Cummins KTA19G1 - 675 kVA Generator Set - DPX-12679

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Last service inspection report:

Following our inspection and assessment of the KTA engine, we offer the following minimum recommendations:
To begin with, it is not advisable to continue operating the engine given the defects identified.

Upon removing the cylinder heads, we observed that all cylinder liners exhibit scoring. This appears to be damage resulting from thermal overload and/or markings caused by carbonized oil. It is likely that contamination within the cooling system impaired cooling efficiency, leading to the development of "hot spots" or localized boiling. Alternatively, it is possible that oil combustion occurred, with the resulting hard carbon residue causing scoring as it accumulated around and within the piston ring grooves. Over time, this will lead to increased "blow-by" and exacerbate the already excessive oil consumption—which, in turn, will negatively affect exhaust emissions and engine power output.

Furthermore, it is clear that virtually all the gaskets and sealing rings we examined have hardened and dried out. This will inevitably lead to leaks. Should the seals around the cylinder liners fail, coolant could enter the oil system, creating a high risk of damage to the bearings or the engine block itself.

In summary, our recommendations are as follows:

● Remove the engine from the unit to allow for the extraction of the cylinder kits.
● Transport the engine to the workshop in Maassluis.
● Disassemble the engine (remove cylinder kits).
● Replace the cylinder liners and piston rings; clean and measure the pistons, reusing them if they are within specifications.
● Perform a minor overhaul of the cylinder heads, including the removal of excessive carbon deposits. ● Testing and recalibrating the injectors
● Cleaning and adjusting the fuel pump
● Cleaning the aftercooler
● Overhauling the fouled turbocharger
● Cleaning the engine block and the cooling system
● Replacing the (hardened) crankshaft oil seal
● Engine assembly
● Engine start-up (no-load)

Trailer included