Cummins B3.9, B5.9,B Series Engine Workshop 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

Cummins B3.9, B5.9,B Series Engine Workshop Service Repair Manual

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