Details
Cummins KT38-DM560 Marine Auxiliary & Industrial Diesel Engine
HekoPower supplies factory-direct, genuine CCEC Cummins KT38-DM560 engine assemblies, complete power units, and replacement engines for global marine and industrial operations. The KT38 series features a 12-cylinder, 37.8-liter V-type mechanical platform engineered for extreme continuous duty cycles. Whether powering a 560 kW marine auxiliary generator set or serving as the drive for heavy mining, drilling, and crushing machinery, the mechanical PT fuel system delivers high reliability with minimal electronic failure points.
As an established engine supplier, HekoPower verifies every CCEC Chongqing Cummins engine assembly through original factory documentation, ensuring seamless replacement for existing plant equipment, vessel repowers, and OEM industrial machinery.
Tech Specs of Cummins KT38-DM560
General Engine Data
Engine Model: Cummins KT38-DM560
Type: 12 Cylinders, V Type, 4 Stroke, Diesel
Displacement: 38 L
Bore * Stroke: 159 * 159
Net Weight (with flywheel & alternator): 3923 Kg
Overall Dimension: 2003mm*1362mm*1661mm
Engine Configuration No.: D232018DX02
Key Performance Data
Rated Power: 560 kW/750HP
Rated Speed: 1500 rpm
Low Idle Speed: 675-775 rpm
Fuel Consumption (Running Speed): 232 g/kW.hr
Torque/Rated Speed: 3565 N.m @ 1500 rpm
More Technical Data
Certification: CCS/IMO Certificates
Aspiration: Turbocharged
Compression Radio: 15.5:1
Fuel System: Cummins Pressure Time (PT Pump)
Starting System: Electrical starting motor (24V)
Cooling Method: Water cooling
Cooling Method: Sea water pump, Heat exchanger, Wet exhaust manifold
Technical Architecture & Mechanical Systems
Understanding the mechanical layout of the CCEC KT38-DM560 helps fleet managers select the correct configuration for their vessel or facility. Built on a heavy-duty cast-iron block with wet cylinder liners, the KT38 platform balances fuel efficiency, structural rigidity, and ease of field serviceability.
PT Fuel System and Mechanical Injection
The engine utilizes the proprietary Cummins Pressure-Time (PT) mechanical fuel system. Unlike modern common-rail engines that rely on complex electronic control units (ECUs) and sensitive sensors, the PT system uses mechanical governor linkages and camshaft-driven unit injectors.
This mechanical design makes the KT38-DM560 exceptionally resilient against poor fuel quality, water contamination, and harsh environmental conditions often encountered on offshore vessels or remote mining sites. Fuel delivery is precisely metered based on engine speed and load, providing predictable fuel consumption rates at 1500 RPM continuous operation.
Holset Turbocharging and Charge-Air Cooling
To achieve 560 kW output efficiently, the KT38-DM560 integrates twin Holset turbochargers paired with a jacket-water or raw-water aftercooler system. The turbochargers force dense air into the V12 combustion chambers, boosting low-end torque and ensuring complete fuel combustion.
The intake air temperature is regulated by the aftercooler, reducing thermal stress on pistons and valves while maintaining compliance with IMO Tier II marine emissions standards.
Engineering Configuration: Heat Exchanger vs. Keel Cooling
When ordering a CCEC KT38-DM560 marine auxiliary unit from HekoPower, specifying the correct cooling package is vital for operational longevity and vessel compatibility.
Heat Exchanger Cooling Package
The heat exchanger option uses a closed-loop freshwater system inside the engine block, cooled by sea water flowing through a shell-and-tube exchanger mounted directly on the engine frame. A dedicated gear-driven raw water pump circulates seawater through the system.
This self-contained setup is ideal for vessels with tight engine room layouts where external keel coolers cannot be fitted. Regular maintenance involves inspecting sacrificial zinc anodes and descaling the tube bundle to maintain cooling performance.
Keel Cooling Configuration
In shallow-water vessels, dredges, or river tugs, abrasive silt and marine growth rapidly clog raw water strainers and wear out sea water pumps. The keel cooling setup routes the engine coolant through external pipe grids mounted on the hull exterior.
Because sea water never enters the engine room, internal corrosion and strainer clogging are eliminated. HekoPower supplies the KT38-DM560 pre-configured with dry exhaust manifolds and specialized expansion tank connections to suit keel-cooled vessels.
KT38-DM560 vs. KTA38-DM Series
Buyers often evaluate the KT38-DM560 alongside aftercooled variants like the KTA38-DM664 or KTA38-DM768. The structural differences lie in aspiration and temperature control:
- Aspiration Method: The KT38-DM560 utilizes single-stage twin turbocharging without a jacket-water or low-temperature aftercooler. The KTA38 series adds a water-to-air aftercooler (Jack-Water or LTA) to cool intake air, pushing power outputs above 660 kW.
- System Complexity: Without the additional aftercooler piping and secondary water circuits, the KT38-DM560 offers a smaller footprint and fewer points of maintenance failure, making it ideal for standard 560 kW marine auxiliary duties.
- Fuel Consumption Profile: At a constant 1500 RPM (50 Hz), the KT38-DM560 consumes roughly 145 liters per hour at 100% prime power load. Its specific fuel consumption averages 232 g/kW.h.
Heat Exchanger vs. Keel Cooling Configuration
Selecting the cooling system depends on hull design and operating waters:
- Heat Exchanger Cooling: Uses an engine-mounted plate heat exchanger paired with a raw water sea pump. Sea water circulates through the exchanger to cool internal engine coolant. This setup is compact and self-contained, but raw water strainers and impellers require frequent cleaning in shallow or muddy waters.
- Keel Cooling: Routes engine coolant through external pipes attached along the outside of the vessel's hull. The surrounding sea water cools the coolant directly, eliminating raw water pumps, strainers, and heat exchanger fouling. It works best for workboats, dredgers, and tugs operating in debris-filled rivers or shallow harbors.
Real Application Scenarios
The Cummins KT38 platform is used across diverse industries worldwide due to its balance of displacement, mechanical simplicity, and heavy-duty structural design.
Marine Auxiliary Generator Sets
On cargo ships, offshore supply vessels, and bulk carriers, the KT38-DM560 serves as the prime mover for 560 kW 50 Hz auxiliary diesel generators. These units operate continuously under varying electrical loads, running heavy deck machinery, bow thrusters, and shipboard power grids. The heavy marine sump allows the engine to operate reliably during vessel pitch and roll conditions.
Mining Equipment & Heavy Industrial Drives
In land-based industries, modified variants of the KT38 power large mechanical equipment, including hydraulic excavators, haul trucks, stone crushing plants, and stationary power generation stations. The high displacement enables rapid transient load acceptance, allowing heavy machinery to crush dense rock or lift heavy loads without sudden voltage or frequency drops.
Oilfield Drilling & Hydraulic Power Units
In oilfield applications, the KT38 drives mud pumps, well-servicing rigs, and hydraulic power packs. The mechanical PT fuel system allows operators to run the engine in remote environments without relying on specialized electronic diagnostic tools or ECU programming.
Maintenance Standards and Overhaul Guidelines
Proper maintenance extends the service life of a Cummins KT38 engine beyond 25,000 to 30,000 operating hours before requiring a major overhaul.
Preventive Maintenance Intervals
- Every 250 Hours: Change engine oil using high-grade heavy-duty diesel oil. Replace full-flow and bypass oil filters. Inspect air cleaner restriction indicators and check drive belt tension.
- Every 500 Hours: Replace fuel filter elements and clean the PT fuel pump inlet screen. Inspect the cooling system additive levels to prevent cylinder liner cavitation.
- Every 1500 Hours: Check lash on intake and exhaust valves. Inspect injector rocker arm adjustments using the Cummins outer base circle method.
- Every 4000 Hours: Test and calibrate PT fuel injectors and fuel pump performance on a test bench. Inspect turbocharger shaft play and housing seals.
Engine Overhaul Indicators
When an engine approaches the end of its service life, several key indicators signal the need for an overhaul:
- Sustained reduction in oil pressure at normal operating temperatures.
- Increased crankcase blow-by gases visible through the breather tube.
- Higher fuel consumption paired with persistent black or blue exhaust smoke.
- Unexplained loss of power under standard load conditions.
HekoPower supplies complete CCEC overhaul kits, including cylinder liners, pistons, rings, main bearings, gasket sets, and remanufactured fuel system components to restore engines to original factory specifications.
Cummins K38-DM Series, Marine Auxilliary Diesel Engines for commercial and recreational applications, original products from Chongqing Cummins Engine Plant(CCEC). This series mainly includes KT38-DM560, KT38-DM679, KTA38-DM664, KTA38-DM768, KTA38-DM809, KTA38-DM814, KTA38-DM880, KTA38-DM1007. All engines complete with sea water pump, heat exchanger, CCS/IMO certificates.
Frequently Asked Questions
What does CCEC stand for, and how does it relate to Cummins?
CCEC stands for Chongqing Cummins Engine Company, a joint venture between Cummins Inc. and Chongqing Machinery & Electronics Co., Ltd. CCEC manufactures heavy-duty Cummins engines, including the K series (K19, K38, K50) and N series, under strict Cummins quality control standards and licensing.
Is the KT38-DM560 compliant with current marine emissions rules?
Yes, the KT38-DM560 engine supplied by HekoPower complies with IMO Tier II marine emissions standards, making it suitable for international vessel operations requiring certified auxiliary power.
What is the typical lead time for a complete CCEC KT38 engine assembly?
Factory-new CCEC KT38 complete engine assemblies usually ship within 2 to 4 weeks, depending on the specific cooling, housing, and flywheel configurations required. HekoPower maintains inventory on popular engine models for urgent replacement needs.
Can HekoPower supply replacement parts for older KT38 engines?
Yes, HekoPower supplies a complete range of genuine CCEC replacement parts, including cylinder heads, crankshafts, water pumps, fuel pumps, Holset turbochargers, and complete lower/upper engine overhaul gasket kits.
What warranty coverage comes with a new engine from HekoPower?
All new genuine CCEC Cummins KT38 engine assemblies supplied by HekoPower come with standard manufacturer warranty coverage against defects in materials and workmanship, supported by international documentation and serial number verification.
