Parts Manual

Engine
CPCB Compliant
S 3.8 G3
S 3.8 G4
S 3.8 G6
S 3.8 G7

English - Original Instructions 05- 2012 A024J829 (Issue4)

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

“Intentionally Left Blank”

Page 2 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Table of Contents
Description Page
SECTION A (Base Engine Parts)
Alternator....................................................................... ........................................................................ 7
Camshaft & Rocker Arm......................................................................................................................... 9
Connecting Rod Assembly..................................................................................................................... 11
Cooling System......................................................... ............................................................................. 13
Crankshaft ............................................................ ................................................................................ 15
Cylinder Block......................................................... ............................................................................... 17
Gasket Set............................................................. ................................................................................ 17
Cylinder Head.......................................................... .............................................................................. 19
Dipstick Arrangment............................................................................................................................... 20
Exhaust Manifold....................................................... ............................................................................ 21
Fuel Filter....................................................................... ........................................................................ 22
Fuel injection Pump.................................................... ........................................................................... 23
Flywheel............................................................... .................................................................................. 24
Injector....................................................................... ............................................................................ 25
Lubricating System..................................................... ........................................................................... 27
Piston Assembly..................................................................................................................................... 28
Srarter....................................................................... ............................................................................. 29
Turbocharger.......................................................................................................................................... 30

SECTION B (Upfit Parts)

Air Cleaner (S 3.8 G4/G6/G7)................................................................................................................. 32
Air Cleaner (S 3.8 G3)............................................................................................................................ 33
Control Installation................................................... .............................................................................. 35
Control Panel & Electrical Parts.............................................................................................................. 37
Engine Installation (S 3.8 G3)....................................... ......................................................................... 39
Engine Installation (S 3.8 G4)....................................... ......................................................................... 41
Engine Installation (S 3.8 G6)....................................... ......................................................................... 43
Engine Installation (S 3.8 G7)....................................... ......................................................................... 45

2010 Copyright Cummins Power Generation Page 3

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Description Page

Exhaust Installation (S 3.8 G3)...................................................................................................... 46

Exhaust Installation (S 3.8 G4/G6/G7).......................................................................................... 47
Fuel System Installation................................................................................................................ 49
Fuel System Installation................................................................................................................ 50
Radiator Installation (S 3.8 G3/G4/G6)......................................................................................... 53
Radiator Installation (S 3.8 G7)..................................................................................................... 55

Page 4 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

SECTION A
(Base Engine Parts)

2010 Copyright Cummins Power Generation Page 5

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

“Intentionally Left Blank”

Page 6 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Alternator

2
5

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0191- 2532 ALTERNATOR ASSLY 1 12V 35 AMP

2 0191- 2533 BRACKET - ALTERNATOR 1

3 A034J202 ROD - THREADED 1

4 A034J208 NUT - LOCK 1

5 A034J197 BOLT- HEX HD 1

6 A034J196 BOLT- HEX HD 2

2010 Copyright Cummins Power Generation Page 7

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Cam Shaft & Rocker Arm

27 28
12
13
10
15
16
15
26 20

30
19
9
11
14
17 18
8 21

24
7
29 23 5
22

4
3
25
6 2

Page 8 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Cam Shaft & Rocker Arm

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0105- 0790 CAMSHAFT ASSLY WITH CYL PIN 1

2 0507- 0044 GEAR SPUR 1

COMPLETE SET OF CAMSHAFT
3 0105- 0791 BEARING CAMSHAFT 1
BUSHES
4 0105- 0792 SHIM CAMSHAFT 1
5 0406- 1243 KEY LOCK 1
6 0323- 2690 HOUSING PIN 1
7 0115- 0572 TAPPET 8
8 0115- 0573 PUSH ROD 8
9 0115- 0574 SHAFT ROCKER ARM 4 RKR LEVER ASSY LEFT
10 0115- 0575 SHAFT ROCKER ARM 4 RKR LEVER ASSY RIGHT
11 0508- 1347 BUSHING 8 INCKUDED IN SR NO 9 & 10
12 0115- 0576 NUT TAPPET 8
13 0506- 0062 SPRING COMPRESSION 3
14 0115- 0577 SHAFT ROCKER ARM 1
15 0800- 6555 SCREW HEX HD 3
16 0800- 6556 SCREW HEX HD 1
17 0518- 0828 CLIP SPRING 2
18 0110- 4149 SPRING VALVE 8
19 0406- 1244 RETAINER SPRING 8
20 0406- 1245 RETAINER SPRING 16 COLLETS
0541- 1729 VALVE KIT 1 G3-CPCB
21
0541- 1769 VALVE KIT 1 G4/G6/G7-CPCB
22 0115- 0586 BRACKET- ROCKER ARM (NO 1) 1
23 0115- 0588 BRACKET- ROCKER ARM (NO 2&3) 2
24 0115- 0587 BRACKET- ROCKER ARM (NO 4) 1
25 0800- 6594 SCREW HEX HD 4
26 0115- 0585 TAPPET ADJUSTER 8
27 0506- 0065 SPRING- COMPRESSION 1
28 0505- 2558 NIPPLE- PIPE 1
29 0815- 1606 SCREW- DRIVER (GRUB) 1
30 0506- 0066 SPRING- COMPRESSION 2
— 0526- 2427 WASHER- FL 8 FOR VALVE SPRING

2010 Copyright Cummins Power Generation Page 9

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

“Intentionally Left Blank”

Page 10 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Connecting Rod Assembly

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0114- 0457 CONNECTING ROD 4

2 0114- 0458 CONNECTING ROD BUSH 1 (SET OF 4 BUSHES)

3 0114- 0459 BOLT CONNECTING ROD 8

4 0114- 0460 BUSHING CONN ROD 1 (SET OF CR BEARINGS)

2010 Copyright Cummins Power Generation Page 11

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Cooling System

14

13
12

13
16
11

15

4
3

7
2
10

Page 12 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Cooling System

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0132- 0528 PUMP WATER ASSLY 1

2 0512- 0452 PULLEY 1

3 0130- 8413 SPACER FAN 1

4 0205-0390 FAN RADIATOR 1

5 0511- 0260 BELT DRIVE 1

6 0132- 0532 GASKET-WATER PUMP 1

7 0800- 6604 SCREW-HEX HD 4

8 0155- 5062 GASKET- FLANGE 2

9 0406- 1254 PLATE- LOCK 3

10 0512- 0458 SCREW-HEX HD 6

11 0130- 8460 TUBE-WATER (Assly) 1

12 0503- 3178 HOSE COOLANT 1

13 0503- 3195 CLAMP- HOSE 2

14 0130- 8415 THERMOSTAT 1

15 0503- 3179 HOSE COOLANT 1

16 0503- 3036- 02 CLAMP 2

2010 Copyright Cummins Power Generation Page 13

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

“Intentionally Left Blank”

Page 14 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Crankshaft

7
8

1
2

5 4

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0104 -2190 CRANKSHAFT ASSLY 1

2 0507- 0045 GEAR SPUR 1

3 0406- 1246 KEY LOCK 2

4 0512- 0453 PULLEY 1

5 0800- 6557 SCREW HEX HD 1

6 0509- 0561 SEAL SHAFT 2

7 0510- 0272 THRUST BEARING 1 [SET]

8 0104- 2191 SET BEARING- CRANKSHAFT (STD) 1

9 0516- 2155 PIN- DOWEL 1

2010 Copyright Cummins Power Generation Page 15

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Cylinder Block
17
9
2
18
23

15

1
22

21
26
16

14 13

5
20 4
19

3
8 12
7 6

10

25

24

11

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0110- 4158 BLOCK CYLINDER 1

CYLINDER LINER OD FIN-

2 0110- 4143 4 HONING IS REQUIRED
ISHED / ID SEMIFINISHED

3 0800- 6558 SCREW HEX HD 10

4 0103- 0870 GEARCASE 1

5 0130- 0871 GASKET GEARCASE 1

6 0103- 0872 COVER GEARCASE 1

Page 16 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Cylinder Block

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

7 0509- 0562 SEAL SHAFT 1

8 0103- 0873 GASKET GEARCASE 1

9 0115- 0578 SHIELD PUSH ROD 1

10 0102- 1580 PAN OIL 1

11 0517- 0457 PLUG DRAIN 1

12 0102- 1591 GASKET OIL BASE 1

13 0526- 2428 WASHER- FL 1

14 0517- 0470 PLUG- CAP 1

15 0502- 1735 SLEEVE- TUBE 1

16 0502- 1736 SLEEVE- TUBE 1

17 0516- 2157 PIN-DOWEL 2

18 0516- 2158 PIN- DOWEL 2

19 0516- 2159 PIN- DOWEL 12

20 0800- 6597 SCREW- HEX HD 3

21 0234- 1113 GASKET- COVER 1

22 0130- 8463 COVER- GUARD 1

23 0526- 2429 WASHER- FL 3

24 0526- 2428 WASHER- FL 1

25 0800- 6599 SCREW- HEX HD (COMBI) 12

26 0123- 2436 BREATHER CRANKCASE 1

— 0509- 0576 SEAL- O RING 1

— 0516- 2156 PIN-DOWEL 4

— 0800- 6596 SCREW- HEX HD (COMBI) 3

Gasket Set

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

— 0541- 1731 GASKET KIT (OVERHAUL) 1 COMPLETE SET OF GASKETS

2010 Copyright Cummins Power Generation Page 17

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Cylinder Head

2 7
3

6
13
9

1
12

11
10

14
4
5

Page 18 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Cylinder Head

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

0110-4150 HEAD CYLINDER ASSLY WITH VALVES 1 G3

1
0110-4172 HEAD CYLINDER ASSLY WITH VALVES 1 G4/G6/G7

2 0110-4152 GUIDE VALVE INLET STD 4 G4/G6/G7

0110-4167 GUIDE-VALVE EXHAUST STD 4 G4/G6/G7

3
0110-4181 GUIDE-VALVE EXHAUST STD 4 G3

0110-4156 SEAT-VALVE INLET 4 G3

4
0110-4183 RING VALVE SEAT INLET 4 G4/G6/G7

5 0110-4157 RING VALVE SEAT EXHAUST 4 COMMON TO ALL

6 0520-2699 STUD 17

7 0860-2139 NUT HEX 17

8 0110-4159 GASKET CYLINDER HEAD 1

9 0134-5408 COVER CYLINDER HEAD 1

10 0154-3307 GASKET MANIFOLD 1

11 0520-2704 STUD 2

12 0509-0573 SEAL-O RING 4 G4/G6/G7

13 0502-1737 SLEEVE TUBE (PROTECTIVE) 4 G4/G6/G7

14 0234-1116 GASKET COVER 1

GUIDE VALVE SEAL
— 0110-4175 4 G4/G6/G7
EXHAUST (STEM SEAL)

— 0110-4182 GUIDE VALVE SEAL EXHAUST 4 G3

GUIDE VALVE SEAL
— 0110-4174 4 G4/G6/G7
INLET (STEM SEAL)

GUIDE VALVE SEAL

— 0110-4178 4 G3
INLET (STEM SEAL)

— 0159-1741 CAP FILLER 1

2010 Copyright Cummins Power Generation Page 19

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Dipstick Arrangment

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0123-2437 DIPSTICK OIL 1

2 0123-2438 TUBE OIL 1

3 0505-2550 FLANGE PIPE 1

4 0155-5040 GASKET FLANGE 1

Page 20 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Exhaust Manifold

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

0154-3308 MANIFOLD EXHAUST 1 G3

1
0154-3310 MANIFOLD EXHAUST 1 G4/G6/G7

2 0154-3309 GASKET MANIFOLD 1

3 0155-5074 GASKET EXHAUST TC TO MANIFOLD 1 G4/G6/G7

2010 Copyright Cummins Power Generation Page 21

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

8
Fuel Filter 3
9
6

4
7

6
1
7

6
5

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0148-1394 BRACKET FUEL FILTER 1

2 0149-2967 ELEMENT FUEL FILTER 1

3 0122-0973 HEAD-FILTER 1

4 0501-1182 LINE FUEL 1 FUEL FILTER TO FIP

5 0501-1181 LINE FUEL 1 FEED PUMP TO FUEL FILTER

6 0502-1625 BOLT-BANJO (M14) 3

7 0509-0495-02 WASHER-SEALING 6

8 0502-1624 BOLT-BANJO (M12) 1

9 0509-0495-01 WASHER-SEALING 2

10 0800-6594-62 SCREW-HEX HD 2

11 0526-2400-31 WASHER-FL 2

Page 22 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Fuel Injection Pump

1

5
3

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

0501-1152 LINE FUEL 1 G4/G6/G7

1
0501-115 1 LINE FUEL 1 G3

2 0149-2940 FEED PUMP 1 G3/G4/G6/G7

3 0149-2953 GASKET FIP SUPPORT 1

0149-2939 PUMP FUEL 1 G3

0149-2937 PUMP FUEL 1 G4

4
0149-2936 PUMP FUEL 1 G6

0149-2938 PUMP FUEL 1 G7

5 0507-0055 GEAR-SPUR 1 FIP DRIVE

2010 Copyright Cummins Power Generation Page 23

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Flywheel

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

0104-2193 FLYWHEEL ASSLY WITH RING GEAR 1 SAE - 10 G4/G6/G7

1
0104-2206 FLYWHEEL ASSLY WITH RING GEAR 1 SAE - 10 G3

2 0507-0047 GEAR RING 1

3 0104-2194 HOUSING FLYWHEEL 1 SAE - 3

— 0406-1252 PLATE-LOCK 4

— 0800-6612 SCREW-HEX HD 8

Page 24 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Injector

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

0147-1002 INJECTOR FUEL 4 G3 - CPCB

1
0147-1003 INJECTOR FUEL 4 G4/G6/G7 - CPCB

2010 Copyright Cummins Power Generation Page 25

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Lubrication System

12

11

5 6

9
4
10

Page 26 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Lubrication System

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0120-0963 HEAD-FILTER 1

2 0122-0962 ELEMENT-OIL FILTER 1

3 0122-0960 GASKET OIL FILTER 1

4 0102-1582 COOLER OIL 1

5 0102-1583 GASKET OIL BASE 1

6 0102-1594 COVER-OIL COOLER 1

7 0509-0585 WASHER-SEALING 4

8 0526-2425 WASHER-FL (SEAL) 8

9 0800-6608 SCREW-HEX HD 8

10 0800-6609 SCREW-HEX HD 27

11 0102-1584 GASKET-OIL BASE 1

12 0120-1405 PUMP-OIL ASSEMBLY 1

2010 Copyright Cummins Power Generation Page 27

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Piston Assembly

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0112-0353 PISTON SET 1 (PISTON - 4 + PIN - 4 + CIRCLIP - 8)

2 0541-1761 RING SET PISTON 1 (TOP - 4 MIDDLE - 4 + OIL RING - 4)

Page 28 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Starter

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0191-2534 STARTER MOTOR 1

2010 Copyright Cummins Power Generation Page 29

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Turbocharger

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

4038834 TURBOCHARGER 1 G4/G6

1
4036823 TURBOCHARGER 1 G7

2 0505-2574 CROSS PIPE 1 G4/G6

3 0503-3202 HOSE AIR 1 G4/G6/G7

4 0503-3203 CLAMP HOSE 2 G4/G6/G7

— 0502-1744 ADAPTER HOSE 1 G4/G6/G7

— 0503-3201 CLAMP HOSE 2

— 0123-2449 TUBE OIL 1 G4/G6/G7

— A040G639 HOSE OIL 1 G4/G6/G7

Page 30 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

SECTION B
(Upfit Parts)

2010 Copyright Cummins Power Generation Page 31

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

8
Air Cleaner (S 3.8 G4/G6/G7)

3
5

11 4
9
10

1
4

6
2
7

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0140- 4310 BRACKET AIR CLEANER 1

2 0800- 6520- 56 SCREW HEX FLG HD 2 M12 X 1.75 X 25L

3 0140- 4311 AIR CLEANER 1

4 0526- 2400- 28 WASHER FL 8 M10

5 0800- 6494- 45 SCREW HEX HD 4 M10 X 1.5 X 30L

6 0850- 2114- 11 WASHER SPR LK 4 M10

7 0860- 2127- 13 NUT HEX 4 M10 X 1.5

8 0140- 4323- 01 INDICATOR SERVICE 1

9 0503- 3152 HOSE AIR 1

10 0503- 2923 CLAMP HOSE 1

11 0502- 1721 CLAMP TUBE 1

Page 32 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

8
Air Cleaner (S 3.8 G3)

2 5

4
9
11 10 12

4
6
7
3

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0140- 4308 BRACKET AIR CLEANER 1

2 0140- 4211 AIR CLEANER 1

3 0800- 6520- 56 SCREW HEX FLG HD 2 M12 X 1.75 X 25L

4 0526- 2400- 28 WASHER FL 8 M10

5 0800- 6494- 44 SCREW HEX HD 4 M10 X 1.5 X 25L

6 0850- 2114- 11 WASHER SPR LK 4 M10

7 0860- 2127- 13 NUT HEX 4 M10 X 1.5

8 0140- 4213 INDICATOR SERVICE 1

9 0130- 8358 TUBE AIR 1

10 0503- 3173 ELBOW HOSE 1

11 0503- 2923 CLAMP HOSE 1

12 0503- 3163- 03 CLAMP HOSE 1

2010 Copyright Cummins Power Generation Page 33

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Control Installation

6
6

2
3

4
5

Page 34 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Control Installation

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0193- 0610 TRANSDUCER 1

2 0505- 2544 BUSHING REDUCER 1

3 0309- 0714 SWITCH PRESSURE 1

4 0193- 0609 SENSOR TEMPERATURE 1

5 0309- 0741 SWITCH TEMPERATURE 1

6 A032X741 COIL (ELECTRICAL) 1

7 0338- 5117 HARNESS SWITCH (NOT SHOWN) 1

2010 Copyright Cummins Power Generation Page 35

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Control Panel & Electrical Parts

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0307- 3197 RELAY CONTROL 1

2 0300- 6445 CONTROL ASSLY (PS 500) 1

3 0315- 1658- 02 TRANSFORMER CURRENT 3 (S 3.8 G6/G7)

— A030X919 HARNESS ENGINE 1

— 0338- 5324 HARNESS AC 1

— 0338- 5325 HARNESS TRANSFORMER 1

— 0338- 5350 HARNESS TRANSFORMER 1

— AO26M768 MANUAL OPERATION 1

Page 36 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Control Panel & Electrical Parts

1 2

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

— 0541- 1695 CONTROL BOX KIT 1

1 0300- 6357- 01 CONTROL (PCC 0301) 1

2 0302- 2096- 06 MULTIFUNCTION - METER 1

— 0338- 5014 HARNESS-CONTROL PANEL 1

— 0315- 1779 TRANSFORMER - CURRENT 3

— 0307- 3190 RELAY-CONTROL 2

2010 Copyright Cummins Power Generation Page 37

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Engine Installation (S 3.8 G3)

2
3

Page 38 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Engine Installation (S 3.8 G3)

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0100- 4202 ENGINE DIESEL 1

2 0099- 2601 NAMEPLATE ENGINE 1

3 0818- 1181- 01 RIVET RND HD BLIND 2

4 0099- 2604 NAMEPLATE CONTROL 1

5 0503- 3099- 01 HOSE FUEL 1

6 0504- 0319 VALVE BALL 1

7 0517- 0443- 02 PLUG DRAIN 1

2010 Copyright Cummins Power Generation Page 39

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Engine Installation (S 3.8 G4)

4
1

2
3

1 5

Page 40 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Engine Installation (S 3.8 G4)

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0100- 4203 ENGINE DIESEL 1

2 0099- 2601 NAMEPLATE ENGINE 1

3 0818- 1181- 01 RIVET RND HD BLIND 2

4 0099- 2604 NAMEPLATE CONTROL 1

5 0503- 3099- 01 HOSE FUEL 1

6 0504- 0319 VALVE BALL 1

7 0517- 0443- 02 PLUG DRAIN 1

2010 Copyright Cummins Power Generation Page 41

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Engine Installation (S 3.8 G6)

4

2
3

5
1

Page 42 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Engine Installation (S 3.8 G6)

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0100- 4204 ENGINE DIESEL 1

2 0099- 2601 NAMEPLATE ENGINE 1

3 0818- 1181- 01 RIVET RND HD BLIND 2

4 0099- 2604 NAMEPLATE CONTROL 1

5 0503- 3099- 01 HOSE FUEL 1

6 0504- 0319 VALVE BALL 1

7 0517- 0443- 02 PLUG DRAIN 1

2010 Copyright Cummins Power Generation Page 43

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Engine Installation (S 3.8 G7) 4

2
3

Page 44 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Engine Installation (S 3.8 G7)

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0100- 4205 ENGINE DIESEL 1

2 0099- 2601 NAMEPLATE ENGINE 1

3 0818- 1181- 01 RIVET RND HD BLIND 2

4 0099- 2604 NAMEPLATE CONTROL 1

5 0503- 3099- 01 HOSE FUEL 1

6 0504- 0319 VALVE BALL 1

7 0517- 0443- 02 PLUG DRAIN 1

2010 Copyright Cummins Power Generation Page 45

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Exhaust Installation (S 3.8 G3)

3

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0155- 5027 PIPE EXHAUST 1

2 0155- 4776 CLAMP EXHAUST 1

3 0155- 4779 PIPE EXHAUST 1

Page 46 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Exhaust Installation (S 3.8 G4/G6/G7)

3

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0155- 5028 PIPE EXHAUST 1

2 0155- 4776 CLAMP EXHAUST 1

3 0155- 4779 PIPE EXHAUST 1

2010 Copyright Cummins Power Generation Page 47

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

“Intentionally Left Blank”

Page 48 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Fuel System Installation

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0146- 0898- 02 FUEL SYSTEM (ASSLY) 1

2010 Copyright Cummins Power Generation Page 49

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Fuel System Installation

23
8
9
7

10
16
4 15
14
12
11
5 17

3 13
25
22 2
24

19

6
20
18

21

Page 50 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Fuel System Installation

Item Part No. Description Qty

1 A040M834 ADAPTER,HOSE 1
2 A041U699 HOSE,FUEL 2
3 A040M819 STRAINER,FUEL 1
4 A040P511 TUBE,FUEL SUPPLY 1
5 A041W261 CLAMP,HOSE 4
6 A041U705 BRACKET,FUEL FILTER 1
7 0122-0961 FILTER,OIL 1
8 A041U895 ADAPTER,FUEL LINE 2
9 A041W194 WASHER SEALING 1
10 A041V988 BRACKET 1
11 0503-3097-01 CLAMP,HOSE 1
12 A041W269 HOSE,FUEL 1
13 A041W192 TUBE,FUEL SUPPLY 1
14 0526-2400-22 WASHER,FLAT 1
15 0850-2114-07 WASHER,LOCK 1
16 0800-6494-10 SCREW,HEX HEAD 1
17 0860-2127-09 NUT,HEX 1
18 0800-6520-40 SCREW,HEX FLANGE HEAD 2
19 0800-6520-11 SCREW,HEX FLANGE HEAD 2
20 0503-3097-03 CLAMP,HOSE 1
21 0800-6520-37 SCREW,HEX FLANGE HEAD 1
22 0509-0495-02 WASHER,SEALING 4
23 A034T522 HOSE,FUEL 1
24 0502-1625 BOLT,BANJO 2
25 0149-2952 FILTER,FUEL 1

2010 Copyright Cummins Power Generation Page 51

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

“Intentionally Left Blank”

Page 52 2010 Copyright Cummins Power Generation

Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Radiator Installation (G3,G4,G6)

8
14 13
9

12

15 2

16 17

18

11
10

5
6 4
7

2010 Copyright Cummins Power Generation Page 53

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Radiator Installation (S 3.8 G3, G4, G6)

G3,G4,G6)

Item Part No. Description Qty

1 0420-0970 ISOLATOR,VIBRATION 1
2 A034C259 RADIATOR 1
3 0130-8449 BRACKET,RADIATOR 1
4 0800-6520-46 SCREW,HEX FLANGE HEAD 2
5 0526-2401-10 WASHER,FLAT 2
6 0850-2114-11 WASHER,LOCK 2
7 0860-2127-13 NUT,HEX 2
8 0503-3153 HOSE,VACUUM 1
9 0503-2926 CLAMP 6
10 0503-3155-01 HOSE,COOLANT 2
11 0130-8365 TUBE,WATER 1
12 0130-8409 TANK, COOLANT 1
13 0503-3211 HOSE COOLANT 1
14 0130-8406 PRESSURE CAP 1
15 0130-8412 SHROUD FAN 1
16 0130-5406 GUARD FAN 1
17 0130-8479 GUARD RADIATOR 1
18 0517-0456 PLUG DRAIN 1
 Publication A024J829 Parts Manual
Issue 4 - 5 - 2012 Model: S 3.8 G3, G4, G6, G7

Radiator Installation (S 3.8 G7)

23
22

2
14

4 13

14
4 8

15
10 7
20
21 23
12
22
10
11
19
18
10
20
21

13

2010 Copyright Cummins Power Generation Page 55

Parts Manual Publication A024J829
Model: S 3.8 G3, G4, G6, G7 Issue 4 - 5 - 2012

Radiator Installation (S 3.8 G7)

Sr.No PART NO. PART DESCRIPTION QTY REMARKS

1 0130- 8401 FAN- RADIATOR 1

2 0130- 8492 RADIATOR 1

3 0130- 8398 TUBE- WATER 1

4 0503- 3170 HOSE- VACUUM 2

5 0130- 8266- 02 BRACKET- TUBE 1

6 0130- 8403- 01 TUBE- AIR 1

7 0130- 8363- 02 TUBE- AIR 1

8 0130- 8359 TUBE- AIR 1

9 0505- 2545 PLUG- PIPE 1

10 0526- 2400- 28 WASHER- FL 14 M10

11 0800- 6494- 44 SCREW- HEX HD 2 M10 X 1.5 X 25L

12 0130- 8355 BRACKET- TUBE 1

13 0503- 3151 ELBOW- HOSE 2

14 0503- 3094 CLAMP- HOSE 8

15 0502- 1724 CLAMP- TUBE 2

16 0526- 2400- 31 WASHER- FL 4 M12

17 0800- 6494- 46 SCREW- HEX HD 4 M10 X 1.5 X 35L

18 0850- 2114- 11 WASHER- SPR LK 6 M10

19 0860- 2127- 13 NUT- HEX 6 M10 X 1.5

20 0526- 2400- 25 WASHER- FL 4 M8

21 0800- 6494- 27 SCREW- HEX HD 4 M8 X 1.25 X 25L

22 0850- 2114- 09 WASHER- SPR LK 4 M8

23 0860- 2127- 11 NUT- HEX 4 M8 X 1.25

24 0503- 3155- 01 HOSE- COOLANT 1

25 0503- 2926 CLAMP- HOSE 4

Page 56 2010 Copyright Cummins Power Generation

Cummins India Limited
Power Generation Business Unit
35 A/1/2, Erandawana,
Pune 411 038 India
Tel (91) 020 - 3024 8600
Fax (91) 020 - 6602 8090
www.cumminsindia.com
®
Cummins , the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
©2012 Cummins Power Generation, Inc. All rights reserved.