Cummins KTA19 Parts List: Complete OEM Spare Parts Catalog with Part Numbers
The Cummins KTA19 is the most widely deployed medium-range generator engine in the world, powering generator sets from 300 kVA to 640 kVA across hospitals, data centers, telecom towers, manufacturing plants, and marine auxiliary applications. First introduced in the 1970s as the KT-1150 (later the KTA-1150, then KTA19), this 19-liter inline-6 engine has a reputation for robustness that borders on legendary—it is not uncommon to find KTA19 generator engines with 25,000+ operating hours still in service with only routine maintenance and a single in-frame overhaul. This parts list catalog covers all major assemblies for KTA19-G2, KTA19-G3, and KTA19-G4 generator-drive variants, providing OEM Cummins part numbers that procurement managers, service technicians, and parts specialists can use for ordering, cross-referencing, and inventory planning.
All part numbers in this catalog are sourced from Cummins QuickServe and the KTA19 Illustrated Parts Catalog (IPC), valid as of 2024. Always verify part numbers against your specific Engine Serial Number (ESN) before ordering—Cummins frequently issues supersession bulletins that update part numbers for improved components.
KTA19 Engine Technical Specifications
| Parameter | KTA19-G2 | KTA19-G3 | KTA19-G4 |
|---|---|---|---|
| Configuration | Inline 6-cylinder, 4-stroke diesel | ||
| Bore x Stroke | 159 mm x 159 mm (6.25 in x 6.25 in) | ||
| Displacement | 19.0 L (1,150 in³) | ||
| Compression Ratio | 13.9:1 | ||
| Aspiration | Turbocharged | Turbocharged / Aftercooled | Turbocharged / Aftercooled |
| Standby Rating | 400 kW / 500 kVA | 470 kW / 587 kVA | 510 kW / 640 kVA |
| Prime Rating | 365 kW / 456 kVA | 425 kW / 531 kVA | 465 kW / 581 kVA |
| Fuel System | Cummins PT (Pressure-Time) mechanical injection | ||
| Governor | Mechanical (std) / Electronic (optional) – 1500/1800 RPM | ||
| Dry Weight | Approx. 1,830 kg (4,035 lbs) | ||
| Oil Capacity | 57-60 L (15-16 gallons) with standard oil pan | ||
Cylinder Head Assembly Parts
| Part Description | Cummins Part Number | Quantity Required | Notes |
|---|---|---|---|
| Cylinder Head (bare) | 3802532 | 1 (covers all 6 cylinders) | Single-piece cast iron crossflow head |
| Intake Valve | 3802640 | 12 | 47.6 mm head diameter; Stellite-faced |
| Exhaust Valve | 3802641 | 12 | 42.8 mm head diameter; Stellite-faced and sodium-cooled stem |
| Valve Seat Insert (Intake) | 3802668 | 12 | Cast iron alloy; replace at overhaul |
| Valve Seat Insert (Exhaust) | 3802669 | 12 | High-temperature alloy; always replace at overhaul |
| Valve Guide | 3802522 | 24 | Replace at overhaul if stem clearance exceeds 0.10 mm |
| Valve Spring (inner) | 3802688 | 24 | Always replace as a set with outer springs |
| Valve Spring (outer) | 3802689 | 24 | Replace as set; check free length vs. spec |
| Valve Collet / Keeper | 3032439 | 48 | Two per valve; replace as set |
| Cylinder Head Gasket | 3802675 | 1 | Multi-layer steel (MLS); critical torque sequence required |
| Head Bolt Set (26 bolts) | 3802678 | 1 set | Always replace bolts at overhaul; torque-to-yield design |
| Rocker Lever Assembly | 3802785 | 12 | Includes roller and bushing; inspect for wear |
| Rocker Shaft | 3802778 | 1 | Replace if pitted or worn at rocker contact points |
Piston, Liner, and Connecting Rod Parts
| Part Description | Cummins Part Number | Quantity Required | Notes |
|---|---|---|---|
| Piston Assembly (complete with rings and pin) | 3802433 | 6 | Includes piston, pin, pin retainers, and ring set; sold per cylinder |
| Piston Ring Set (top, second, oil control) | 3802610 | 6 | Top ring: barrel-faced chrome; 2nd: taper-faced; Oil: 3-piece |
| Cylinder Liner (wet type) | 3802612 | 6 | Replaceable wet liner with 3 O-ring seals; protrusion 0.08-0.15 mm |
| Liner O-ring Kit (upper, middle, lower) | 3802613 | 6 kits | 3 O-rings per cylinder; always replace when liner is disturbed |
| Cylinder Liner Shim | Various (height-coded) | As needed | Used to adjust liner protrusion; available in 0.05mm increments |
| Connecting Rod Assembly | 3802592 | 6 | Forged steel, I-beam section; includes cap screws |
| Connecting Rod Bearing (Std) | 3802480 | 12 halves | Tri-metal bearing; std, 0.25mm, 0.50mm, 0.75mm undersizes available |
| Piston Pin | 3802596 | 6 | Full-floating; retained by snap rings in piston |
| Piston Pin Bushing | 3802622 | 6 | Press-fit into connecting rod small end |
Crankshaft and Main Bearing Parts
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| Crankshaft Assembly | 3802635 | 1 | Forged steel, 7 main bearings, induction-hardened journals |
| Main Bearing Set (Std) | 3802550 | 7 pairs (14 halves) | Upper: grooved; Lower: plain. Undersizes: 0.25/0.50/0.75 mm |
| Thrust Bearing (Rear Main) | 3802555 | 1 pair | Flanged bearing at position #7; controls crankshaft end-play |
| Front Crankshaft Oil Seal | 3802639 | 1 | PTFE lip seal; always replace when front cover is removed |
| Rear Crankshaft Oil Seal | 3802870 | 1 | PTFE lip seal; replace during any flywheel housing service |
| Vibration Damper | 3802646 | 1 | Viscous-type; inspect rubber element annually; replace every 10,000 hrs |
| Damper Mounting Bolts | 3802647 | 6 | Replace if damper is removed; torque to 115 ft-lbs (156 Nm) |
Camshaft, Gear Train, and Timing Parts
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| Camshaft Assembly | 3802565 | 1 | Chilled iron cam lobes; 12 lobes for valve actuation + 6 for injector |
| Camshaft Bearing Set | 3802510 | 7 | Replace at overhaul; line-bore check recommended |
| Crankshaft Timing Gear | 3032440 | 1 | Helical cut, pressed onto crankshaft nose |
| Camshaft Timing Gear | 3032445 | 1 | Helical cut, bolt-on; timing marks must align with crank gear |
| Idler Gear Assembly | 3802518 | 1 | Includes idler shaft, gear, bushings, and thrust washers |
| Accessory Drive Gear | 3802530 | 1 | Drives PT pump, water pump, and oil pump |
Turbocharger and Air System Parts
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| Turbocharger (Holset HX40W) | 3802491 | 1 | Wastegate-controlled; replaces earlier HX40 model |
| Turbocharger Gasket Kit | 3802492 | 1 kit | Oil feed/drain gaskets, exhaust inlet/outlet gaskets, air outlet O-ring |
| Turbo Oil Feed Pipe Assembly | 3802495 | 1 | Flexible braided steel line; inspect for coking at connection points |
| Turbo Oil Drain Pipe | 3802496 | 1 | Rigid pipe with flange gasket; replace if kinked or cracked |
| Air Filter (Donaldson Primary) | P181038 | 1 | Heavy-duty radial seal; replace at restriction indicator red (25 in H₂O) |
| Air Filter (Safety Element) | P182039 | 1 | Inner safety filter; replace every 3 primary filter changes |
| Aftercooler Core | 3802505 | 1 | Air-to-water type (KTA19-G3/G4); clean externally every 1,000 hrs |
Fuel System (PT) Parts
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| PT Fuel Pump Assembly | 3020960 | 1 | Complete PT (Type G) pump; includes governor and AFC |
| Fuel Injector (PT Type) | 3802135 | 6 | N14-style mechanical PT injector; requires flow-setting |
| Injector O-ring Kit | 3802140 | 6 kits | Upper/lower O-rings, copper seating washer per injector |
| Fuel Shutoff Solenoid (ETR) | 3082560 | 1 | Energized-to-run (ETR); fail-safe—engine stops if solenoid loses power |
| Fuel Filter (Primary / FF105) | 3355905 (FF105) | 1 | 10-micron with water separator; replace every 250 hrs |
| Fuel Filter (Secondary / FF202) | 3896693 (FF202) | 1 | 3-micron final filtration; replace with primary filter |
| Fuel Transfer Pump | 3093942 | 1 | Gear-type; mounted on PT pump; 55 gph (208 L/hr) flow rate |
Lubrication System Parts
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| Oil Pump Assembly | 3098687 | 1 | Gear-type; mounted in oil pan; 95 psi (6.5 bar) relief setting |
| Oil Filter (Fleetguard LF9009) | LF9009 | 1 | Full-flow spin-on; 15-micron; replace every 250 hrs |
| Oil Cooler Assembly | 3089526 | 1 | Plate-type, oil-to-water; inspect for internal leakage annually |
| Oil Cooler Gasket Kit | 3089528 | 1 kit | Includes housing gaskets and O-rings for oil cooler service |
| Oil Pressure Sensor | 3408446 | 1 | 2-wire analog; 0-100 psi range; triggers alarm at 15 psi |
| Oil Pan Gasket | 3802695 | 1 | Cork/rubber composite; single-piece perimeter seal |
Cooling System Parts
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| Water Pump Assembly | 3802258 | 1 | Belt-driven centrifugal pump; replace at 6,000 hrs or shaft play |
| Thermostat (82°C / 180°F) | 3802437 | 1 | Full-open at 95°C; replace every 4,000 hrs |
| Thermostat Housing Gasket | 3802439 | 1 | Replace with thermostat |
| Coolant Temperature Sensor | 3408345 | 1 | 2-wire analog; triggers high-temp alarm at 105°C (221°F) |
| Fan Drive Belt (V-belt, set of 2) | 3802230 | 2 | Matched pair; replace as set; tension 110-130 lbs with gauge |
Gasket, Seal, and Overhaul Kits
| Part Description | Cummins Part Number | Quantity | Notes |
|---|---|---|---|
| Upper Engine Gasket Kit | 3802552 | 1 kit | Head gasket, rocker cover, intake/exhaust manifold, thermostat, water outlet, fuel connections |
| Lower Engine Gasket Kit | 3802553 | 1 kit | Oil pan, front cover, rear cover, oil cooler, oil pump, tappet cover |
| Complete Overhaul Gasket Kit | 3802554 | 1 kit | Upper + Lower kits combined; includes all seals, O-rings, and gaskets for a complete in-frame overhaul |
| In-Frame Overhaul Kit | 3802540 | 1 kit | 6 pistons w/ rings & pins, 6 liners w/ O-ring kits, 12 conn rod bearings, upper gasket kit, lower gasket kit |
| Major Overhaul Kit | 3802541 | 1 kit | In-Frame Kit + main bearings, thrust washers, camshaft bearings, front/rear crankshaft seals, head bolts |
Maintenance and Service Part Intervals
- Every 250 hours / 6 months: Engine oil (SAE 15W-40 CI-4 or CJ-4), oil filter LF9009, fuel filters FF105 + FF202. Check belt tension, coolant level, air filter restriction indicator.
- Every 500 hours / annual: Air filter primary element (replace if restriction shows red), valve clearance check and adjust (intake 0.30mm / exhaust 0.61mm, cold engine), injector timing and adjustment by Cummins-qualified technician.
- Every 2,000 hours / 2 years: Coolant drain, flush, and replace with Cummins-approved SC (Supplemental Coolant Additive) treated coolant. Replace thermostat. Inspect turbocharger shaft play and blade condition.
- Every 6,000 hours: Water pump replacement (preventive). Inspect and replace vibration damper if rubber element shows cracking. Replace belts and radiator hoses regardless of visual condition.
- 15,000-20,000 hours: In-frame overhaul (pistons, liners, bearings, cylinder head reconditioning, injectors, turbocharger). PT pump and injector calibration by Cummins-certified fuel shop.
- 30,000-40,000 hours: Major overhaul (includes crankshaft reconditioning, camshaft replacement, complete engine teardown).
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As a trusted Cummins parts supplier in China, we stock a comprehensive inventory of KTA19-G2, G3, and G4 parts—from individual gaskets to complete overhaul kits. All parts shipped with Certificate of Origin, full traceability, and competitive B2B pricing. Contact us for a quotation.
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Frequently Asked Questions
Q1: What is the difference between KTA19-G2, G3, and G4 models?
The primary difference is power output, which increases from G2 to G4. G2 (400 kW standby) is naturally aspirated with a turbocharger only. G3 (470 kW) adds an aftercooler for denser intake air. G4 (510 kW) has a larger turbocharger, upgraded aftercooler, and revised fuel system calibration. Many parts are interchangeable, but turbocharger, aftercooler, injectors, and pistons are model-specific. Always verify by ESN.
Q2: How do I find the correct part number for my KTA19?
Locate the Engine Serial Number (ESN) on the dataplate (front gear housing, right side). Enter the ESN into Cummins QuickServe Online (quickserve.cummins.com, free registration) to access the complete illustrated parts catalog specific to your engine. The ESN is the master key—Cummins often issued mid-production changes, and the ESN tells you exactly which revision applies.
Q3: Can I use aftermarket pistons and liners in a KTA19 overhaul?
Aftermarket pistons and liners are available from Federal-Mogul (FP Diesel), Mahle, and IPL with CE, ISO, and cummins interchange data. However, genuine Cummins pistons are strongly recommended for generator applications where reliability is critical. Aftermarket pistons have been known to vary in compression height tolerance (±0.05mm vs. ±0.02mm for genuine), affecting compression ratio and cylinder balance. For standby generators that may run 200 hrs/year for 30 years, the cost difference is negligible amortized over the service life.
Q4: What is included in the KTA19 in-frame overhaul kit (3802540)?
The in-frame overhaul kit includes: 6 piston assemblies (with rings, pins, retainers), 6 cylinder liners with O-ring kits (upper, middle, lower per cylinder), 12 connecting rod bearing halves (standard size), upper engine gasket kit (head, manifold, rocker cover, water connections), and lower engine gasket kit (oil pan, front/rear cover, oil cooler). It does NOT include main bearings, camshaft bearings, head bolts, or crankshaft seals—those are in the major overhaul kit (3802541).
Q5: How often should I replace KTA19 fuel injectors?
PT injectors (P/N 3802135) typically last 10,000-15,000 hours in well-maintained engines with clean fuel and proper filtration. Diagnostic signs for replacement: (1) injector fails flow test on a PT injector test stand; (2) visible dribble or poor spray pattern; (3) cylinder exhaust temperature variation >50°C between cylinders; (4) excessive smoke at rated load. Always replace injectors as a complete set of 6—mixing new and old injectors causes unequal fuel distribution and rough running.
Q6: Can I upgrade my KTA19-G2 to a G4 with different parts?
Upgrading a G2 to G4 output requires: (1) turbocharger replacement to the G4-spec HX40W (3802491); (2) addition of an aftercooler and associated plumbing (G2 does not have an aftercooler); (3) fuel pump recalibration to G4 specifications by a Cummins-certified PT pump shop; (4) potentially different injectors depending on ESN. The engine block, crankshaft, and connecting rods are identical across G2/G3/G4, so the bottom end can handle the upgrade. However, the generator alternator must also be rated for the increased output. This is an engineering change that should be documented and verified.
Q7: What causes KTA19 cylinder head gasket failures?
The most common causes: (1) Overheating—KTA19 head gasket failure typically occurs at 110°C+ coolant temperature. (2) Incorrect torque sequence during installation—KTA19 head bolts require a specific torque-angle procedure (initial torque + 90° + 90°). (3) Liner protrusion out of specification (must be 0.08-0.15mm above block deck). (4) Pre-ignition/detonation from poor fuel quality or advanced injection timing. (5) The 3802675 MLS gasket itself is extremely robust—most failures are installation or overheating-related, not gasket defects.
Q8: What are the critical torque specifications I need to know?
Key torque values: Head bolts (4-step torque-angle: 100 ft-lbs cold, + 90°, + 90°, + 90°), Main bearing cap bolts (300 ft-lbs), Connecting rod cap screws (160 ft-lbs), Vibration damper bolts (115 ft-lbs), Flywheel bolts (180 ft-lbs), Injector hold-down (6 ft-lbs + 1.5 ft-lbs torque to yield). Always use a calibrated torque wrench—under-torque causes leaks and loosening; over-torque stretches fasteners beyond yield, causing eventual failure.
Q9: How do I store spare KTA19 parts long-term?
Cylinder liners and crankshaft: store in VCI (Vapor Corrosion Inhibitor) paper or apply LPS-3 rust inhibitor; store horizontally on padded racks. Pistons and rings: keep in original sealed packaging; store in climate-controlled area (15-25°C, <60% RH). Gaskets: store flat; do not hang on pegs (causes warping). Rubber seals/O-rings: replace every 5 years regardless of visual condition—rubber degrades even in sealed packaging. Injectors: keep in sealed plastic bags with desiccant packs; injector rack storage with oil fog preferred. Record all part numbers, dates received, and storage locations in your inventory management system.