Piston Rings Page 1 of 8

001-047   Piston Rings

Failure Analysis Inspection

Inspect the piston rings for

the following:

l Abrasive wear.

NOTE: Abrasive wear of 
the intermediate ring can 
be indicated by a rapid 
reduction of the dark 
finish coating on the 
front face of the ring, in 
some cases, to the point 
where the dark finish 
coating is no longer 
visible (A). This is 
commonly referred to as 
full face ring wear. This 
rapid reduction will 
typically leave a sharp 
edge on the bottom of 
the intermediate ring. 
Abrasive wear can also 
be indicated by 
concentrated vertical 
scratches on the top ring 
(B).

Abrasive wear can be

caused by:

1. Ingested abrasive
material
2. Inadequate cleaning
during a previous
repair
3. Particles embedded
in the bore
4. High soot content in

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the lubricating oil

from extended oil
drain intervals
5. Scuffing and scoring.

NOTE: Scuffing and 
scoring is indicated by 
heavy scratches, metal 
discoloration, and voids 
(B).

Scuffing and scoring can

be caused by:

1. Engine overheating
2. Oil dilution
3. Improper
maintenance of the
lubrication system
4. Piston cooling nozzle
malfunction
5. Oil ring plugged by
deposits.

NOTE: Scuffing and 
scoring on the piston 
rings indicates a 
breakdown of the oil film 
on the cylinder bore wall, 
causing transfer of 
material from the piston 
ring face to the cylinder 
bore.

NOTE: Oil ring plugging 
is indicated by deposits 
on the oil ring grooves 
(B).

Oil ring plugging can be

caused by:

1. Low engine operating

temperatures - long
periods of idling or a
cooling system
malfunction
2. Extended oil change

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intervals
3. Use of the wrong
grade of engine oil
4. Use of a poor quality
engine oil.

NOTE: Plugging of the oil 
ring drains restricts oil 
drain back, which floods 
the piston ring belt area, 
resulting in a loss of oil 
control.

NOTE: The following 
measurements are 
intended for inspecting 
new piston rings.

NOTE: Before 
completing this 
inspection, make sure 
the cylinder bore is 
within specification. 
Refer to Procedure 001-
026 in Section 1.

Measure
Front Gear Train

Measure the piston ring

gap by installing the piston
rings into the cylinder bore
in which they will be used.
Position the rings below
the ring reversal area.
Position each ring in the
cylinder 89 mm [3.5 in]
below the top deck (A),
and using a clean piston to
square it with the bore.

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The piston ring sets are

different. While both sets
consist of three rings, the top
ring of the
turbocharged/aftercooled set
has a keystone profile that
operates in a ni-resist insert
cast into the piston. The
naturally aspirated (NA) top
ring is square cut and
operates in a groove
machined into the aluminum
piston.

NOTE: The top ring for a 
turbocharged engine is not
the same as the top ring for 
a naturally aspirated 
engine.

Use a feeler gauge to

measure the gap.

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

Ring Gap
mm in
Oil 0.25 MIN 0.010
Control
0.55 MAX 0.022

Piston Ring Gap Cross Referencing Tables

l To establish the correct top and intermediate piston ring gap, the part numbers of the
piston rings must be known. If the engine has been rebuilt previously, then check for
records of the parts used during the previous rebuild. If no records are present for the
parts used during rebuild, then this table can’t be used to determine the correct ring gap.
If this is the case, then new piston rings should be used during the rebuild of the engine.
l The cross referencing tables are ordered by ring size (Standard, 0.5 mm oversize, then
1.0 mm oversize) and then by part number in descending order. First identify the correct
bore / piston ring size, then find the part number of the rings in the appropriate table.

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NOTE: Piston ring gap sizes are given in mm [inch].

Standard Size Piston Ring
Top ring Intermediate Ring
Part  Minimum  Maximum  Part  Minimum  Maximum 
Number Gap Gap Number Gap Gap
4897899 0.22 [0.009] 0.38 [0.015] 4897900 0.60 [0.024] 0.86 [0.034]
3959079 0.26 [0.010] 0.42 [0.017] 3943544 0.85 [0.033] 1.21 [0.048]
3947678 0.26 [0.010] 0.42 [0.017] 3943544 0.85 [0.033] 1.21 [0.048]
3937392 0.35 [0.014] 0.51 [0.020] 3942265 0.25 [0.010] 0.61 [0.024]
3918315 0.40 [0.016] 0.76 [0.030] 3940777 0.25 [0.010] 0.61 [0.024]
3904529 0.40 [0.016] 0.76 [0.030] 3937393 0.55 [0.022] 0.90 [0.035]
3902401 0.40 [0.016] 0.76 [0.030] 3932519 0.25 [0.010] 0.61 [0.024]
2831144 0.30 [0.012] 0.46 [0.018] 3904531 0.25 [0.010] 0.61 [0.024]
3904530 0.25 [0.010] 0.61 [0.024]
3902400 0.25 [0.010] 0.61 [0.024]
3902286 0.25 [0.010] 0.61 [0.024]

0.5 mm [0.02 in] Oversize Piston Ring
Top ring Intermediate Ring
Part  Minimum  Maximum  Part  Minimum  Maximum 
Number Gap Gap Number Gap Gap
4898855 0.22 [0.009] 0.38 [0.015] 4898858 0.60 [0.024] 0.86 [0.034]
3957244 0.26 [0.010] 0.40 [0.016] 3943545 0.85 [0.033] 1.21 [0.048]
3937428 0.35 [0.014] 0.51 [0.020] 3942266 0.25 [0.010] 0.61 [0.024]
3919050 0.40 [0.016] 0.76 [0.030] 3937430 0.55 [0.022] 0.90 [0.035]
3902392 0.40 [0.016] 0.76 [0.030] 3933583 0.25 [0.010] 0.61 [0.024]
2831145 0.30 [0.012] 0.46 [0.018] 3904347 0.25 [0.010] 0.61 [0.024]
3902393 0.25 [0.010] 0.61 [0.024]

1.0 mm [0.04 in] Oversize Piston Ring
Top ring Intermediate Ring
Part  Minimum  Maximum  Part  Minimum  Maximum 
Number Gap Gap Number Gap Gap
4898856 0.22 [0.009] 0.38 [0.015] 4898859 0.60 [0.024] 0.86 [0.034]
3957245 0.26 [0.010] 0.40 [0.016] 3943546 0.85 [0.033] 1.21 [0.048]
3937429 0.35 [0.014] 0.51 [0.020] 3942267 0.25 [0.010] 0.61 [0.024]

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3919051 0.40 [0.016] 0.76 [0.030] 3937431 0.55 [0.022] 0.91 [0.036]
3902441 0.40 [0.016] 0.76 [0.030] 3933585 0.25 [0.010] 0.61 [0.024]
2831146 0.30 [0.012] 0.46 [0.018] 3904348 0.25 [0.010] 0.61 [0.024]
3902442 0.25 [0.010] 0.61 [0.024]

If the piston ring gap is not within specification:

1. Verify the correct type and part number piston ring is being used
2. Verify the cylinder bore is within specification. Refer to Procedure 001-026 in Section 1.
3. Verify the piston ring gap measurement is being taken 89 mm [3.5 in] below the cylinder
block deck
4. Try another set of piston rings.

After each ring gap is

checked and verified,
identify the ring sets for
installation in the cylinder
bore where the end gap
was measured.

Rear Gear Train

Measure the piston ring

gap by installing the piston
rings into the cylinder bore
in which they will used.
Position the rings below
the ring reversal area.
Position each ring in the
cylinder 89 mm [3.5 in]
below the top deck (A),
and using a piston to
square it with the bore.

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The piston ring type and

location can be identified
by piston ring profile.

1. Top piston ring

2. Intermediate piston
ring
3. Oil control ring.

Use a feeler gauge to

measure the gap.

B4.5 RGT Engines Ring Gap

mm in
Top 0.30 MIN 0.012
0.46 MAX 0.018
Intermediate 0.82 MIN 0.032
1.18 MAX 0.047
Oil 0.22 MIN 0.010
0.58 MAX 0.023

If the piston ring gap is not

within specification:

1. Verify the correct type

and part number piston
ring is being used
2. Verify the cylinder bore
is within specification.
Refer to Procedure 001-
026 in Section 1.
3. Verify the piston ring
gap measurement is
being taken 89 mm [3.5
in] below the cylinder
block deck
4. Try another set of piston
rings.

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After each ring gap is

checked and verified,
identify the ring sets for
installation in the cylinder
bore where the end gap
was measured.

Last Modified:  10-Jan-2012

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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