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 computers
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.


  • 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


SKU: MPM00601 Category: Tags: ,