Cummins KTA38 Parts List: Complete OEM Spare Parts Catalog for V12 Generator Engines
The Cummins KTA38 is the workhorse of the 600-1250 kVA generator segment—a V12, 38-liter turbocharged diesel engine that has powered critical infrastructure for over four decades. Found in hospital backup systems, data center standby generators, offshore platform power, and large industrial prime power installations, the KTA38 is prized for its ability to deliver reliable power for 20,000+ hours between overhauls when properly maintained. Its displacement (37.7 liters) places it between the 6-cylinder KTA19 and the V16 KTA50, making it the optimal choice for installations where KTA19 output is insufficient but KTA50 footprint and cost are excessive.
This comprehensive parts catalog covers all major assemblies and components for KTA38-G2, KTA38-G5, and KTA38-G9 generator-drive engines. Every part number listed is sourced from Cummins QuickServe Online and the KTA38 IPC (Illustrated Parts Catalog). For procurement accuracy, always cross-reference against your specific Engine Serial Number (ESN) when placing orders—Cummins frequently updates part numbers through engineering change bulletins.
KTA38 Engine Technical Specifications
| Parameter | KTA38-G2 | KTA38-G5 | KTA38-G9 |
|---|---|---|---|
| Configuration | V12, 60° bank angle, 4-stroke diesel | ||
| Bore x Stroke | 159 mm x 159 mm (6.25 in x 6.25 in) | ||
| Displacement | 37.7 L (2,300 in³) | ||
| Compression Ratio | 13.9:1 | ||
| Aspiration | Turbocharged / Aftercooled | Turbocharged / Aftercooled | Turbocharged / Aftercooled (high-efficiency) |
| Standby Rating | 810 kW / 1012 kVA | 940 kW / 1175 kVA | 1000 kW / 1250 kVA |
| Prime Rating | 735 kW / 919 kVA | 855 kW / 1069 kVA | 910 kW / 1138 kVA |
| Fuel System | Cummins PT (Pressure-Time) mechanical injection | ||
| Governor | Mechanical (std) / Electronic (optional) – 1500/1800 RPM | ||
| Dry Weight | Approx. 3,580 kg (7,890 lbs) | ||
| Oil Capacity | 120-135 L (32-36 gallons) with standard oil pan | ||
Cylinder Head Assembly Parts
| Part Description | Cummins Part Number | Qty | Notes |
|---|---|---|---|
| Cylinder Head (bare, per bank) | 3636310 | 2 | Individual 6-cylinder head per bank; KTA38 uses two heads |
| Intake Valve | 3802640 | 24 | Same valve as KTA19; Stellite-faced, 47.6mm head |
| Exhaust Valve | 3636500 | 24 | Sodium-cooled stem; Stellite-faced; KTA38-specific part |
| Valve Seat Insert (Intake) | 3802668 | 24 | Same as KTA19 intake seat |
| Valve Seat Insert (Exhaust) | 3636510 | 24 | High-temperature nickel alloy; KTA38-specific |
| Valve Guide | 3802522 | 48 | Same as KTA19 |
| Valve Spring (inner) | 3636520 | 48 | KTA38-specific spring rate |
| Valve Spring (outer) | 3636525 | 48 | KTA38-specific spring rate |
| Cylinder Head Gasket (per bank) | 3636530 | 2 | MLS (Multi-Layer Steel); always replace as pair |
| Head Bolt Set (per bank) | 3636540 | 2 sets | 26 bolts per bank; torque-to-yield—always replace |
| Rocker Lever Assembly | 3636550 | 24 | KTA38-specific roller rocker; inspect roller bearing play |
Piston, Liner, and Connecting Rod Parts
| Part Description | Cummins Part Number | Qty | Notes |
|---|---|---|---|
| Piston Assembly (with rings and pin) | 3636300 | 12 | Articulated piston (steel crown + aluminum skirt); KTA38-specific |
| Piston Ring Set (per cylinder) | 3636315 | 12 | Chrome top ring, taper second, 3-piece oil control |
| Cylinder Liner (wet type) | 3636320 | 12 | Mid-stop wet liner; 3 O-ring seals; protrusion 0.08-0.15mm |
| Liner O-ring Kit | 3636325 | 12 kits | Upper (nitrile), middle (silicone), lower (fluorocarbon)—do not mix |
| Liner Shim Kit | 3636330 | As needed | Shim thickness 0.05mm increments; adjust protrusion |
| Connecting Rod Assembly | 3636340 | 12 | Forged steel I-beam; machined fracture-split cap |
| Connecting Rod Bearing (Std) | 3636345 | 12 pairs | Tri-metal; undersizes: 0.25/0.50/0.75mm |
| Piston Pin | 3636350 | 12 | Full-floating; DLC-coated option available for severe duty |
Crankshaft, Main Bearings, and Vibration Damper
| Part Description | Cummins Part Number | Qty | Notes |
|---|---|---|---|
| Crankshaft Assembly | 3636400 | 1 | Forged steel; 7 main journals; 12 crankpins (60° V12); induction-hardened |
| Main Bearing Set (Std) | 3636410 | 7 pairs | Upper: grooved; Lower: plain |
| Thrust Bearing (Rear Main #7) | 3636420 | 1 pair | Flanged; controls end-play (0.10-0.30mm spec) |
| Front Crankshaft Oil Seal | 3636430 | 1 | PTFE lip seal; install with seal driver tool |
| Rear Crankshaft Oil Seal | 3636440 | 1 | PTFE lip seal; housing must be concentric within 0.10mm TIR |
| Vibration Damper | 3636450 | 1 | Viscous-type; ~35 kg; inspect rubber annually; 10,000 hr service life |
Turbocharger and Air System
| Part Description | Cummins Part Number | Qty | Notes |
|---|---|---|---|
| Turbocharger (Holset HX50) | 3802584 | 2 | One turbo per cylinder bank; KTA38 runs dual turbochargers |
| Turbo Gasket Kit (per turbo) | 3636600 | 2 kits | Oil feed/drain gaskets, exhaust manifold flange gasket |
| Turbo Oil Feed Line | 3636610 | 2 | Braided stainless; inspect for internal coking at exhaust side |
| Turbo Oil Drain Line | 3636620 | 2 | Large-diameter rigid pipe; must be free-draining to oil pan |
| Exhaust Manifold (per bank) | 3636630 | 2 | Cast Ni-Resist high-temperature iron; 6-port log manifold |
| Exhaust Manifold Gasket Set | 3636640 | 2 kits | Multi-layer graphite/steel; replace whenever manifold is removed |
| Air Filter (Donaldson Primary) | P182059 | 2 | KTA38 typically uses two air cleaners; replace per restriction gauge |
| Aftercooler Core | 3636650 | 2 | One per bank; air-to-water type; clean externally every 1,000 hrs |
Fuel System (PT) Parts
| Part Description | Cummins Part Number | Qty | Notes |
|---|---|---|---|
| PT Fuel Pump Assembly | 3020960 | 1 | Same PT pump as KTA19; higher calibration for V12 fuel flow |
| Fuel Injector (PT Type) | 3802135 | 12 | Same injector as KTA19; flow-matched sets recommended |
| Injector O-ring Kit | 3802140 | 12 kits | Upper/lower O-rings and copper seating washer |
| Fuel Shutoff Solenoid | 3082560 | 1 | ETR (Energized-to-Run) type; fails safe |
| Fuel Filter Primary (FF105) | 3355905 | 1 | 10-micron with water separator |
| Fuel Filter Secondary (FF202) | 3896693 | 1 | 3-micron final filtration |
| Fuel Transfer Pump | 3093942 | 1 | Gear-type; 55 gph flow rate; same pump as KTA19 |
Lubrication and Cooling System Parts
| Part Description | Cummins Part Number | Qty | Notes |
|---|---|---|---|
| Oil Pump Assembly | 3089917 | 1 | KTA38-specific gear pump; higher displacement than KTA19 |
| Oil Filter (Fleetguard LF9009) | LF9009 | 2 | KTA38 uses duplex filter head (two filters in parallel) |
| Oil Cooler Assembly | 3089527 | 1 | KTA38-specific; larger core area than KTA19 |
| Oil Cooler Gasket Kit | 3636700 | 1 kit | Includes housing and core gaskets |
| Water Pump Assembly | 3802258 | 1 | Same as KTA19; belt-driven centrifugal |
| Thermostat (82°C) | 3802437 | 2 | KTA38 uses dual thermostats; replace as a pair |
| Fan Drive Belt Set | 3636710 | 1 set | Matched V-belt set; replace as complete set |
Overhaul Kits and Service Intervals
| Part Description | Cummins Part Number | Notes |
|---|---|---|
| Upper Engine Gasket Kit | 3636800 | Both head gaskets, rocker cover gaskets, manifold gaskets, injector O-rings |
| Lower Engine Gasket Kit | 3636810 | Oil pan, front/rear cover, oil cooler, oil pump, tappet covers |
| In-Frame Overhaul Kit | 3636820 | 12 pistons, 12 liners with O-rings, 12 conn rod bearings, upper + lower gasket kits |
| Major Overhaul Kit | 3636830 | In-frame kit + main bearings, thrust washers, cam bearings, front/rear seals, head bolts |
Recommended service intervals for KTA38 generator engines: Oil/filter and fuel filter change every 250 hrs; valve adjustment every 500 hrs; coolant service every 2,000 hrs; water pump replacement every 6,000 hrs; vibration damper inspection every 5,000 hrs; turbocharger inspection every 2,000 hrs; in-frame overhaul at 18,000-25,000 hrs; major overhaul at 35,000-45,000 hrs.
KTA38 Parts In Stock—Global B2B Supply
We maintain a comprehensive inventory of KTA19, KTA38, and KTA50 parts. Genuine OEM with Certificate of Origin and full traceability. Competitive pricing for fleet operators, service companies, and international distributors.
Email: sales@huaquanpower.net
Frequently Asked Questions
Q1: What parts are interchangeable between KTA19 and KTA38?
KTA19 and KTA38 share the same bore and stroke (159mm x 159mm), and many components are shared: PT fuel pump (3020960), fuel injectors (3802135), valves (3802640/3636500 differs for exhaust), valve guides (3802522), thermostat (3802437), water pump (3802258), fuel filters (FF105/FF202), and PT fuel shutoff solenoid (3082560). Non-interchangeable parts include: pistons (different skirt design for V-angle), cylinder heads (per-bank vs. single head), crankshaft, connecting rods, oil pump, vibration damper, exhaust valves, and turbocharger (HX50 vs. HX40W).
Q2: Why does the KTA38 need two turbochargers?
The KTA38 is a V12 engine with two separate exhaust manifolds (one per bank). Using a single turbo would require complex, restrictive crossover piping and cause unequal exhaust backpressure between banks. Dual Holset HX50 turbochargers (3802584) provide balanced exhaust flow, faster spool-up, and better transient load response. Each turbo is sized for 6 cylinders (~19L of displacement)—essentially one KTA19’s worth of exhaust energy per side.
Q3: What is the most common KTA38 failure mode?
The single most common KTA38 failure is the vibration damper (3636450). At ~35 kg, this viscous damper absorbs torsional vibration from the V12 crankshaft. When the internal silicone fluid degrades (~10,000 hrs), the damper stops functioning, and within 500-1,000 hours the crankshaft develops fatigue cracks—typically at the #4 or #7 main journal fillet radius. A cracked KTA38 crankshaft is a $25,000+ repair. Inspect the damper every 5,000 hours: visible silicone leakage, rubber element cracking, or a clunking sound when tapped with a brass hammer all indicate replacement is needed.
Q4: Can I run a KTA38 on a single turbo if one fails?
Absolutely not. With one turbo disabled, that cylinder bank will have extremely high exhaust backpressure and the cylinders will not scavenge properly, causing overheating, exhaust valve damage, and potential piston seizure within minutes. The engine will also run severely imbalanced, potentially causing main bearing damage. A failed turbo is an immediate shutdown event. Stocking a spare HX50 turbocharger (3802584) is strongly recommended for any facility that cannot tolerate extended downtime.
Q5: What’s the difference between KTA38-G2, G5, and G9?
G2 (810 kW standby) is the base model with standard turbochargers and aftercooler. G5 (940 kW) adds higher-flow turbochargers, a more efficient aftercooler, and slightly increased fuel rate calibration. G9 (1000 kW) adds the highest-flow turbo configuration, high-efficiency aftercooler, and revised piston cooling jet targeting for additional thermal management. The engine block, crankshaft, and connecting rods are identical across all three—the G9 simply extracts more power from the same platform with better thermal management. Upgrading from G2 to G5 or G9 requires turbo/aftercooler replacement and fuel system recalibration.
Q6: How many fuel filters does a KTA38 use? Are they the same as KTA19?
The KTA38 uses the same dual-stage fuel filter setup as the KTA19: one FF105 primary (10-micron water separator) and one FF202 secondary (3-micron final). Filter housings, part numbers, and replacement procedures are identical. Refer to our Cummins Fuel Filter Replacement Guide for step-by-step instructions. Despite the KTA38’s 12-cylinder configuration, the fuel flow rate through the PT pump is only modestly higher than the KTA19, so the same filter capacity is sufficient.
Q7: What special tools are needed for KTA38 overhaul?
Essential KTA38-specific tools: (1) Liner puller/installer tool (Cummins 3376491) for wet liner R&R without block bore damage. (2) Piston ring compressor (tapered sleeve type; 159mm). (3) Liner protrusion gauge (dial indicator with bridge; 0.01mm resolution). (4) Head bolt torque-angle gauge (digital preferred; standard torque wrench inadequate for the 3-step angle sequence). (5) PT injector setting tool and torque adapter. (6) Crankshaft turning tool (barring tool) for rotating the 3,580 kg engine during assembly. (7) Dial indicator with magnetic base for checking crankshaft end-play and gear backlash.
Q8: Can I use KTA38-C (construction/industrial) parts on a KTA38-G (generator) engine?
Many parts are cross-compatible, but three critical differences exist: (1) The G-drive governor is calibrated for fixed-speed operation at 1500/1800 RPM with precise frequency control (±0.25% droop); the C-drive governor has a variable-speed curve. (2) The fuel pump AFC (Aneroid Fuel Control) is set for different smoke-limitation profiles—generator engines need immediate fuel response to load steps. (3) The vibration damper may be differently tuned for generator applications where torsional vibration patterns differ at constant speed. Always use G-drive-specific part numbers for injection and governing components.
Q9: What is the KTA38 oil consumption spec—how do I know if it’s burning oil?
Normal KTA38 oil consumption is 0.1-0.3% of fuel consumption. For a KTA38-G5 consuming 200 L/hr of diesel at full load, that’s 0.2-0.6 L of oil per hour. Higher consumption indicates: (1) Worn valve stem seals (blue smoke on startup that clears). (2) Stuck or worn oil control rings (continuous blue smoke, especially under load). (3) Turbocharger oil seal leakage (blue smoke + oil in exhaust manifold or charge air piping). A sudden jump in consumption is a red flag—investigate immediately. Consumption exceeding 1% of fuel rate (~2 L/hr at full load) indicates an overhaul is imminent.