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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