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FP Diesel PhilosophyFP Diesel – part of the Federal-Mogul EngineSystems group – is the industry’s leadingbrand of premium heavy-duty replacementengine parts and gaskets, providing totalengine system solutions for such well-knownbrands as Case, Caterpillar, Cummins, DetroitDiesel, IH/Navistar, John Deere, Komatsu, Mack, Waukesha and White Superior .Federal-Mogul maintains a steadfastcommitment to unsurpassed product qualityand customer service. We serve construction,marine, agricultural, mining, gas compression,trucking and industrial markets aroundthe globe. As the global leader in heavy-dutypowertrain systems, Federal-Mogul is instrumentalin the development of every new generation ofgasoline and diesel engine technology. When youchoose FP Diesel, you get unparalleled globalengineering and manufacturing resources built intoevery product.Today’s medium and heavy duty commercialmarkets demand performance. Performancemeans precision-engineered parts thatmeet your demanding specifications; andare backed by a team of knowledgeablecustomer service representatives who canprovide technical information and assistance;computerized order and inventory tracking forfast and accurate order fill; unprecedentedwarranty programs and a company-widecommitment to customer satisfaction.ConstructionAgricultureOn-Highway 2010 Federal-Mogul Corporation. FP Diesel and their respective designs are registered trademarksof Federal-Mogul Corporation. Case is the registered trademark of Case Corporation, Inc.; Cat andCaterpillar are the registered trademarks of the Caterpillar, Inc.; Cummins is the registered trademarkof Cummins Engine Company; Detroit Diesel is the registered trademark of Detroit Diesel Corporation;IH/Navistar is the registered trademark of International Truck and Engine Corporation; John Deere is the registered trademark of Deere & Company; Komatsu is the registered trademark of KomatsuLimited, Inc.; Mack is the registered trademark of Mack Trucks, Inc.; Waukesha is the registeredtrademark of the Waukesha Engine Division of Dresser Industries, Inc.; White Superior is theregistered trademark of White Superior Corporation, Inc. Jacobs is a registered trademark of JacobsVehicle Systems. All rights reserved.ivMarine

ManufacturingPrecise manufacturing and fabricating techniques,rigorous quality control procedures, utilization of thelatest CAD technology and innovative solutions toindustry challenges – coupled withFederal-Mogul’s global manufacturing capabilities –have established FP Diesel as the industry leader inthe medium and heavy duty commercial market.FP Diesel applies stringent quality controlprocedures with expertly skilled technicianssupervising the manufacturing process in allphases to ensure that our parts will performand last.FP Diesel is a military approved supplier for the53 Series Detroit Diesel engine. But the parts wesupply for the 53 aren’t the only ones that gothrough government testing. Every FP Diesel partmust pass through high-level quality control.Plus, every part is tracked throughout the entiredistribution process.Customer Servicerepresentative you’ll have answers toany product, technical, order processing,billing, warranty, pricing, order trackingor availability questions you may have.Customer service that goes the extra milealso means you not only get the parts youneed, but expert assistance from a personwho knows the market.FP Diesel customer service representativesare among the most experienced andknowledgeable in the industry, with handson medium and heavy-duty experience andin-depth knowledge of engine parts andapplications. With one call to yourPlus, our computerized inventory system allowsus to ship orders promptly anywhere inthe world, while our easy-to-use catalogingsystem makes ordering FP Diesel parts fastand simple. For the parts and informationyou need, count on FP Diesel to go theextra mile.v

CoverageCOVERAGEThe FP Diesel product offeringis a comprehensive line of dieseland natural gas engine replacementparts that provides all the coveragenecessary to meet your heavy-dutyengine rebuilding needs. FP Dieselalso offers a full line of gaskets andelastomeric products. For morespecific information, pleaserefer to our full-line catalogs,which are engine and machinespecific and follow OEM format.To ensure exact part numberreplacement, these catalogsreference OEM part numbers andfeatures technical information relating tothe specific engine being serviced.Products and Catalogs&DWHUSLOODUReplacement Caterpillar products cover 3200, 3300,3400, 3500, D Series and G Series engines. Thiscoverage extends from cylinder heads, fuel injection,cam and crankshafts, cylinder kits, valvetrain andeletrical to engine bearings, transmission, hydraulicgasket sets and more. 5HIHU WR )3 'LHVHO FDWDORJ N743, KT/KTA 19-, 38- and 50-liter engines, and theCummins 855. 5HIHU WR )3 'LHVHO FDWDORJ 1R & 0DFNFP Diesel has a broad line for Mack, early ENDT 675and 676 engines, as well as parts for later EM6 withboth two- and four-valve head configurations. 5HIHU WR 1R & SDUWV DQG & JDVNHWV )3 'LHVHO FDWDORJ 1R & &XPPLQVFP Diesel provides replacement parts coverage forV378, V504, V555, Small Vee Engines, V/VT 903,855 Series, N14, L10, B Series, C Series, V/VT1710,N743 and K/KTA 18-, 38- and 50-liter engines, as wellas components for Jacobs brakes. 5HIHU WR )3 'LHVHO ,QWHUQDWLRQDO 1DYLVWDUInternational coverage extends from the 6.9 and7.3 liter, DT-360 and DT-466 through the 9.0 liter engine.5HIHU WR )3 'LHVHO FDWDORJ 1R & .For agricultural applications, FP Diesel also servicesthe DT-414 and DT-436 Case/I.H. engines. )RU LQGXVWULDO DQG DJULFXOWXUDO DSSOLFDWLRQV UHIHU WR )3 'LHVHO FDWDORJ 1R & FDWDORJ 1R & 'HWURLW 'LHVHOFP Diesel offers the most complete coverage in thereplacement parts industry for Detroit Diesel, with anextensive line of components and kits for the 8.2-liter,53 Series, 60 Series, 71 Series, 92 Series and 149Series engines. 5HIHU WR )3 'LHVHO FDWDORJ 1R & &DVHFP Diesel has a complete range of kits and componentsfor the 188, 207, 301, 366, 451 and 504-Case enginesalong with the 4-390 & 4T-390, 6-590 & 6T-590, 6T-830& 6TA-830, LTA 10 and NTA 855 B/C III Cumminsengines. 5HIHU WR )3 'LHVHO FDWDORJ 1R & IRU F\FOH HQJLQHV RU )3 'LHVHO FDWDORJ 1R & IRU F\FOH HQJLQHV &RPPHUFLDO J ,QGXVWULDO (QJLQHVThe FP Diesel CA0188 catalog includes all the enginemanufacturers not covered in the FP Diesel name-platespecific catalogs. Replacement engine components forAllis-Chalmers, Bedford, Bendix-Westinghouse, Briggs& Stratton, Buda, Case Tractor, Chevrolet MD Truck,Climax, Continental, Dodge MD Truck, Ford Tractor,GMC MD Truck, Hercules, IHC Tractor, Isuzu Forklift,KHD, Kohler, LeRoi, Massey Ferguson, Mercedes,Mazda Forklift, Minneapolis-Moline, Mitsubishi,Novo, Oliver, Perkins, Superior, Thermo-King, Volvo,Waukesha, White and Wisconsin are included in the)3 'LHVHO & FDWDORJ -RKQ 'HHUHFP Diesel offers a broad range of in-frame andcomplete overhaul kits and related components for 300Series, 400 Series, 500 Series and Powertech enginesis available from FP Diesel. 5HIHU WR )3 'LHVHO FDWDORJ 1R & .RPDWVXExtensive coverage for Komatsu S6D155 andSA6D155 engines, as well as a full line ofreplacement parts for Komatsumachines using Cumminsvi

Engine KitsENGINEKITSThe FP Diesel Engine Kit program allows you to select a kit tailored to the job athand. Whetherperforming a complete overhaul, or in-frame repair, FP Diesel engine kits contain all thenecessary components to complete the rebuild job. This comprehensive program providesyou with the following:ssss#ONCISE APPLICATION INFORMATION/NE PRICE LOOK UP! FULL COMPLEMENT OF OVERSIZES AND UNDERSIZES-ASTER KITS THAT INCLUDE FULL GASKET SETSEngine kits are listed at the back of this catalog and under the In-Frame and Overhaul specificsections.How To Specify FP Diesel Engine KitsMany FP Diesel engine kits have several variations incomponents that are available depending on the specificengine. Overhaul Kits are designed to contain all theparts necessary to rebuild a particular engine. To assurethat the kit is correct and complete, all that is necessaryis for you to supply the engine information located onthe Data Plate on the side of the engine block. In somecases the block casting number and the connecting rodnumber are also required. This information enablesyour FP Diesel service representative to configurethe Engine Kit to your particular requirementsinsuring that everything is properly accounted for.In cases where there are no variable components,we have pre-configured the kits to include all thenecessary parts for that application.viivii

Engine BearingsEngine Bearing Material SelectionWhen selecting engine bearings, mostrebuilders concentrate on getting the properclearances and maintaining adequate oilpressure. Durability is expected from anybearing chosen, and the advantages ofdifferent bearing materials may not beconsidered. If engine operating conditionsare considered and bearing materialschosen accordingly, the likelihood of enginelongevity is greater. No single material canbe correct for every application. FP Dieselengine bearings are equal to or betterthan the original equipment specificationsfor material and design. We also providealternatives to address unique problems andspecial needs.Bi-Metal Aluminum AlloysPlated and UnplatedTri-Metal AlloysDiesel fuels, moisture, and engine “blow-by”introduce many contaminants into thecrankcase. Aluminum engine bearingmaterials provide outstanding resistance tothe corrosive effects of these substances,and are the product of choice for mostcurrent original equipment vehiclemanufacturers. The modern bi-metalaluminum engine bearing contains silicon.As a result of using silicon,the alloy resists seizureand dramatically reducesor eliminates bearing wear.This contributes to today’sextended engine life. Aluminumis often the best material fora daily driven vehicle. Addingan overplate to an aluminumengine bearing will furtherenhance embedability andconformability. Continuedefforts to remove leadfrom our environmentguarantee thataluminum willbecome thepreferredenginebearingmaterial formost applications.In heavy duty applications there are a numberof materials that will do an excellent job. Eachalloy has advantages in terms of resistanceto corrosion, rate of wear and fatigue strength.The latter characteristic is critical in enginesthat operate under high loads, generateconsiderable heat and may be subjectedto occasional detonation.Tri-Metal engine bearings, such as our H-14and H-24 alloys, have excellent fatigueresistance, but are less resistant to corrosiondamage than aluminum bearings. Thesebearing materials are accepted by enginebuilders worldwide, and are proven to bereliable in a wide range of uses. While OEmanufacturers are moving to aluminum fortheir needs, many rebuilders still specify thetri-metal bearings for older engines.Typical Commercial Engineviii

Engine BearingsENGINEBEARINGSThrustBearingRod and Main BearingPLASTIGAGEFederal-Mogul offers Sealed PowerPlastigage. It ends the guessing gamewhen measuring clearances of main andcconnecting rod bearings. Specially formulatedand oil soluble, Plastigage strips flattenaprecisely for accurate reading. Plastigagesstrips are available in four size ranges,packaged 12 to a carton, (enough to do12 engines). Part number SPG-1 cartonsccontain strips in the .001-.003 inch range.Part number SPR-1 cartons hold strips in the.002-.006 inch range. SPB-1 cartons includesstrips in the .004-.009 inch range. SPY-1ccartons contain strips in the .009-.020 inchrange. This complete range of sizes will fitevery heavy duty engine.A Quick and Accurate Methodfor Measuring Main andConnecting Rod Bearing Clearances.63* 63* 635 63% 63 LQ LQ LQ LQ ix

Heavy Duty PistonsHeavy Duty PistonsFP Diesel heavy duty pistons are designedand produced for severe operating conditions.Federal-Mogul is one of the world’s leadingmanufacturers of heavy duty pistons offeringone and two-piece designs including aluminumarticulated, cast iron and steel materials. Forsevere and high load applications, FP Dieselpistons include a metallurgically bondedNI-resist insert in the top and in some cases,the second ring groove. The NI-resist insertminimizes groove wear and reduces pound-outfrom the compression ring. Anodized headsand graphite-coated skirts offer additionaldurability in severe applications. Federal-Mogulalso utilizes an in-house, patented magnesiumphosphate coating to reduce the pistoncorrosion caused by high-sulfate diesel fuelsand break-in wear on problematic applications.We design our heavy duty pistons usingthe latest in computer aided design (CAD)software. Each application is thoroughlyresearched to ensure the proper dimensionaland metallurgical requirements. And since wealso design and manufacture cylinder linersand piston rings, our engineers can make sureeach piston we develop provides optimumperformance as part of the “power-cylinder”system.x

Medium Duty PistonsDUROSHIELD PistonsA growing number of our pistons areavailable with our exclusive factory-appliedgraphite anti-friction coating. This patentedtechnological advance can extend the life ofan engine and essentially eliminate pistonscuffing problems. Coated pistons areideal for severe duty performance enginesand everyday applications. The coating isprecisely applied to pistons with a computercontrolled application and unique curingprocess. There is no overspray with ourprocess and no coatingends up in thering grooves.'8526 ,(/' 3LVWRQV O ,PSURYH SLVWRQ OLIH O 5HGXFH IULFWLRQ O (VVHQWLDOO\ HOLPLQDWH VFXIILQJ DQG ZHDU O HOS SUHYHQW GDPDJH IURP LQDGHTXDWH OXEULFDWLRQ HVSHFLDOO\ GXULQJ VWDUW XS O ,PSURYH F\OLQGHU VHDOLQJ IRU OHVV EORZ E\ DQG PRUH SRZHU O 5HTXLUH QR LQFUHDVH LQ VNLUW FOHDUDQFHxixi

Sleeves and AssembliesCylinder sleeves are produced byFederal-Mogul in a QS9000 registeredfacility complete with casting, inductionhardening, machining, measurement anddesign capabilties. We start with raw castingsproduced on a state-of-the-art molding linespecifically designed for the manufacture ofstatic cast cylinder liners. The static castingsproduced by our foundry have a veryconsistent microstructure and superior scuffingresistance.Certain applications are induction hardenedor thru-hardened to enhance the wearcharacteristics and strength of the liner.Hardened liners are typically used in engineshighly susceptible to dirt contamination, suchas construction or agricultural applications.Machining is performed on modern CNCequipment to ensure dimensional stability andexacting tolerances. Cylinder liners are typicallyfinish honed to generate a plateau finish. Theplateau finish promotes rapid ring seatingduring break-in while providing a long-wearingsealing surface.FP Diesel offers sleeves for wet, dry and repairapplications. Sleeve assemblies or kits includethe sleeve, piston, piston pin and lock rings,piston rings and sealing rings.xii

Piston RingsFP Diesel offers a broad range of pistonrings that dominate the industry withtechnically advanced design, dedicatedresearch and superior quality. Our ringsminimize cylinder leakage under trueoperating conditions, and provide maximumoil control.Top RingFP Diesel top rings provide reliablecompression sealing and maximum poweroutput, and control "blow-by." They areengineered for instant seating, superiorcylinder sealing and optimum durability. Weoffer cast iron, high strength ductile iron,and steel material choices. All premium ringsets feature moly, chrome or plasma-molyfacings for enhanced performance underdemanding conditions. The inherent strengthof our materials provides sealing integrityat extreme pressures and RPM. We supplyrings for all popular

The new CA0188 Heavy Duty Engine Parts Catalog contains all of the components currently offered from FP Diesel for heavy and medium duty truck engines, agricultural and irrigation engines, industrial engines and marine engines not covered in the FP Diesel name-plate specific