Cummins B3.9 B4.5 B5.9 Engine Troubleshooting & Repair Manual

Covers: Cummins B Series Diesel Engines – B3.9, B4.5, B4.5 RGT and B5.9

• Pre-ISB engines only (mechanical fuel system)

Pages: 1,464
Format: PDF
File size: 77mb
Works with: Windows/Mac/Tablet/Smartphone
Notes: Searchable, printable, instant download

This 2-volume downloadable PDF manual set contains instructions for mechanical troubleshooting and repair of the Cummins B Series engine according to Cummins OEM standards. Complete step-by-step disassembly, cleaning, inspection and assembly instructions are also included, with all of the necessary torque specs and technical data to get the job done correctly. View the PDF on your computer or tablet, or print pages for the shop as needed.

11/2013 revision.

Topics:

• Engine and System Identification
• Familiarization
• Troubleshooting Symptoms (Mechanical)
• Complete Engine
• Engine Disassembly
• Engine Assembly
• Cylinder Block
• Cylinder Head
• Rocker Levers
• Cam Followers/Tappets
• Fuel System
• Injectors and Fuel Lines
• Lubricating Oil System
• Cooling System
• Drive Units
• Air Intake System
• Exhaust System
• Compressed Air System
• Electrical Equipment
• Engine Testing
• Mounting Adaptations
• Miscellaneous
• Specifications
• Technical Data
• Torque Data

Example Troubleshooting Symptoms

• Air Compressor Problems
• Alternator Not Charging or Insufficient Charging
• Alternator Overcharging
• Coolant Contamination
• Coolant in the Lubricating Oil
• Coolant Loss
• Coolant Temperature Abnormal
• Crankcase Gases (Blowby) Excessive
• Engine Acceleration or Response Poor
• Engine Cranks Slowly — (Electric Starter)
• Engine Difficult to Start or Will Not Start (Exhaust Smoke)
• Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
• Engine Noise Excessive
• Engine Power Output Low
• Engine Runs Rough at Idle
• Engine Runs Rough or Misfires
• Engine Speed Surges at Low or High Idle
• Engine Starts But Will Not Keep Running
• Engine Vibration Excessive
• Engine Will Not Crank — (Electric Starter)
• Engine Will Not Reach High Idle
• Engine Will Not Shut Off
• Excessive Noise
• Fuel Consumption Excessive
• Fuel in the Lubricating Oil
• Fuel Knock
• Fuel or Lubricating Oil Leaking From Exhaust Manifold
• Intake Manifold Air Heater System Malfunctioning
• Lubricating Oil Pressure Low
• Black or White Smoke

Natural Gas, Lucas CAV Rotary, Bosch P Pumps, Bosch and Delphi Rotary, Bosch A Pump, Nippondenso, Stanadyne, ZEXEL – VE Rotary, ZEXEL – Inline, All Mechanical Fuel Systems, CM558

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