Cummins KTA 19 Engine Parts - Injector Section

Cummins KTA19 Injector Kits & Components Catalog

The fuel injection system is the heart of any high-horsepower diesel engine, and for the Cummins KTA19—one of the most trusted powerplants in marine propulsion, mining equipment, and industrial applications—fuel injector performance is critical. Diesel Pro Power proudly supplies a complete line of injector kits, mounting hardware, and installation accessories designed for a wide range of CPL configurations across the KTA19 and QSK19 platforms.

With over 40,000 satisfied customers worldwide, our injector components are trusted by fleets, shipyards, and operators who demand uptime, precision fuel delivery, and OEM-grade reliability.

Overview: The Role of Injectors in the KTA19 Fuel System

The KTA19 uses a mechanical fuel injection system that relies on precision-calibrated injectors to deliver atomized diesel into the combustion chamber under extremely high pressure. This ensures efficient combustion, reduced emissions, and maximum horsepower output.

Proper injector function is essential for:

• Balanced cylinder performance

• Optimal fuel economy

• Reduced smoke and soot

• Smooth acceleration under load

• Extended engine life

Injectors wear over time due to carbon buildup, high-pressure erosion, or contamination. Timely replacement is critical to maintaining performance and avoiding fuel system failures.

Injector Kits for Cummins KTA19 Engines

Diesel Pro Power offers injector kits tailored to specific CPL (Control Parts List) numbers. Each injector kit is fully assembled, calibrated, and tested to deliver factory-grade performance in the harshest operating conditions. All injector kits are compatible with the KTA19 and QSK19 platforms and are suitable for marine and industrial duty cycles.

Injector Kit for CPLs 476, 477, 610, 640, 884

This injector kit is designed for early-to-mid generation KTA19 and QSK19 engines operating in marine propulsion, generator sets, and heavy-duty construction applications.

Applications:

• Marine propulsion engines on tugs, fishing vessels, barges

• Diesel electric generators with mid-range load demand

• Industrial engines in mining or drilling operations

Kit Includes:

• Complete fuel injector with preinstalled nozzle

• Internal spring and plunger components

• Fuel delivery check valves

• Protective shipping caps to prevent contamination

Ideal for engine rebuilds or field service replacement.

Injector Kit for CPLs 478, 501, 503, 505, 520, 521, 526, 584, 672, 687, 688, 736, 737, 738, 824, 885, 886, 888, 1190, 1506, 2634

This is our most comprehensive injector kit option, compatible with a wide range of late-model KTA19 engine variants. These configurations are commonly found in Tier 1 to Tier 2 emissions-compliant units used globally in high-output installations.

Performance Benefits:

• Improved atomization for enhanced fuel efficiency

• Cleaner combustion for reduced visible smoke

• Drop-in fit with existing KTA19 injector mounting hardware

• Long service life in continuous-duty environments

Each injector is tested for crack pressure, flow balance, and spray pattern integrity before shipment.

Injector Kit for Later Generation CPL Variants

This injector kit fits specialized CPLs on high-performance KTA19 and QSK19 platforms, particularly those used in export markets or high-speed power generation where specific fueling strategies are needed.

Target Applications:

• High-speed marine engines operating near redline RPMs

• Emergency power systems requiring rapid fuel response

• Engines with factory-optimized fuel maps for specific load curves

Why Choose This Kit:

• Designed to meet tighter combustion tolerances

• Enhanced durability for high-RPM cycling

• Built to maintain injector performance over extended intervals

For technicians working on mission-critical systems, this kit ensures injector reliability in demanding environments.

Injector Kit for CPLs 502, 724, 952, 969, 2184

This injector kit is compatible with KTA19 engines configured for high-altitude or variable climate operation. These CPLs are often calibrated to manage fuel delivery in conditions where air density and turbocharger output fluctuate.

Benefits:

• Fuel metering calibrated for consistent output regardless of altitude

• Resists internal sticking caused by moisture or varnish

• Compatible with cold-weather fuel blends and heaters

This is the injector of choice for operations in mountainous terrain, northern climates, or offshore vessels in varying barometric conditions.

Injector Kit for CPLs 508, 513, 514, 515, 823

Used in more specialized or custom-configured KTA19 and QSK19 builds, this injector kit offers premium-grade components for engines operating under continuous full-load conditions.

Typical Use Cases:

• Marine main engines operating at full throttle for prolonged durations

• Remote gensets running 24/7

• Process-critical powerplants in oil and gas or municipal infrastructure

Features:

• Hardened nozzles for improved wear resistance

• Tight flow tolerances for fuel mapping stability

• Compatible with both mechanical and early electronic governor systems

This kit is ideal for fleet operators standardizing injectors across CPLs with similar fueling curves.

Injector Installation Kit for High-Pressure Injectors

Installing new KTA19 injectors requires precision and the right accessories. Our injector installation kit includes everything needed to safely and correctly install high-pressure injectors without damaging internal components or compromising sealing surfaces.

Included in the Kit:

• Special installation washers

• Copper or steel combustion seals

• Precision-fit hold-down bolts

• Mounting alignment shims (if applicable)

• Instructions for torque spec compliance

This kit ensures that each injector is seated properly to prevent combustion gas leaks or injector "lift" under pressure.

Cummins KTA19 Injector Mounting Seal

Each injector requires a dedicated mounting seal that isolates fuel and combustion pressures from engine oil and coolant systems. We supply OEM-grade injector mounting seals engineered to maintain tight tolerances in extreme temperature cycles.

Seal Features:

• Precision-machined to prevent injector blow-by

• Manufactured from heat-resistant elastomers or copper

• One seal required per injector

• Ideal for both new injector installation and reassembly after inspection

Neglecting to replace these seals can result in combustion leaks, poor cold starts, or injector seat damage.

When Should KTA19 Injectors Be Replaced?

Fuel injectors should be inspected or replaced at regular intervals, particularly in engines that:

• Run 24/7 or under continuous load

• Exhibit white or black exhaust smoke

• Experience hard starting or poor idle

• Show signs of injector knock

• Consume more fuel than normal

• Have poor throttle response

Recommended Injector Replacement Intervals:

• Marine engines (continuous duty): Every 10,000–12,000 hours

• Industrial engines (variable duty): Every 8,000–10,000 hours

• Standby engines: Every 5–7 years regardless of hours

Periodic pop-testing or flow testing can help determine if your injectors are still performing within specification.

Importance of Using the Correct CPL-Compatible Injector

Cummins KTA19 engines are built with Control Parts List (CPL) numbers that define the exact calibration of the fuel system, turbochargers, pistons, and injectors. Using the wrong injector—even if it physically fits—can lead to:

• Over-fueling or under-fueling

• Detonation or pre-ignition

• Increased exhaust temps

• Premature piston or turbo failure

• Emissions violations for regulated units

Diesel Pro Power helps customers match injectors to the correct CPL, ensuring safe, efficient, and compliant operation.

Tips for Injector Replacement and Installation

1. Always clean the injector bore before installation.
Debris can damage the injector tip or prevent proper sealing.

2. Use new mounting seals.
Never reuse old seals—they compress during operation and lose their effectiveness.

3. Follow torque specifications.
Over-torquing can crack the injector body; under-torquing can cause combustion leaks.

4. Prime the fuel system.
Ensure all air is bled from the lines to avoid dry starts or airlocks.

5. Retest cylinder balance.
Use a diagnostic tool or manual method to verify injector firing balance.

Additional Components Commonly Paired with Injector Replacement

While replacing KTA19 injectors, consider inspecting or replacing the following components:

• Fuel lift pump: Ensures consistent feed pressure to the injection pump

• Fuel lines and return fittings: Check for leaks, cracks, or corrosion

• Fuel pressure sensors or switches: Maintain monitoring systems for alarms

• Fuel filters and water separators: Install new filters to protect new injectors

• Turbocharger health: Over-fueling can be caused by poor air intake

Why Choose Diesel Pro Power for Your KTA19 Injector Needs?

• Fast, global shipping to over 180 countries

• Technical support for CPL matching and injector troubleshooting

• In-stock inventory means no long lead times

• Trusted by 40,000+ customers in marine, industrial, and power generation sectors

• High-quality components equal to or better than OEM standards

Whether you're overhauling a genset, maintaining a tugboat fleet, or servicing a stationary engine in the oilfield, we provide injector kits and accessories you can count on.