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Diesel & Gas Engine Assembly

Diesel & Gas Engine Assembly
What is Diesel Engine Assembly

 

Diesel engine assembly refers to the process of assembling various components of a diesel engine into a complete functional unit. It involves putting together major engine components such as the piston, connecting rod, crankshaft, cylinder head, camshaft, and fuel injectors. The process may include machining, inspection, cleaning, and testing of individual components before they are assembled. The final step in the diesel engine assembly involves testing the complete engine to ensure it meets performance and emissions standards.

Main models and applications

Model and power

main purpose

Mainstream supporting equipment models

NTA855(14L inline 6-cylinder, mechanical PT pump) 240–400HP（179–298kW）

Diesel generator set
Model suffix NTA855-G

Bulldozer: Shantui SD22, SD23; Komatsu D85; Xuanhua SD7

Construction machinery (non road)
The suffix NTA855-C

Loader: LiuGong ZL50, XuGong 50 series old models; Xiagong 951

Ship Power
Suffix NTA855-M

Generator set: Yuchai, Weichai, Cummins joint venture 200-320kW unit

Industrial Drive Power (P-type)
NTA855-P

Ships: Various domestic 300 horsepower fishing boats, coastal small workboats

KTA19 (19L inline 6-cylinder, mechanical PT, K series first generation) 450-700HP (336-522kW)

Generator set: 400-560kW mining, oil field, and field engineering power stations; KTA19-G

Mining card: old models of Bilis 7555D, Tongli Heavy Industry, and XCMG medium-sized mining cards

Construction machinery/mining: medium-sized mining trucks, large loaders, roller drills, cementing equipment; KTA19-C

Drilling rigs: roller drilling rig, water well drilling rig, oilfield cementing truck

Ship main/auxiliary engines: offshore fishing boats, tugboats, and transport ships; KTA19-M

Ship: 450-600 horsepower coastal engineering ship, offshore fishing boat

Oil and gas equipment: fracturing pump, drilling auxiliary power

  

KTA38 (38L V12, mechanical PT)
Power range: 800-1350HP (597-1007kW)

Generator set: 800-1120kW large factory area, data center backup, offshore platform auxiliary equipment; KTA38-G

Mining trucks: Belas 75131, XCMG, old models of three to one hundred ton mining trucks

Heavy mining equipment: large mining dump trucks, electric shovel auxiliary power, large crushing stations; KTA38-C

Engineering vessels: 800-1200 horsepower tugboats, supply ships

Ship power: Port tugboats, traffic boats, fuel supply ships, and offshore engineering ships; KTA38-M

Large mobile crushing stations, large air compressors

Oil and gas: power and fracturing units for large drilling platforms

  

KTA50 (50L V16, mechanical PT)Power range: 1350-2200HP (1007-1640kW)

Generator set: 1200-1800kW large industrial main power supply, island power station, offshore platform; KTA50-G

Mining cards: Belas 75306, 7540; Large 150-220 ton mining dump truck

Ultra heavy mining equipment: mining trucks of over 100 tons, large open-pit electric shovel power; KTA50-C

Port operation of high-powered tugboats and offshore engineering supply ships

High power vessels: high-powered tugboats, ocean going supply ships, fishery management ships; KTA50-M

  

Main driving force for oil and gas drilling

  
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NTA855 KTA19 KTA38 KTA50 Common faults

Hard starting, especially cold start

1.PT fuel pump internal wear, low fuel supply pressure

2.Clogged fuel filter, air ingress in fuel line, excessive water in fuel separator

3.Sticking fuel injectors, incorrect valve lash

4.Low cylinder compression pressure, worn piston rings

Lack of power, black smoke under heavy load

1.Severe clogged air filter

2.Insufficient fuel delivery from PT pump, poor injector atomization

3.Turbocharger carbon deposit, low boost pressure

4.Valve leakage, exhaust manifold leakage

Unstable idle speed, engine hunting

1.Worn governor assembly inside PT pump

2.Continuous air entering fuel circuit

3.Malfunction of individual cylinder injector

4.Excessive deviation of valve clearance

High oil consumption, light blue smoke

1.Worn valve stem seals, piston rings

2.Oil leakage from turbocharger oil seal

3.Blocked crankcase breather, high crankcase pressure

 

Why choose us
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Customer Service

We earn your respect by delivering on time and on budget. We built our reputation on exceptional customer service. Discover the difference it makes.

Fuel Injectors 3016675 3016676

World-Wide Expertise

We know international markets and trends. Our expertise, experience and network cover all corners of the world.

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Commitment To Quality

We're committed to quality and concrete actions. That means we always deliver solutions in a professional and practical way.

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The company's business philosophy

People-oriented, quality first, sincere communication, honest management, and the spirit of continuous innovation, dare to challenge, self-reflection and self-revolution, provide customers with professional products and services.

 

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Types of Diesel Engine Assembly

 

 

QSK60（60L V16）

Common ordering models
1. Power generation - G QSK60-G4, G10; Commonly used 1470-1630kW, backup 1620-1800kW
2. Mining Machine - C QSK60-C2500
3. Ship Machine - M QSK60-M2250

QSK50 (50.3L V16, replacing KTA50)

Common ordering models
1. Power generation - G QSK50-G4; Commonly used 1180-1320kW, backup 1300-1470kW
2. Mining Machine - C QSK50-C1800, C2000
3. Ship Machinery - M QSK50-M1600, M1800

QSK38 (38L V12, replacing KTA38)

Common ordering models
1. Power generation - G QSK38-G20, G28; Commonly used 920-1020kW, backup 1010-1130kW
2. Mining Machine - C QSK38-C1350
3. Ship Machinery - M QSK38-M1000, M1250

KTA50 (50.3L V16, mechanical PT)

Common ordering models
1. Power generation - G KTA50-G3, G8, G9, G12A; Commonly used 1100-1250kW, spare 1220-1380kW
2. Mining Machine - C KTA50-C1600, C1800
3. Ship Machinery - M KTA50-M1600, M1875

 

 
Main components of Cummins engine
 
01/

Engine Block: The Engine Block is made of plates and castings which are welded both vertically and horizontally to increase strength and lend more support to the engine cylinder liners, crankshafts, and heads.

02/

Bedplate: This is a metal plate that forms the foundation on which the diesel engine is built. The design and construction of the bedplate must be stable and durable enough to provide support to the engine and the crankshaft.

03/

Cylinder Liners:A type of bore where an engine piston moves back and forth and is made of material strong enough to handle high heat and tremendous pressure.

04/

Valves:These are located on the cylinder head and are responsible for the diesel engine's smooth functioning. It does this by regulating the flow of air fuel mixture inside the cylinder and by exhausting gas outside the cylinder.

05/

Valve Guides:A cylindrical-shaped piece of metal that conducts heat from the combustion process by processing it out of the exhaust valve and into the cylinder head.

06/

Piston: This diesel engine component compresses the air fuel mixture then converts fuel energy into mechanical energy. The power is then transmitted to the Crankshaft.

Application of Cummins QSK Electronic Control Series
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QSK19 (19L straight 6, electronic control, replacing KTA19)
Power: 506-800HP (377-597kW)
Purpose
1. Generator set QSK19-G: 450-640kW, data center, industrial backup power supply
2. Non road mining machine QSK19-C: medium-sized mining trucks, large loaders, roller drills, mobile crushers
3. Ship engine QSK19-M: Offshore workboats, yachts, fishing boats, ship auxiliary equipment
4. Oil and gas equipment, large water pump units
Mainstream supporting facilities
Sany, XCMG, and Lingong medium-sized mining trucks; Mountain bulldozer with high horsepower; Internationally renowned drilling rig manufacturer; Imported/Domestic High end Generator Sets

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QSK38 (38L V12, electronic control, replacing KTA38)
Power: 1000-1600HP (746-1193kW)
Purpose
1. Power generation QSK38-G: 900-1400kW high-end backup power supply, IDC data center, hospital, overseas power station
2. Heavy duty mining machine QSK38-C: 100-150 ton ore trucks, open-pit mining equipment, large loaders
3. Ship QSK38-M: IMO Tier II/III marine main engine, marine auxiliary ship, tugboat
4. Large fracturing equipment and large pumping stations
matching
Sany, XCMG, and Northern Heavy Industries' 100 ton mining trucks; Large scale mobile crushing station; High end silent generator sets both domestically and internationally; Marine vessels.

 
Fuel Filter 2
 

QSK50 (50L V16, electronic control, replacing KTA50)
Power: 1600-2500HP (1193-1864kW)
Purpose
1. Power generation QSK50-G: 1400-2200kW large-scale hub and island continuous main power supply
2. Super heavy mining QSK50-C: 180-240 ton large mining trucks and large electric shovels with auxiliary power
3. High power ship QSK50-M: ocean supply ship, high power tug, marine factory ship
4. Large scale drilling equipment on land
matching
Belas, Sany, XCMG 200 ton heavy-duty mining trucks; Offshore platform auxiliary equipment and high-power engineering vessels.

 
Cylinder Head 3
 

QSK60 (60L V16, Cummins flagship with high displacement, no corresponding traditional KTA model)
Power: 2250-3000HP (1678-2237kW)
Purpose
1. Generator set QSK60-G: 2000-2500kVA, suitable for ultra large data centers, large chemical plants, overseas large power stations, and continuous operation main power supply
2. Super large open-pit mining equipment QSK60-C: 240-360 tons top-level mining dump trucks and giant mining equipment
3. Ship QSK60-M: large offshore factory ship, ocean tug, platform supply ship (PSV)
Positioning: Currently, Cummins' high displacement non road flagship is mainly used in ultra large mines, high-power power stations, and high-end marine engineering.
auxiliary equipment
Extra large mining trucks such as Belas 75710 (450 ton class), Sany SR400, XCMG XDE400, etc

 
Maintenance Tips for Diesel Engine Assembly

 

Regular Oil Changes

Diesel engines require regular oil changes to prevent wear and tear of the engine components. Change the oil and oil filter at regular intervals as recommended by the manufacturer.

Fuel Filter Replacement

The fuel filter prevents debris from entering the diesel engine. A dirty or clogged fuel filter can affect the performance of the engine. Replace the fuel filter at regular intervals as per the manufacturer's recommendations.

Check for Leaks

Check for oil and fluid leaks and repair them immediately. Leaks can cause a loss of engine oil, coolant, or hydraulic fluid leading to engine damage.

Air Filter Replacement

Clean or replace the air filter as per manufacturer recommendations. A clogged air filter can restrict the air flow and reduce engine performance.

Battery Maintenance

Check battery voltage regularly and keep the battery clean. Replace the battery if it shows signs of deterioration or weakness.

Warm-up and Cool-down

Allow the engine to warm up before driving the vehicle. Also, allow the engine to cool down after driving before turning it off. This helps prevent engine damage and premature failure.

Certifications

 

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Our Factory

 

 

We have sufficient inventory, short delivery time, reliable quality and favorable price, which is the professional backing for us to quote quickly and provide high-quality products. And long-term after-sales service is another advange of us.

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FAQ

Q: What causes diesel engine failure to start?

A: If your diesel engine won't start, the problem could be the amount of pressure in the fuel system. The engine may not start if the fuel pressure is too low. Fuel pressure that is too high can cause damage to the exhaust system while also increasing soot pollution in the exhaust.

Q: What causes a diesel engine to overheat?

A: Worn-out hoses, clogged radiators, and thermostats that are stuck open are all examples of parts that can cause your engine to overheat. If you notice any of these issues, be sure to have them fixed as soon as possible by a qualified mechanic.

Q: What is the basic structure of a diesel engine?

A: Most modern diesel engines use the conventional cylinder and piston arrangement operated with a slider crank mechanism common to other internal combustion engines such as the gasoline engine. Considering this basic mechanism, there is very little difference between the basic structure of diesel and gasoline engines.

Q: What is the most important fuel system component of a diesel engine?

A: Diesel fuel injectors are arguably the most important fuel system component. The job of the injectors is to deliver a precise amount of atomized and pressurized fuel into each cylinder.

Q: What does a diesel engine need to run?

A: A diesel engine takes air, compresses it, and then injects fuel into the compressed air. The heat of the compressed air ignites the fuel spontaneously. A diesel engine does not contain a spark plug.

Q: What causes fuel starvation on diesel engine?

A: Drawing fuel under vacuum means the fuel pump is pulling at negative pressure, which causes the formation of vapor in fuel, and can starve the engine for fuel, especially during hard accelerations.

Q: Why do diesel engines airlock?

A: When you change a diesel fuel filter, run out of fuel or disturb the fuel system, air is trapped. When you try to start the engine this air acts as a lock, preventing the normal supply of fuel into the cylinder.

Q: How does temperature affect diesel engines?

A: In general it shows that the temperature increases will decrease the SMD, this is due to the effect on the viscosity and the shape of the fuel during break up. From some researches above, it can be concluded that the fuel temperature affects the combustion process in diesel engine.

Q: What temperature is hot for a diesel engine?

A: Generally, the operating temperature of an engine should be between 190-220 degrees. Temperatures above that range will put stress on the cylinder head, cylinder liners and engine block.

Q: What is the cooling system in a diesel engine?

A: Most diesel engines use a closed loop jacket type cooling system. Coolant flows through the engine absorbing heat from the cylinder liners, cylinder heads, and other engine components.

Q: What is the main function of the diesel engine?

A: Diesel engines, like gas engines, are internal combustion engines that convert chemical energy into mechanical energy. This process moves pistons up and down inside cylinders, which then leads to the motion that turns the wheels of a vehicle.

Q: Why is compression ratio high in diesel engines?

A: Diesel engines use higher compression ratios than petrol engines, because the lack of a spark plug means that the compression ratio must increase the temperature of the air in the cylinder sufficiently to ignite the diesel using compression ignition.

Q: What is the cause of unburned diesel?

A: A few reasons for this issue could be an engine that isn't hot enough to burn the fuel, low compression in the cylinder, issues with the fuel injectors, a clogged air filter, burnt-out glow-plugs, or the use of low-quality fuel.

Q: Why do diesel engines need bleeding?

A: As you know, diesel engines operate under extremely high fuel pressure. When fuel runs dry, air gets sucked into the system, and it must be vented (bled) out. Adding fuel is the first step, and bleeding the lines and injectors immediately follows.

Q: What is the difference between open and closed cooling system of diesel engine?

A: Closed system is designed to use the same coolant with a closed circuit, preventing the losses of the coolant. While the open system uses the coolant once and discharges it or recirculates the coolant through systems, which cool the coolant by evaporation.

Q: What technology is used in the diesel engine?

A: Diesel engines are sometimes called compression-ignition engines because initiation of combustion relies on air heated by compression rather than on an electric spark. In a diesel engine, fuel is introduced as the piston approaches the top dead centre of its stroke.

Q: Why do diesel engines airlock?

A: When you change a diesel fuel filter, run out of fuel or disturb the fuel system, air is trapped. When you try to start the engine this air acts as a lock, preventing the normal supply of fuel into the cylinder.

Q: Why do diesel engines need bleeding?

A: As you know, diesel engines operate under extremely high fuel pressure. When fuel runs dry, air gets sucked into the system, and it must be vented (bled) out. Adding fuel is the first step, and bleeding the lines and injectors immediately follows.

Q: What causes high engine temperature?

A: Engines can overheat for many reasons. In general, it's because something's wrong within the cooling system and heat isn't able to escape the engine compartment. The source of the issue could include a cooling system leak, bad radiator fan, faulty water pump, low engine oil level, or thermostat failure.

Q: What are the 4 starting methods of diesel engine?

A: These methods involve either an electric starter, a hydraulic starter or an air starter. The electric starter usually consists of a 12-volt battery and a 12-volt starting motor along with suitable auxiliary components.

Chongqing Kyson Machinery Equipment Co., Ltd. is one of the most professional diesel & gas engine assembly manufacturers and suppliers in China, featured by good service and competitive price. Please rest assured to buy high quality diesel & gas engine assembly in stock here from our factory. Contact us for more details.

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