Document number 3666017-01 marks this as the Shop Manual Cummins printed for its 4BT3.9 and 6BT5.9 diesel engines; this Cummins 4BT3.9, 6BT5.9 service manual PDF reproduces all 480 pages. Engine disassembly and assembly fills nearly a quarter of the book, and exploded views of the cylinder block and head show how each assembly stacks back together. Two injection pump families, the Bosch VE and the Lucas CAV DPA, have separate repair procedures, and the specifications section gathers component torque values in one place. Check fuel transfer pump spring free length before you reuse one: 53.5 mm on the 3918076 pump and 58 mm on the 3918000, with the nozzle nut going down at 30 N·m (22 ft-lb). Alone at the bench, there is nobody to ask. Searchable text and section bookmarks let you confirm a torque sequence before reassembly, and your parts order carries the right pump number the first time.
What's Inside This Cummins 4BT3.9, 6BT5.9 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 7-20 | General Cleaning Instructions, Glossary of Terms |
| Engine Identification | 21-30 | Engine Dataplate, General Engine Specifications |
| Engine Disassembly and Assembly | 31-144 | Engine Disassembly and Assembly Service Tools, Engine Disassembly Check List |
| Cylinder Block | 145-204 | Cylinder Block General Information, Cylinder Block Cleaning |
| Cylinder Head | 205-226 | Cylinder Head Cleaning, Valve Inspection |
| Rocker Levers | 227-234 | Rocker Lever Assembly General Information, Rocker Levers Disassembly |
| Cam Followers | 235-240 | Tappets and Push Rods General Information, Valve Tappets Inspection |
| Fuel System | 241-296 | Injection Pump Repairs Bosch VE, Injection Pump Repairs Lucas CAV DPA |
| Injectors and Fuel Lines | 297-316 | Injector Assembly, Fuel Lines Clean and Inspect |
| Lubricating Oil System | 317-332 | Oil Pan and Suction Tube Cleaning and Inspection, Oil Pump Inspection |
| Cooling System | 333-346 | Water Pump Inspection, Fan Hub Inspection |
| Drive Units | 347-352 | Accessory Drive Cleaning, Accessory Drive Adaptor Assembly |
| Air Intake System | 353-362 | Turbocharger Cleaning and Inspection, Aftercooler Assembly Cleaning and Inspection |
| Exhaust System | 363-366 | Exhaust Manifold Inspection |
| Air Equipment | 367-370 | Air Compressor Cleaning and Inspection |
| Electrical Equipment | 371-374 | Alternator Inspection |
| Engine Testing | 375-412 | Engine Dynamometer Test Performance Checking, Chassis Dynamometer Operation |
| Mounting Adaptations | 413-418 | Flywheel and Ring Gear Inspection, Flywheel Housing Inspection |
| Specifications | 419-462 | Engine Component Torque Values, Component Specifications and Torque Values |
| Service Literature | 463-468 | Additional Service Literature, Service Literature Ordering Location |
| Component Manufacturers: Names and Addresses | 469-472 | United States and United Kingdom Offices |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Lever lock washer and nut torque | 5-10 N·m [4-7.5 ft-lb] | p. 259 |
| Overflow adapter torque | 23 N·m [17 ft-lb] | p. 260 |
| Fuel transfer pump 3918076 spring free length | 53.5 mm [2 7/64 in] | p. 301 |
| Fuel transfer pump 3918000 spring free length | 58 mm [2 9/32 in] | p. 301 |
| Nozzle nut torque | 30 N·m [22 ft-lb] | p. 307 |
| Turbocharger shaft end play | 0.03 mm - 0.08 mm [0.001 in - 0.003 in] | p. 357 |
| Turbocharger radial clearance | 0.30 mm - 0.46 mm [0.012 in - 0.018 in] | p. 358 |
| Aftercooler pressure test | 552 kPa [50 psi] | p. 359 |
| Intake Restriction (Maximum) - Clean Filter (light duty) | 254 mm H2O [10 in. H2O] | p. 381 |
| Intake Restriction (Maximum) - Clean Filter (medium duty) | 305 mm H2O [12 in. H2O] | p. 381 |
| Maximum pressure drop across aftercooler/charge air cooler | 21 kPa [3 psi] | p. 397 |
| Aftercooler Mounting | 24 N·m [18 ft-lb] | p. 421 |
Cummins 4BT3.9, 6BT5.9 Common Problems This Manual Covers
Cummins 4BT3.9 and 6BT5.9 turbocharger shaft end play or radial clearance out of spec on inspection
Measure turbocharger shaft end play against 0.03 mm to 0.08 mm following page 357, then check radial clearance against 0.30 mm to 0.46 mm on page 358. On serial numbers before 840638, page 450 lists axial clearance at 0.10 mm to 0.16 mm. Torque the mounting nuts to 43 N·m (page 433) on reinstall.
Manual Section: Air Intake System p. 357Aftercooler leaking or charge air cooler pressure drop above limit during performance check
Test the aftercooler assembly under pressure following page 359 and inspect the core for leaks. Measure the pressure drop across the aftercooler or charge air cooler against the 21 kPa [3 psi] maximum on page 397. Torque the aftercooler capscrews to 24 N·m on reassembly and check every clamp before running it.
Manual Section: Air Intake System p. 359Fuel shutoff solenoid failing pull-in or hold-in resistance check on the injection pump
Measure solenoid resistance on page 294: a 12V unit needs at least 0.22 ohms pull-in and 11.1 ohms hold-in; a 24V unit needs at least 0.82 and 41.3 ohms. Verify run dimension A at 66.9 mm on page 292, then torque the solenoid to 9 N·m per page 291.
Manual Section: Fuel System p. 294Intake restriction or exhaust back pressure over maximum during engine performance check
Measure intake restriction during the performance check on page 381. With a clean filter, a light duty engine should not exceed 254 mm H2O, and the dirty filter limit is 635 mm. Check exhaust back pressure against 76 mm Hg for industrial engines, and check fuel filter restriction against 35 kPa.
Manual Section: Engine Testing p. 381Fuel injector failing bench test on the stand after cleaning and nozzle inspection
Test, clean and inspect each injector following the Injector Testing procedures starting on page 297 before you condemn it. When reassembling the nozzle, torque the nozzle nut to 30 N·m [22 ft-lb] per page 307. Clean and inspect the fuel lines at the same time so debris does not go straight back into a clean injector.
Manual Section: Injectors and Fuel Lines p. 297Valve lash out of adjustment after cylinder head reinstall on the stand
Torque the head capscrews in sequence per page 126: all to 90 N·m, recheck at 90 N·m, long capscrews to 120 N·m, recheck the long capscrews, then rotate all 90 degrees. Adjust valve lash to 0.25 mm intake and 0.51 mm exhaust using page 26 before the engine goes back together.
Manual Section: Cylinder Head p. 126Frequently Asked Questions
What are the torque specifications for the cylinder head mounting capscrews on a Cummins B Series engine?
The cylinder head mounting capscrews must be tightened in a specific five-step sequence. The final torque is achieved by tightening all capscrews to 90 N-m [66 ft-lb], then tightening the six long capscrews to 120 N-m [89 ft-lb], followed by an additional 90-degree rotation for all capscrews, and finally an overcheck to 136 N-m [102 ft-lb]. p. 126
What are the fuel injector replacement specs for the Cummins 4BT3.9, 6BT5.9 B Series engine?
The injector needle valve and nozzle tip are machined to precise tolerances and must be replaced as a matched set. When installing, the injector nozzle nut should be tightened to 60 N-m [44 ft-lb] using a 24 mm deep well socket. p. 130
What is the correct valve clearance adjustment for the Cummins 4BT3.9, 6BT5.9 B Series engine?
The intake valve clearance is 0.25 mm [0.010 in] and the exhaust valve clearance is 0.51 mm [0.020 in]. These adjustments should be made when the engine is at Top Dead Center (TDC) compression stroke for the respective cylinder. p. 128
What is the oil capacity for a standard 6-cylinder Cummins 4BT3.9, 6BT5.9 B Series engine?
The oil capacity for a standard 6-cylinder B Series engine is 14.2 liters [15 U.S. quarts]. The total system capacity, including the filter, is 16.4 liters [17.3 U.S. quarts]. p. 26
What's the minimum recommended battery capacity for a 12-volt 6-cylinder Cummins 4BT3.9, 6BT5.9 with heavy accessories?
For a 12-volt system on a 6-cylinder engine equipped with heavy accessories like a hydraulic pump and torque converter, the minimum recommended battery capacity is 950 CCA. p. 28
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