's compartment or on the controls. • Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. • If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler cap to relieve the pressure from the cooling system. • Always use blocks or proper stands to support the product before performing any service work. Do not work on anything that is supported ONLY by lifting jacks or a hoist. • Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant. • To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. • Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. • Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. • To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas flow, and hot fluids in lines, tubes, and compartments. • Always use tools that are in good condition. Make sure you understand how to use the tools before performing any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. • Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. • Liquified petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas. • Natural gas is lighter than air and can accumulate under hood and awnings. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect natural gas and liquified petroleum gas lines in a well ventilated area. • Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations. • The catalyst reagent contains urea. Do not get the substance in your eyes. In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent is ingested, contact a physician immediately.

Cummins B3.9, B4.5, B4.5 RGT, B5.9 Engines Service Repair Manual

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