Cummins 2872544 Injector Needle Valve – Precision Metering Component for CELECT & XPI Fuel Systems
1. Product:2872544
2. Compatible Equipment: Diesel Fuel Injection Systems
3. Manufacturer: Aftermarket OEM Replacement
4. Condition: Brand New, Fully Tested
5. Origin: ABOSEDE Diesel
6. Shipping period: 3-5 business days
7. Payment terms: T/T, Western Union, PayPal
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Product Introduction
In high-pressure diesel injection systems, the needle valve is the component that directly controls the fuel spray characteristics – its opening and closing events determine injection timing, duration, and atomisation quality. The Cummins 2872544 is a precision-ground needle valve engineered for use in Cummins CELECT and XPI fuel system injectors, serving as the moving sealing element within the nozzle assembly. Unlike the complete injector, this needle valve is a service component intended for professional overhaul, designed to restore injector performance without replacing the entire unit. The needle features a seat angle of 60° with a seat diameter of 3.8 mm, and is manufactured from a high-speed steel (M42-grade) with a surface hardness of 60–64 HRC, and a diamond-like carbon (DLC) coating on the guide surface to reduce friction and minimise wear. The defining metric of the 2872544 is its needle-to-nozzle clearance, held to 4–6 microns – a tolerance that ensures minimal internal leakage while allowing free movement, enabling the injector to maintain the precise pilot and main injection quantities demanded by the ECU.
█ Application Coverage – Cummins CELECT, CELECT Plus, and XPI Injectors
The 2872544 needle valve is used in the following Cummins engine families:
N14 – CELECT and CELECT Plus injectors for N14 industrial and truck engines
ISM – CELECT and CELECT Plus injectors for ISM 10.8L engines
ISX – XPI injectors for ISX 15L engines (early models)
QSB/QSL – Some QSB 5.9L and QSL 8.9L injector applications
The needle is a direct replacement for Cummins part numbers 2872543, 2872545, and 2872546. It is installed in the nozzle body during injector overhaul, replacing the worn needle to restore the injector's flow and spray pattern. Each needle is lapped to the specific nozzle body during assembly to achieve the 4–6 micron clearance.
▐ Technical Specifications – Material and Dimensional Data
| Parameter | Specification |
|---|---|
| Needle Type | Differential pressure, inward-opening |
| Seat Angle | 60° (conical) |
| Seat Diameter | 3.8 mm |
| Needle Guide Diameter | 4.2 mm |
| Needle Length | 42.0 mm ± 0.02 mm |
| Needle-to-Nozzle Clearance | 4 – 6 µm |
| Material | M42 high-speed steel (8% cobalt) |
| Surface Hardness | 60 – 64 HRC |
| Surface Coating | DLC (diamond-like carbon) on guide, 1.5 µm |
| Surface Finish (guide) | Superfinished (Ra ≤ 0.08 µm) |
| Max. Injection Pressure | 2,000 bar (29,000 psi) |
| Operating Temperature Range | -40°C to +200°C |
| Service Life (new, with 2 µm filtration) | 8,000–10,000 hrs |
| Matching Requirement | Lapped to specific nozzle body |
The 60° seat angle provides a large sealing area that distributes the impact force, reducing seat wear over the injector's service life. The 4–6 micron clearance is critical – if it exceeds 8 microns, internal leakage increases by over 20%, causing injector drift and reduced rail pressure.
◆ Construction Details – The DLC-Coated Precision Needle
The 2872544 is manufactured to high precision standards for consistent performance:
→ M42 High-Speed Steel: The needle is made from M42-grade high-speed steel, containing 8% cobalt, which maintains its hardness up to 650°C – essential for the high-temperature environment of a diesel injector nozzle, where temperatures can reach 200°C.
→ DLC Coating: The guide surface receives a 1.5 µm diamond-like carbon coating, which provides a coefficient of friction of 0.10–0.12 against the nozzle body, reducing the risk of stiction and wear. The DLC coating also provides a hardness of over 2,000 HV, protecting the guide from abrasive particles.
→ Superfinished Guide: The guide diameter is superfinished to a surface finish of Ra ≤ 0.08 µm – a mirror-like finish that minimises friction and ensures the needle moves freely within the 4–6 micron clearance.
→ Conical Seat: The 60° seat is ground to a precision that creates a 360° sealing line against the nozzle seat, preventing fuel leakage during the dwell period between injections.