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

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

• Pre-ISB engines only (mechanical fuel system)

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

This 2-volume PDF manual set contains instructions for mechanical troubleshooting and repair of the Cummins B Series engine according to OEM standards. Complete step-by-step disassembly, cleaning, inspection, assembly, and rebuild procedures are also included. View the PDF manuals on your computer/tablet or print off pages 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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