Engine Identification

B3.9, B4.5, B4.5 RGT, and B5.
9
Series Engines
Bulletin Number 3666087
Copyright ©2006
ENgine Diagrams 100-002)
TO
Engine Views C
The following illustrations show the locations of the major external engine
components, filters, and other service and maintenance points. Some external
components will be at different locations for different engine models.
NOTE: The illustrations are only a reference to show a typical engine.
6BTA5.9-DM Front View
1. Air cleaner inlet

2. Heat shield
3. Belt and damper guard
4. Heat shield connector clamp
6BTA5.9-DM Rear View
1. Heat exchanger
2. Engine coolant out of heat exchanger
3. Flywheel
4. Expansion tank mounting bracket
6BTA5.9-DM Fuel Pump Side
1. Exhaust outlet
2. Heat shield connector clamps
3. Air cleaner
4. Blowby outlet tube
5. Sea water inlet
6. Fuel pump
7. Heat shield
6BTA5.9-DM Exhaust Side
1. Exhaust outlet connection

2. Heat shield
3. Heat exchanger coolant inlet
4. Lubricating oil filter
5. Turbocharger oil drain connection
6. Heat exchanger
7. Heat exchanger sea water outlet
Automotive - Fuel Pump Side View
1. Intake air preheater (optional)

2. Fuel filter/water separator
3. Water heater supply (3/4-inch NPTF)
4. Fuel inlet connection (1/4-inch NPTF)
5. Magnetic pickup location (3/4-16 UNF)
6. Fuel lift pump
7. Dipstick
8. Oil pressure (1/8-inch NPTF)
9. Engine dataplate
10. Air compressor
11. Air compressor intake
12. In-line fuel injection pump
13. High pressure fuel lines
14. Engine air inlet.
Automotive - Rear View

1. Turbocharger exhaust outlet
2. Clutch mounting plate
3. Flywheel housing
4. Flywheel flexplate
5. Fuel return connection
6. Rear engine lifting bracket.
Automotive - Turbocharger Side View
1. Turbocharger wastegate actuator
2. Oil fill
3. Front engine lifting bracket
4. Water outlet
6. Lubricating oil cooler
7. Water inlet
8. Water heater return (1/2-inch NPTF)
9. Oil drain
10. Provision for oil immersion heater
11. Starter motor solenoid
12. Fuel injection nozzles.
Automotive - Front View
1. Turbocharger air outlet

2. Engine air inlet
3. Fuel pump drive cover
4. Air compressor air outlet
5. Front gear cover
6. Fan drive belt
7. Vibration damper
8. Water inlet
9. Water pump
10. Alternator
11. Fan pulley
12. Automatic belt tensioner
13. Turbocharger air inlet.
B3.9 Industrial - Air Intake Side View

1. Engine air inlet
3. Fuel inlet connection
5. Fuel lift pump
6. Crankcase breather tube
7. Lubricating oil dipstick
8. Fuel drain connection
9. Front engine mounting bracket
10. Engine dataplate
12. Fuel injection pump
13. Intake air preheater (optional).
B3.9 Industrial - Rear View
1. Rear engine lifting bracket
3. Flexplate mounting holes
4. Flywheel housing
5. Flywheel/flexplate.
B3.9 Industrial - Exhaust Side View

1. Fuel injection nozzles
3. Lubricating oil fill
5. Water outlet
7. Water inlet
9. Lubricating oil drain
10. Provision for lubricating oil immersion heater
11. Starter motor and solenoid
12. Provision for coolant heater.
B3.9 Industrial - Front View

3. Engine air inlet
5. Front gear cover
6. Accessory drive cover (optional)
7. Fan drive belt
8. Front Pulley
9. Water pump
11. Water inlet
12. Alternator
13. Fan pulley
B3.9 Industrial - Top View
1. Water outlet
2. Turbocharger
3. Exhaust manifold
B4.5 Industrial - Air Intake Side View

1. Engine air inlet
5. Fuel lift pump

4. Flywheel housing

5. Water outlet
7. Water inlet

3. Engine air inlet
5. Front gear cover
7. Fan drive belt
8. Front Pulley
9. Water pump
11. Water inlet
12. Alternator
13. Fan pulley
1. Water outlet
2. Turbocharger
3. Exhaust manifold
B4.5 RGT - Air Intake Side View
1. Engine air inlet

3. Inlet fuel filter
5. Fuel lift pump
8. Fuel return line and fuel drain connection
9. Rear engine mounting bracket
13. Intake air preheater (optional)
14. Provision for lubricating oil immersion heater.
B4.5 RGT - Rear View

2. Exhaust outlet
4. Flywheel housing
5. Flywheel/flexplate
6. Rear gear train housing
7. Fuel return and fuel drain connection
8. Fuel Inlet connection
9. Crancase breather tube
10. Inline fuel filter
B4.5 RGT - Exhaust Side View

3. Water outlet
5. Water inlet
B4.5 RGT - Front View
1. Engine air inlet

3. Fan drive belt
4. Front pulley
5. Water pump
7. Alternator
8. Fan pulley
9. Lubricating oil fill.
B4.5 RGT - Top View
1. Water outlet
2. Engine air inlet
3. Exhaust manifold
4. Magnetic pickup location (3/4-16 UNF).
1. Engine air inlet

5. Fuel lift pump

4. Flywheel housing

5. Water outlet
7. Water inlet
9. Provision for coolant heater
12. Starter motor and solenoid.
3. Engine air inlet
5. Front gear cover
7. Fan drive belt
8. Vibration damper
9. Water pump
11. Water inlet
12. Alternator
13. Fan pulley
1. Water outlet
2. Turbocharger
3. Exhaust manifold
C Power Heat Exchanger Cooled - Exhaust Side View (B Series)

1. Local Control Panel
2. Coolant Expansion Tank
3. Air Cleaner
4. Heat Exchanger
5. Exhaust Connection
6. Coolant Filter
7. Duplex Lubricating Oil Filter
8. Starter
9. Lubricating Oil Sump Hand Pump
10. Sea Water Outlet Connection
11. Alternator.
C Power Heat Exchanger Cooled - Air Intake View (B Series)
1. Seawater Pump
2. Emergency Shutdown Sensors
3. Fuel Filters
4. Seawater Inlet Connection.
C Power Keel Cooler Cooled - Exhaust Side View (B Series)

2. Air Cleaner
3. Coolant Expansion Tank
5. Coolant Thermostat Location
6. Coolant Filter
8. Starter
10. Alternator.
C Power Keel Cooler Cooled - Air Intake View (B Series)
1. Fuel Filters
2. Emergency Shutdown Sensors.
C Safe Radiator Cooled - Exhaust Side View (B Series)

2. Air Cleaner
4. Coolant Thermostat Location
5. Radiator Fan Drive Shroud
6. Coolant Filter
8. Spring Starter
10. Alternator.
C Safe Radiator Cooled - Air Intake Side View (B Series)
1. Radiator and Expansion Tank

2. Emergency Shutdown Sensors
3. Starter
4. Duplex Fuel Filters.
Last Modified: 31-Mar-2006
Copyright ©2006
Cummins Inc.
All rights reserved
Engine Identification
(100-001)
TO
Engine Dataplate C
B3.9, B5.9, and B4.5 Engines
The engine dataplate shows specific

facts about your engine. The engine serial
number and Control Parts List provide
information for ordering parts and for
service. The engine dataplate must not
be changed unless approved by Cummins
Inc.
SMALL | MEDIUM | LARGE
B4.5 RGT Engines
The engine dataplate shows specific facts

about your engine. The engine serial
number and Control Parts List provide
information for ordering parts and for
service. The engine dataplate must not
be changed unless approved by Cummins
Inc.

Have the following engine data available when communicating with a Cummins
Authorized Repair Location. The information on the dataplate is mandatory when
sourcing service parts.
1. Control parts list (CPL)

2. Model
3. Engine serial number
4. Emissions certification
5. Horsepower and rpm rating.
NOTE: If the engine dataplate (1) is not

readable, the engine serial number (2)
can be identified on the engine block
above the oil cooler.
TO
Cummins® Engine Nomenclature C
B5.9
The model name provides the

following engine data:
B = Engine series
5.9 = Displacement in liters.

Principio del formulario
B3.9
The model name provides the

following engine data:
B = Engine series
3.9 = Displacement in liters.
The Cummins engine

nomenclature provides the data as
illustrated in the graphic.

The model name for engines in
automotive applications provides
the data shown below For
example:
B3.9-105
B = Engine series
3.9 = Displacement in liters
105 = Advertised horsepower.
The model name for engines in

industrial applications provides the
data shown below For example:
4BTAA-3.9
4 = Number of cylinders
B = Engine series
T = Turbocharged SMALL | MEDIUM | LARGE
AA = Charge air cooled
3.9 = Displacement in liters. Principio del formulario
NOTE: The suffix RGT refers to Principio del formulario

“Rear Gear Train” engines.
TO
Fuel Injection Pump Dataplate C
Bosch® Rotary
The injection pump dataplate for
the Bosch® VE pump is located on
the side of the injection pump. The
dataplate provides information for
fuel pump calibration.

Bosch® In-line

the Bosch® in-line pump is located
on the side of the injection pump.
The data plate provides
information for fuel pump
calibration.

CAV Rotary

the Lucas DPA pump is located on

Stanadyne Rotary

the Stanadyne DB4 is located on
the fuel pump calibration.

Denso In-line
The Denso fuel injection pump

dataplate contains the following
information:
(A) Fuel injection pump part

number
(B) Denso serial number
(C) Cummins part number
(D) Fuel injection pump bar code. SMALL | MEDIUM | LARGE
The Cummins part number for the

fuel pump-governor combination is
located on the governor dataplate.


Delphi Rotary

the Delphi DP pump is located on
Last Modified: 31-Mar-2006
Engine Testing (In Chassis)

(014-008)
Intial Check
B3.9, B5.9, and B4.5

Engines:
Use compression gauge and
See appropraite procedures
adapter to check for
to replace failed
following component
components.
failures:
Piston ring sealing

(Procedure 001-054 for
piston ring replacement).
Intake and exhaust valve

sealing (Procedure 002-004

for cylinder head
replacement).
Cylinder head gasket

sealing (Procedure 002-021

for cylinder gasket
replacement).
Cylinder head cracked.
For B4.5 RGT engines, no

compression service tools
are available. To inspect for
loss of compression, a blow-
by check should be
performed (Procedure 014-
010).
Test:
Compressor must be
unloaded during
Regulated Air Pressure: 655
performance check. Apply
kPa [95 psi].
air prressure to compressor
unloader.
If engine does not start

Crank engine and observe wirhin 30 seconds allow
oil pressure at start. starting motor to cool for 2
minutes be cranking again.
Lubricating oil pressure

must be at least 69 kPa [10
psi] at approximately 700
rpm.
Horsepower readings will be

inaccurate if lube oil and fuel Ensure engine is at

temperatures are out of operating temperature.
specification.
Move throttle lever to FULL-

OPEN position. Adjust

dynamometer load until
engine maintains rated rpm.
Allow readings to stabilize.

Read horsepower.
Lubricating Oil Temperature:

Check gauges and record
90°C [194°F], Fuel
readings.
Temperature: 32°C [90°F].
Avoid idling longer than five

minutes. Remove load
completely, operate engine
at idle for three to five
minutes to allow
turbocharger and other
components to cool.
Shut off engine after cool-

down period.
Remove all test

instrumentation. Remove
engine from dynamometer.
TO
Initial Check C
B3.9, B5.9, and B4.5 Engines

It is very time consuming
and expensive to remove
internal engine components to
diagnose failures. A
compression gauge and
adapter can be used as an aid
in checking for failures.
Use the compression gauge

and adapter to check for
following component failures:
1. Piston ring sealing

2. Intake and exhaust valve
sealing
3. Cylinder head gasket
sealing SMALL | MEDIUM | LARGE
4. Cylinder head cracked.
See the appropriate procedures

for the replacement of failed
components.
NOTE: Due to variables such

as starter and battery
conditions that affect engine
cranking speed, it is difficult
to establish an absolute
value for compression
pressure; however, the
following values can be used
as guidelines: SMALL | MEDIUM | LARGE
 New engine (cranking

speed @ 250 rpm) 2413
kPa [350 psi]
 Used engine (cranking
speed @ 250 rpm) 2068
kPa [300 psi].
It is recommended that the
compression pressure be
checked on all cylinders and
then compared to specification.
All cylinders must be within
690 kPa [100 psi] of each
other.
Piston Ring Sealing
If the compression is low but

can be increased significantly
by squirting oil into the cylinder,
the cause is inadequate sealing
between the rings and the
cylinder walls.
Refer to Procedure 001-054 for
piston ring replacement.
Intake and Exhaust Valve

Sealing
If the compression is low on

one or more nonadjacent
cylinders, and the pressure can
not be increased by oiling the
rings, poor valve sealing is
suspected. SMALL | MEDIUM | LARGE

cylinder head replacement.
Valve leakage is often an audible

sound from the intake and exhaust
manifolds.
Cylinder Head Gasket Sealing
If the compression is low on

adjacent cylinders, and the
pressure can not be increased
by oiling the rings, the cylinder
head gasket is probably leaking
between the cylinders.
cylinder gasket replacement.
NOTE: Low compression on a

single cylinder can be caused
by an external leak or a leak to a
coolant passage. A leak to a
coolant passage of this
magnitude will also result in
coolant in the cylinder.
A compression leak to the

coolant will normally be
detected by a loss of coolant as
the coolant is blown from the
cooling system.
Service Tip: Remove the drive

belt from the water pump. Refer
to Procedure 008-002 for SMALL | MEDIUM | LARGE
removal and installation of drive
belt.
Run the engine for one to two

minutes, and check for coolant
being blown from the radiator
by compression gases.

B4.5 RGT Engines
For B4.5 RGT engines, no

compression service tools are
available. To inspect for loss of
compression, a blow-by check
should be performed. Refer to
Procedure 014-010.
TO
Test C
NOTE: The compressed air

load in the accompanying
illustration must be attached
to the air compressor outlet
(2).
Make sure the air compressor

will be unloaded during the
performance check. SMALL | MEDIUM | LARGE
Apply regulated air pressure of

655 kPa [95 psi] to the air
compressor unloader (1).

CAUTION
Do not crank the engine for more
than 30 seconds. Excessive heat will
damage the starting motor.
Crank the engine and observe the
oil pressure when the engine
starts. If the engine fails to start
within 30 seconds, allow the
starting motor to cool for two
minutes before cranking the
engine again.
CAUTION
If the lubricating oil pressure is
not within specifications, shut off
the engine immediately. Low
lubricating oil pressure will cause
engine damage. Correct the SMALL | MEDIUM | LARGE
problem if lubricating oil pressure
is not within specifications.
Engine lubricating oil pressure

must be at least 69 kPa [10 psi]
at approximately 700 rpm.
NOTE: The horsepower

readings will not be accurate
if the lubricating oil
temperature and fuel
temperature are not within
specifications.
Make sure the engine is at

operating temperature. SMALL | MEDIUM | LARGE
Move the throttle lever to the
FULL-OPEN position. Adjust
the dynamometer load until the
engine maintains the rated rpm.
Allow the readings to stabilize.

Read the horsepower.
Check all gauges, and record

the readings.
Measurements
celsiu fahrenhei

s t
Lubricating
Oil 90 194
Temperature
Measurements
celsiu fahrenhei

s t
Fuel
32 90
Temperature
CAUTION
Do not shut off the engine
immediately after it has been
loaded. It must be allowed to cool
sufficiently. Failure to do so will
result in engine damage. SMALL | MEDIUM | LARGE
NOTE: Idle periods longer

than five minutes are to be
avoided.
Remove the dynamometer load

completely, and operate the
engine at idle speed for three to
five minutes. This will allow the
turbocharger and other
components to cool.
Shut off the engine after the cool-

down period.
NOTE: If the engine is to be

stored temporarily and does
not have permanent-type
antifreeze, it is necessary to
drain all coolant.
Remove all test

instrumentation.
Remove the engine from the
dynamometer.
Last Modified: 24-Apr-2006
Cylinder Head Gasket
(002-021)
Disconnect batteries.
Remove cylinder head

(Procedure 002-004).
Remove head gasket.
Clean block and cylinder

head combustion deck.
Inspect and measure block

and cylinder head
combustion deck flatness
Never reuse old head

gasket. Always use new
Install new head gasket.
head gasket to prevent
leakage.
Install cylinder head

Connect batteries.
TO
General Information C
Injector protrusion can affect
power from the engine. In
addition to a single sealing
washer (A) on the injector, the
thickness (B) of the head
gasket controls injector
protrusion.
Piston protrusion can affect

startabilty and engine smoke
output. The cylinder head gasket
helps to maintain correct piston
protrusion.
For B3.9, B4.5, and B5.9 series

engines, oversize cylinder head
gaskets are available for
resurfacing of the cylinder head
and cylinder block combustion
decks to maintain correct:
1. Injector protrusion
2. Piston protrusion.

After machining, the cylinder is
stamped in the upper rear right
hand corner surface of the
cylinder block (shown). The
cylinder head is stamped on the
rear of the cylinder head above
where the cylinder block would
be stamped (not shown).
Machining Mark
A - Standard None
B - 0.25 mm [0.010 in]
machined for first oversize X
gasket.
C - 0.25 mm [0.010 in]
machined (0.50 mm [0.020
XX
in] total) for second
oversize gasket.
After determining the amount of

machining that has been
performed, see parts catalog for
the proper oversize head gasket.
For B4.5 RGT series engines, the

combustion deck of the block can
only be resurfaced if, after
resurface, the correct piston
protrusion can be achieved. Refer
to Procedure 001-054.
No specific head gasket with an

increased thickness is available for
combustion deck resurfacing. If
the combustion deck can not be
resurfaced such that the correct
piston can be achieved, the
cylinder block must be replaced.
For B4.5 RGT series engines, the

combustion deck of the cylinder
head can only be resurfaced if
both of the two following criteria
are met:
1. Valve depth is kept in

specification. Refer to
Procedure 002-004 for SMALL | MEDIUM | LARGE
specifications
2. Injector protrusion is kept in
specification. Refer to
Procedure 002-004 for
specifications.
If valve depth and injector

protrusion specifications can be
maintained, the cylinder head can
be resurfaced. If the specifications
can not be maintained, the
cylinder head must be replaced.
No specific head gasket with an

increased thickness is available for
cylinder head combustion deck
resurfacing. If the combustion
deck can not be resurfaced such
that the valve depth and injector
protrusion can be reached, the
cylinder head must be replaced.
TO
Preparatory Steps C
WARNING
Batteries can emit explosive
gases. To reduce the possibility of
personal injury, always ventilate
the compartment before servicing
the batteries. To reduce the SMALL | MEDIUM | LARGE
possibility of arcing, remove the
negative (-) battery cable first and
attach the negative (-) battery
cable last.
 Disconnect the batteries.
WARNING
This assembly weighs 23 kg [50
lb] or more. To reduce the
possibility of personal injury, use
a hoist or get assistance to lift this
assembly. SMALL | MEDIUM | LARGE
 Remove the cylinder

head. Refer to
Procedure 002-004.
TO
Remove C
Remove the head gasket.
TO
Clean and Inspect for Reuse C
NOTE: Cylinder head gaskets

can not be reused. A new
cylinder head gasket must be
used.
Clean the cylinder block and

cylinder head combustion deck.
Inspect and measure the
cylinder block and cylinder SMALL | MEDIUM | LARGE
head combustion deck flatness.
Refer to Procedure 002-004.
TO
Install C
CAUTION
Be sure the gasket is correctly
aligned with holes in the cylinder
block. If the gasket is not
correctly engine damage can
result. SMALL | MEDIUM | LARGE
Install the new head gasket.
NOTE: Never reuse the old

head gasket. Always use a
new head gasket to prevent
leakage.
TO
Finishing Steps C
WARNING
This assembly weighs 23 kg [50
lb] or more. To reduce the
possibility of personal injury, use
a hoist or get assistance to lift this
assembly. SMALL | MEDIUM | LARGE
 Install the cylinder head.

Refer to Procedure 002-
004.

WARNING
Batteries can emit explosive
gases. To reduce the possibility of
personal injury, always ventilate
the compartment before servicing
the batteries. To reduce the SMALL | MEDIUM | LARGE
possibility of arcing, remove the
negative (-) battery cable first and
attach the negative (-) battery
cable last.
 Connect the batteries.
Last Modified: 24-Apr-2006

Engine Identification

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Engine Identification

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B3.9, B4.5, B4.5 RGT, and B5.

Bulletin Number 3666087

NOTE: The illustrations are only a reference to show a typical engine.

6BTA5.9-DM Front View

1. Air cleaner inlet

6BTA5.9-DM Fuel Pump Side

1. Exhaust outlet connection

1. Intake air preheater (optional)

Automotive - Rear View

Automotive - Front View

1. Turbocharger air outlet

B3.9 Industrial - Air Intake Side View

B3.9 Industrial - Exhaust Side View

1. Turbocharger air outlet

B4.5 Industrial - Air Intake Side View

B4.5 Industrial - Rear View

B4.5 Industrial - Exhaust Side View

B4.5 Industrial - Front View

1. Turbocharger air outlet

B4.5 Industrial - Top View

1. Engine air inlet

1. Rear engine lifting bracket

1. Lubricating oil fill

1. Engine air inlet

1. Engine air inlet

B5.9 Industrial - Rear View

B5.9 Industrial - Exhaust Side View

C Power Heat Exchanger Cooled - Exhaust Side View (B Series)

C Power Keel Cooler Cooled - Exhaust Side View (B Series)

1. Local Control Panel

C Power Keel Cooler Cooled - Air Intake View (B Series)

1. Local Control Panel

C Safe Radiator Cooled - Air Intake Side View (B Series)

1. Radiator and Expansion Tank

B3.9, B5.9, and B4.5 Engines

The engine dataplate shows specific

B4.5 RGT Engines

The engine dataplate shows specific facts

1. Control parts list (CPL)

NOTE: If the engine dataplate (1) is not

The model name provides the

The model name provides the

Principio del formulario

Principio del formulario

The Cummins engine

Principio del formulario

Principio del formulario

Principio del formulario

The model name for engines in

NOTE: The suffix RGT refers to Principio del formulario

Principio del formulario

Principio del formulario

The injection pump dataplate for

Principio del formulario

Principio del formulario

The injection pump dataplate for

Principio del formulario

Principio del formulario

The injection pump dataplate for

Principio del formulario

Principio del formulario

The Denso fuel injection pump

(A) Fuel injection pump part

Principio del formulario