B Series Engine

Familiarization

Presented By : Casmun
Program Content:
 General Specification
 Applications
 Design Features
 Serviceability
 Engine Systems
 Options
 4 and 6 Cylinders B series engine have high
degree of parts commonality.
 Different of: Length, Weight and number of
parts to add two more cylinders
Industrial Applications
76 - 210 HP
@ 1500 - 2800 RPM

Stationary Power
Construction
Logging
Agriculture
Generator
 Automotive Applications
105-230 HP @ 2500 RPM

• Delivery Trucks
• Passenger Bus
• Yard Tractors
• Etc.

All 1991 automotive engines

are turbocharged and charge air cooled
Engine Model Nomenclature
Industrial

Nomenclature Content
 Number of Cylinder (s)
 Engine Series
 Aspirated Method
 Engine Displacement
 Engine Nomenclature
Automotive

Engine Series
Engine Displacement
Rated Power
Engine Displacement 4B3.9

Metric Units U.S. Units

Displacement 3.92 liter 239 cu.in.

Bore Diameter 102 mm 4.02 in

Stroke 120 mm 4.72 in

Firing Order 1–3–4–2

Engine Displacement 6B5.9

Metric Units U.S. Units

Displacement 5.88 liter 359 cu.in.

Bore Diameter 102 mm 4.02 in

Stroke 120 mm 4.72 in

Firing Order 1–5–3–6–2–4

Engine Standard Unit

Engine Components
 Metric

Pipe Fittings and Plugs

 SAE Standard
 Engine
Standard
Design

B Series Engines are designed as turbocharged

engines, but available as naturally aspirated and
turbocharged + aftercooled
 An automatic belt tensioner and
variety of hub mounting positions
is used to maintain proper belt
tension, for satisfy application
requirements: automotive,
industrial and marine
 Gear Train Timing Mark

On engines equipped
distributor FIP, timing
alignment is used
between the fuel pump gear
and camshaft gear,
but on engine with in-line FIP
do not require timing mark.

 Gear train use helical-tooth gear, and timing

mark alignment is used between the
crankshaft gear and camshaft gear.
The cylinder block is made from cast iron,
block design includes for:

 Oil cooler housing

 Water pump inlet
 Oil pump housing
 Water pump volute
 Coolant bypass
passage
Additional block casting design feature
include:

 Skirt block design for

superior strength.
 Piston cylinder bore with
120 mm center to center
spacing, and 18 mm
spacing between in order
to provide room for a dry
liner, needed for service.
 Piston cooling nozzle.
The cylinder head design features include:
 The cylinder head is a one piece.
 With cross flow design.
 Each cylinder consist of 2 valves.
A pulse exhaust manifold with a divided entry passage is
used to connect with turbine housing. It’s used to improve
engine efficiency by increase turbine running speed.

 Dual entry can

reduce wide of
passage.
 Increase velocity of
exhaust gasses for
go out.
The cylinder head design as one piece
includes:
 Integral intake
manifold
 Integral thermostat
housing
 Integral fuel filter
head

This design is used to reduce air and fuel

leakage potential.
An additional design feature of the cylinder head includes
integrally-cast valve guides, and induction-hardened valve
seat surfaces.

 Service part and

procedures are
available for
machining-shop
and installing
replacement valve
guides and valve
seats.
The length of inline FIP requires the fuel filter to be
relocated toward the rear of the engine, for this is used
remote filter head.
 The ‘Valve Train’ consists of:

Rocker Lever
 Camshaft
Assembly
 Tappets
Lift Pump

Push Rod
 Push rods
 Rocker lever
Camshaft assembly
Valve Tappet

In addition, the camshaft has a special lobe

for driving the fuel transfer pump (lift pump).
On B series engine is used ‘A single camshaft bushing’,
located in the first cam-bore, is used to support the side
loading from the accessory drives.
Power Component
The power components in engine consist of:

 Piston
 Connecting rod
 Crankshaft
 Connecting Rod & Bearing

 The con rod is angle split  The naturally aspirated

design, engine utilize steel backed
aluminum con rod bearing,
 The pin bore bushing is
lubricated by piston  The turbocharged engines
use steel backed tri-metal
cooling nozzle spray. bearing.
 Piston
 Turbocharged engines use three
ring-groove piston.
 These use a single Ni-resist insert
for ring groove for better wear
characteristic
 Higher HP engines use an anodized
coating on the piston face and bowl
to increase durability.
Emission, application, HP rating
determine which piston are placed
in the engine. Similar features of
the pistons are a high swirl
combustion bowl, a free-floating
piston pin held in by retaining
rings, and cast aluminum
bodies.
 Crankshaft

 The crankshaft is a forged

steel, with integrally
balanced unit.
 Internal cross drillings
The feature of design, connecting rod
and main journals are significantly larger supply oil to connecting
than competitive crankshaft. rod bearing.
Another design feature is the use of stamped
steel components to reduce engine weight,
includes:

 Gear cover
 Tappet cover /
breather assembly
 Oil pan
 Overall Design
 Simplicity
 Reliability
 Durability
 Fewer parts
 Ease of service

No special service tools are required

for a routine overhaul of B series
engine. The tools required
are illustrated here.
Rebuild Procedures
 Disassembly
 Replace Worn Parts
 Grind Valves
 Deglaze Cylinders
 Clean Up Head and Block Surfaces
 Assembly
No special repair / rebuild procedures are necessary
on the B series engine. High-quality field practices used
for other engines in the same HP range.
 Service Tools
 Cummins Engine Company developed
service tools to assist in the
maintenance, overhaul, and repair of B
series engine.
 Refer to the B Series Shop Manual and
Troubleshooting & Repair Manual for
service.
Engine System

• Lubricating
Lubricating System
This schematic
illustrates the
lubricating oil
flow through
the entire
engine system.
Lube System
 The lubricating oil flow
begins as the gerotor
lube pump draws oil
from oil pan through
internal suction tube.
 The pump then delivers
oil to oil cooler housing
and pressure regulator.
 Pressure regulator spec
at 449 kPa (65 psi).
 Lube System
 Oil flowing through the cast
passage in oil cooler cover,
continues through oil cooler
element.
 After cooling, oil through
another cast passage in the
cooler cover into the oil filter

 The filtered oil flows up on the

center of filter, and across to
the back of oil cooler cover.
 At the oil cooler cover, oil flow
is divided. A portion flow to the
turbocharger, and remain
passes down a cast passage
to a cross drilling in the block.
 Lube System

 In the event of plugged filter, bypass valve has been

incorporated into the cooler cover to maintain oil flow.
 If the pressure drop across the oil filter exceeds 138
kPa (20 psi), bypass valve will open, allowing unfiltered
oil to continue into through the engine.
 Lube System
 The oil is cooled and
filtered, flow through cross
drilling between cylinder
no.1 and no.2 entire to main
rifle.
 The main oil rifle divide oil
flow, a portion flow to main
bearing and other to
overhead.

The main oil rifle runs the length of the block, and carries oil
to the overhead and main bearings through individual transfer
drillings.
 Lube System
 The main oil rifle
supplies oil to a
groove in the upper
main bearing.
 Oil is then supplied
to the piston cooling
nozzle, seated in the
upper main bearing,
and cam bore.
 The piston pins are
receive lube oil by
splash lubricated
from piston cooling
nozzle spray.
The new piston cooling nozzle (since 1991 engine),
increase oil flow to the pins for improve piston
targeting.
Lube System
 From the main bearing,
oil enters the crankshaft
and lubricates the
connecting rod bearings
through internal cross
drillings.
 Lube System
 Oil to the overhead
is carried to
cylinder head by
individual vertical
drillings, which
intersecting the
main oil rifle.
 The oil then flows
to transfer slot in
the head gasket.

--------oo0oo--------
Lube System
 From gasket transfer slot,
the oil flows around the
outside diameter of
cylinder head capscrews,
and flows up. Then oil flow
through a groove in the
bottom of rocker lever
support.
 The oil then flows through
vertical drilling in the
rocker support, into the
inside diameter of the
shaft.
 The rocker lever has
drilling that carries up oil
from the rocker lever bore.
Oil flows down each side
of the rocker lever to
lubricate the push rod
socket and valve stem.
Lube System

 Gear train assembly

receives lubrication
from oil splash.
 The oil pump idler
gear is pressure-
lubricated.
 From here the oil
drains back to the
pan for recirculation.
 Lube System
Oil Pan Capacity Metric Units U.S. Units
* Four Cylinder
Front/Rear Sump 9.5 Liters 10 Qts
Center Sump 9.5 Liters 10 Qts
* Six Cylinder
Front/Rear Sump 14.2 Liters 15 Qts
Oil Pressure (Minimums)
Idle Speed 69 kPa 10 psi
Rated Speed 207 kPa 30 psi
Engine System

• Lubricating
• Cooling
Cooling System
 Coolant is circulated
by the integrally-
mounted water pump.
 The output from the
water pump empties
into the oil cooler
cavity of the cylinder
block.
 This provides the oil
cooler with the
coolest coolant.
  The coolant then
circulates around each
cylinder and crosses the
block to the fuel pump
side of the engine

 Coolant then flows up into

the cylinder head, crosses
over the valve bridges and
down the exhaust manifold
side of the engine to
thermostat housing.
-------------------------------------
Thermostat Operation
 When the engine is below
operating temperature, the
thermostat is closed, allowing
coolant to bypass the radiator
and flow back to water pump
inlet through internal drilling in
the cylinder head and block.
 When operating temperature is
reached, the thermostat opens,
blocking the bypass passage
to water pump and opening the
outlet to radiator.
WARNING:
Don’t operate the engine without
the thermostat, it cause the
engine overheating.
 Aftercooler - Coolant

 On Aftercooled-Engine, the aftercooler receives its water

supply through external plumbing in the block near the
water pump outlet.
 Coolant flow returns from aftercooler to the head between
cylinder number one and cylinder number two.
Cooling System Capacity
Non-Aftercooled & Charge Air Cooled
Four Cylinder 7 Liters 7.3 U.S. Qts.

Six Cylinder 10.5 Liters 11.1 U.S. Qts.

Aftercooled
Four Cylinder 9.7 Liters 10.3 U.S. Qts.

Six Cylinder 14.5 Liters 15.3 U.S. Qts.

Engine System

• Lubricating
• Cooling
• Air
Intake Air System
 On Charge Air Cooled Engines,
intake air is drawn through the
air cleaner into compressor
side of the turbocharger.
 After leaving the turbocharger,
the hot air flows to the charge
air cooler by a large pipe.
 In the charge air cooler, heat in
the air is transferred to outside
air which flowing around the
fins of cooler, thus decreasing
temperature of the air.
 After cooling process, the
intake air leaves the charge air
cooler and enters another large
pipe to intake manifold, then
into combustion chamber.
Intake Air System
 On Aftercooled Engines, intake
air is drawn through the air
cleaner into compressor side of
the turbocharger.
 After leaving the turbocharger,
the hot air flows to the
aftercooler through the air
crossover connection.
 In the aftercooler, heat in the air
is transferred to outside air
which flowing around the fins of
cooler, thus decreasing
temperature of the air.
 After cooling process, the intake
air leaves the aftercooler and
enters another large pipe to
intake manifold, then into
combustion chamber.
Exhaust Air System
 Exhaust gases then
flow out through the
exhaust manifold into
the divided entry
turbine housing of the
turbocharger.
 In the turbocharger,
exhaust gases drive the
turbine wheel.
 Exhaust gases then
flow to silencer (if
equipped) and flow out
to atmosphere.
Exhaust Air System
 On some automotive
engines, wastegated
turbocharger is used for
better low engine-speed
performance and better
control of high engine-
speed boost pressure.
 More detailed information
on the design and operation
of the wastegated
turbocharger ca be found in
the MidRange Engine
Turbocharging and Intake
Air Cooling Familiarization
Program, Bulletin No.
3387770.
Engine System
• Lubricating
• Cooling
• Air
• Fuel
 Fuel System

The B Series engines

use both distributor
and inline fuel
injection pump
supplied by Bosch,
Stanadyne, Lucas CAV
and Nippondenso.
Fuel System Flow
 Fuel flow begins as the
pump draws fuel from the
supply tank, through the
pre-filter, and to the fuel
transfer pump. Pressure
spec. 20.7-172.5 kPa (3-25
psi).
 Then the fuel flows to
injection pump through
fuel filter.
 The injection pump build-
up the fuel pressure, as
required nozzle injection
pressure to spray fuel
enter to combustion
chamber.
 Fuel Transfer Pump

The fuel transfer pump can be either a diaphragm

or plunger type. Distributor injection pumps use
diaphragm type fuel transfer pumps, while inline
injection pumps use plunger type fuel transfer
pump.
Fuel Injection Pump
 High pressure injection
pumps are used to
build the injection
pressure required for
combustion.
 Many automotive and
industrial applications
use the Bosch VE
distributor pump.
 Four and Six-Cylinder
generator drive engines
use Lucas DPA or
Stanadyne DB4
distributor pump
Fuel Injection Pump
 Some four-cylinder
and six-cylinder
industrial engines use
Lucas CAV (DPA)
distributor pump.
 Some automotive
engines
manufactured in
Europe use Lucas
CAV (DPS) distributor
pump.
Inline FIP
 High HP six-cylinder
engines are equipped
with inline injection
pumps.
 Most of these engines
use Bosch PES P
injection pump.
 High HP marine engines
use Nippondenso EP9
injection pump.
Cam-Gear Bolt & Gear Housing
 Camshaft Gear Bolt
The Bosch PES P injection
pump exerts a higher load
on the nose of camshaft, if
compared to the load
created by the distributor
pump. To compensate for
the higher load, a bolt is
used to strengthen the nose
of the camshaft.
 Gear Housing
When the inline injection
pumps are used, the engine
requires a strong gear
housing to support the extra
weight.
Injector Nozzle
 When the high-pressure
fuel reaches the nozzle,
the pressure lifts the
needle valve against the
spring tension to allow
fuel enter to the
combustion engine.
 The engines equipped with
inline FIP use stronger
high pressure injection
lines and larger line nuts
to handle higher injection
pressure.
 Fuel Drain Manifold

 The fuel drain

manifold routes
vented fuel from the
injection pump and
leakage from the
injectors back to
the fuel filter head
or supply tank.
Options
 Flywheel Housing
 Fan Drive Position
 V-Belt Pulley
 Accessory Drive
 Power Take Off
 Oil Pan Sump
 Oil Fill & Dipstick Location
 Fuel Filter Head
 Exhaust Manifold
Flywheel Housing
 Flywheel housing optional
are available with mounting
arrangement to suitable
various application, as such:
conjunction with flexplate,
torque converter, clutch, and
etc.
 A baring mechanism is
available as an option with
the flywheel housing (wet or
dry type).
Options
 Full complement of fan
drive arrangements for
satisfy most application
requirement. Fan drive
options with automatic belt
tensioning are available
with center from 203.2 mm
to 444.25 mm above the
crankshaft centerline.
 Optional V-belt pulley are
available for the fan hub
and crankshaft pulleys.
This bolt on opti0n can be
used to drive additional
accessories.
Options
 Additional accessory drive
is provided by gear-driven
accessory option, which
installed on the rear face of
gear housing. Up to 105
ft.lbs. of torque can be
realized.
 Power take off is available
as option to cover variety
application. Its torque
capability allow up to 210
ft.lbs.
Options
 Various oil pan options are
available. Its are oil pan
with front / rear sump and
center sump. These oil pan
sump to suitable with
engine compartment in
application.
 The multiple oil fill and
dipstick locations
complement the reversible
oil pan. The valve cover oil
fill may be moved to other
cylinder for easy
serviceable.
Options
 To provide superior fuel
system protection against
water and dirty, a combination
fuel water separator/filter
should be used. A dual filter
head option plumbed in series
is available for severe
environments.
 Multiple turbocharger
locations are also available to
suit space of various
installations, as such:
center/front/rear and high / low
turbo-mounting locations are
offered.
Presented By : Casmun
 Engine Performance
STANDARD RATINGS - CONSTRUCTION

Engine Configuration CPL Max-Output Peak-Torque Torque-

Models Number No BHP@rpm lb.ft@rpm Rise (%)
4B3.9-C D381001CX02 0591 76@2500 184@1200 15

4BT3.9-C D382003CX02 0730 93@2200 263@1300 20

4BT3.9-C D382002CX02 0730 100@2500 260@1500 24

4BTA3.9-C D383003CX02 0594 116@2500 300@1600 23

6B5.9-C D401001CX02 0714 115@2500 270@1200 12

6BT5.9-C D402002CX02 1288 152@2500 414@1600 25

6BT5.9-C D402002CX02 0938 122@2500 370@1200 25

6BTA5.9-C D403003CX02 0599 177@2500 455@1500 22

6BTA5.9-C D403030CX02 1640 200@2500 568@1500 19

 Engine Performance
HIGH-SPEED RATINGS - CONSTRUCTION

Engine Configuration CPL Max-Output Peak-Torque Torque-

Models Number No BHP@rpm lb.ft@rpm Rise (%)
4B3.9-C D381001CX02 0721 80@2800 184@1200 23

4BT3.9-C D382002CX02 1268 105@2800 270@1600 37

4BTA3.9-C D383003CX02 0595 120@2800 305@1500 36

6B5.9-C D401001CX02 0791 120@2800 271@1200 24

6BT5.9-C D402002CX02 0761 160@2800 415@1700 32

6BT5.9-C D402002CX02 0912 192@2800 458@1700 27

 Engine Performance
POWER UNIT

Engine Configuration CPL Max-Output Peak-Torque Torque-

Models Number No BHP@rpm lb.ft@rpm Rise (%)
4B3.9-P D381018PX02 0591 76@2500 184@1200 15

4BT3.9-P D382019PX02 0730 100@2200 260@1500 24

4BT3.9-P D382020PX02 0594 116@2500 300@1600 23

6B5.9-P D401021PX02 0714 115@2500 270@1200 12

6BT5.9-P D401022PX02 1288 152@2500 400@1600 25

6BTA5.9-P D402023PX02 0599 177@2500 455@1500 22

 Engine Data
Model : 4B3.9 CPL No. : 0591
GENERAL ENGINE DATA
• Type ……………………………………………………………… In-Line, Liquid Cooled, 4-Stroke Cycle
• Aspiration ………………………………………………………………………………. Naturally Aspirated
• Bore x Stroke – mm (in) ………………………………………………..….. 102 x 120 (4.02 x 4.72)
• Displacement – liters (in3) …………………………………………………….……………. 3.92 (239.3)
• Compression Ratio ……………………………………………………………………………………. 17.3 : 1
• Firing Order ………………………………………………………………………………………. 1 – 3 – 4 – 2
• Rotation, Viewed from front of engine ……………………………………………………. CLOCKWISE
• Engine Weight :
- Dry – kg (lb) ………………………………………………………..…………………………….. 309 (680)
- Wet – kg (lb) …………………………………………………………………………….………… 325 (715)
COOLING SYSTEM
• Coolant Capacity (Engine only) – Liters (U.S. Qts) ………… ………………………… 7.0 (7.4)
• Thermostat Open – o C (o F) ………………………………………………………………………. 83 (181)
LUBRICATION SYSTEM
• Oil Capacity:
- Pan – Liters (U.S. Qts) .…………………………………………………………………………… 9.5 (10)
- Total – Liters (U.S. Qts) ………………………………………………..……………………. 10.9 (11.5)
• Oil Pressure:
- At Idle – psi (kPa) ………………………………………… 10 (69)
- At Rated Speed – psi (kPa) ………………………….. 30 (207)
 Engine Data
Model : 4B3.9 CPL No. : 0591
PERFORMACE DATA
• Idle Speed - rpm ……………………………..……………………………………………………………. 800
• Rated Speed – rpm ……………………………………………………………………………….………2500
• Governor Droop - % ………………………………………………………………………………………. 6-10
• Power Output:
- Intermittent Rating – HP (kW) …………………………………………………..……………. 76 (57)
- Continuous Rating – HP (kW) …….…………………………………………...……………... 64 (48)
• Maximum Torque Available:
- Intermittent Rating – Lb.ft @ rpm ……………………………………………..…….. 184 @ 1200
- Continuous Rating – Lb.ft @ rpm …………………………………………...……….. 169 @ 1200
• Intake Air Flow – Liter(s)/s …………………………………………………….………………………. 60
• Nominal Fuel Consumption – lb/hr (kg/hr) ……………………………………………. 24.5 (11.2)
 Engine Data
Model : 6B5.9 CPL No. : 0912
GENERAL ENGINE DATA
• Type ……………………………………………………………… In-Line, Liquid Cooled, 4-Stroke Cycle
• Aspiration ………………………………………………………………………… Turbocharged Aspirated
• Bore x Stroke – mm (in) ………………………………………………..….. 102 x 120 (4.02 x 4.72)
• Displacement – liters (in3) …………………………………………………….……………. 5.88 (359.0)
• Compression Ratio ……………………………………………………………………………………. 16.5 : 1
• Firing Order ……………………………………………………………………………. 1 – 5 – 3 – 6 – 2 – 4
• Rotation, Viewed from front of engine ……………………………………………………. CLOCKWISE
• Engine Weight :
- Dry – kg (lb) ………………………………………………………..…………………………….. 411 (905)
- Wet – kg (lb) …………………………………………………………………………….………… 439 (967)
COOLING SYSTEM
• Coolant Capacity (Engine only) – Liters (U.S. Qts) …………………………..………… 14.2 (15)
• Thermostat Open – o C (o F) ………………………………………………………………………. 83 (181)
LUBRICATION SYSTEM
• Oil Capacity:
- Pan – Liters (U.S. Qts) .…………………………………………………………………….…… 14.2 (15)
- Total – Liters (U.S. Qts) ………………………………………………..……………………. 16.4 (17.3)
• Oil Pressure:
- At Idle – psi (kPa) ………………………………………… 10 (69)
- At Rated Speed – psi (kPa) ………………………….. 30 (207)
 Engine Data
Model : 6B5.9 CPL No. : 0912
PERFORMACE DATA
• Idle Speed - rpm ……………………………..……………………………………………………………. 800
• Rated Speed – rpm ……………………………………………………………………………….………2800
• Governor Droop - % …………………………………………………………………………………… 10-15
• Power Output:
- Intermittent Rating – HP (kW) ……………………………………………………………… 192 (143)
• Maximum Torque Available:
- Intermittent Rating – Lb.ft @ rpm ……………………………………………..…….. 458 @ 1700
• Intake Air Flow – Liter(s)/s …………………………………………………….………………………. 234
• Nominal Fuel Consumption – lb/hr (kg/hr) ……………………………………………. 72.7 (33.0)
Engine Performance Curve
CPL 0730
4BT3.9-C
o

o
Engine Performance Curve
6BTA5.9
CPL 0761