Reuse and Salvage for 3500, 3600 & C175 Engine Oil Pans {1302} Caterpillar

Caterpillar Products

All 3500 Engines

All 3600 Engines

All C175 Engines

All G3500 Engines

All G3600 Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8304
20	Added new serial number prefixes. Updated RTV information
19	Combined information from M0067418, SEBF8160, added 3 part numbers and repaired 34 pixelated illustrations.
18	Added new serial number prefixes.
17	Added new serial number prefixes.

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document does not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

The information in this guideline is for the salvage of two-piece and three-piece oil pan groups for the 3500 Family engines, 3600 Family engines, and C175 Family engines. If the oil pans are salvaged correctly with the procedures listed in this guideline, the oil pans can be expected to provide acceptable performance during engine operation when used in the same application.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
Media Number	Title
SEBF8882	Reuse and Salvage Guidelines, "Using Lock-N-Stitch Procedures for Casting Repair"
SEHS8792	Special Instruction, "Using Caterpillar Replacement Thread Inserts"
TIBU2809	Technical Information Bulletin, "Oil Pan Cracking"

Tooling and Equipment

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NOTICE
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Required Tooling and Equipment
Part Number	Description	Qty
1U-5232 221-1058	Welding Electrode 3 mm (0.120 inch) E7018	As needed
1U-5516	Disc (Coarse)	As needed
1U-5518	Shaft, Threaded	As needed
1U-5519	Disc Pad Holder	As needed
1U-9915	Curved Handle Wire Brush	1
4C-3770	Grinding Wheels	As needed
4C-4736	Dye Penetrant	As needed
4C-4804	Penetrant	As needed
4C-4805	Developer	As needed
4C-5831	Tip Tube	As needed
4C-8514	Flapper Wheel (2" x 1" 60 grit)	As needed
4C-8515	Flapper Wheel (2" x 1" 120 grit)	As needed
4C-9442	Flashlight	As needed
4C-9619	Welding Blanket	As needed
4S-9405	Caliper	1
5P-3920	Steel Ruler	1
5P-7414	Seal Pick	1
6V-4249	Bolt	2
6V-5230	Bolt	11
8H-8581	Feeler Gauge	As needed
8S-2257	Eye Loupe	As needed
8T-7765	Surface Reconditioning Pad	As needed
Loctite 596 RTV Silicone High Temp	Silicone	As needed
9A-1593	Comparison Gauge	As needed
9U-5839 138-8436	Liquid Gasket	As needed
9U-6182	Inspection Mirror	1
101-2862	Dowels	As needed
129-8433 142-4159	Integral Seal	As needed
133-5924	Oil Pan	As needed
133-5926	Oil Pan	As needed
137-8252	Oil Pan	As needed
137-8255	Oil Pan	As needed
172-0915	Half Baffle	As needed
198-4766	Washer	11
222-3071	Portable Angle Grinder Group	As needed
222-3074	Wheel Grinder Group	As needed
222-3076	Die Grinder (RIGHT ANGLE)	As needed
222-3080	Air Hammer	As needed
222-9151	Washer	2
223-4356	Weld Breaker	As needed
236-8097	Carbide Burr	As needed
237-5181	Respirator	As needed
254-5319	Surface Condition Brush	As needed
262-8390	Microscope, Pocket 40x	As needed
263-7147(1)	LOCK-N-STITCH Kit	1
263-7184	Crack Detection Kit	1
288-4209	Paper Towel	As needed
386-3364	Straight Edge	As needed
394-7231	Stiffener Plate	1
415-4055	Ultrasonic Tool Group	As needed
420-5317	Tool Cribbing	As needed
459-0184	UV Lamp Group	As needed
471-9747	Oil Pan	1
-	GO/NO-GO Thread Gauge Set, Metric	1
-	GO/NO-GO Thread Gauge Set, SAE	1

(1)	Additional tooling required is listed in SEBF8882. Review the list and obtain the tooling to complete the salvage operation correctly.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Measurement Requirements

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Preparation Recommendations

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 3	g03794147
Typical burr removal tooling. (A) Die grinder/right angle (B) Wheel Grinder Group (C) Conditioning discs, disc pad holder, and threaded shaft (D) Flapper wheel

• Before you inspect a component, clean thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an unacceptable defect.

• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the part.

• During cleaning, do not damage machined surfaces.

• Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature failure of internal components.

• Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the parts in a clean container.

• Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust, nicks, and dents.

• Use appropriate thread taps to chase all threaded holes.

Illustration 4	g03794153
(E) Typical example of chasing threaded holes.

Illustration 5	g06001315
Typical example of checking threaded holes using GO/NO-GO Thread Gauges.

Inspect all threaded holes with appropriate Go/No-Go Thread Gauges.

Note: NO-GO Thread Gauge (F) can be screwed into threaded hole no more than two turns. For acceptance of part, GO Thread Gauge (G) should pass through the entire length of the threaded hole without requiring too much rotational force.

If NO-GO Thread Gauge (F) exceeds two turns, then repair threads. Refer to SEHS8792Special Instruction, "Using Caterpillar Replacement Thread Inserts".

3500 Standard Oil Pans

Earlier oil pans were not equipped with support dowels and used thin gaskets. The procedures described in this guideline involve adding dowels to the deep section, removing material from the end of the shallow section, and adding holes to the shallow section of oil pan groups. The rework procedure uses a thicker integral seal gasket to make up for the material removed from the pan. The dowels locate the pan-to-pan joint integral seal and provide more support.

The three-piece oil pan groups require adding dowels to the front and rear sections with clearance holes in the center section. Also, material must be removed from the rear and center sections.

Nomenclature

Illustration 6	g06306474
Typical two-piece oil pan (1) Front section of the oil pan (2) Rear section of the oil pan (3) Location of the integral seal and dowels

Illustration 7	g06306485
Typical three piece oil pan (1) Front section of the oil pan (2) Locations of integral seals and dowels (3) Rear section of the oil pan (4) Center section of the oil pan

3516 Rework Procedure

1. Remove 3.20 mm (0.126 inch) from the front section of the oil pan in Illustration 27.

2. After machining, inspect the machined surface for porosity. If pin holes larger than 0.25 mm (0.010 inch) are found in the machined surface, fill the holes with Belzona® 1111 Super Metal. This metal can be hand formed and machined after it has cured. The Belzona® 1111 Super Metal is part of Belzona® Kit for Block Repair.
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   Illustration 8	g06306494
   Rework dimensions for the shallow section of the 3516 oil pan.

3. Drill and ream two clearance dowel holes in the joint face of the shallow section of the oil pan.
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   Table 4

   3516 Engine Oil Pan Shallow Section Dimensions
   Item	Dimension or Description
   5	Remove 3.20 mm (0.126 inch) from this surface.
   6	Reamed hole. Drill a 6.00 mm (0.236 inch) diameter hole that is 12.00 mm (0.472 inch) deep. Ream the hole to 6.200 ± 0.050 mm (0.2441 ± 0.0020 inch) diameter to a minimum depth of 8.00 mm (0.315 inch).
   7	Centerline of the pan to block bolts
   A	1344.20 mm (52.921 inch)
   B	23.00 mm (0.906 inch)
   C	530.00 mm (20.866 inch) Centerline of oil pan mounting bolt holes

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   Illustration 9	g06306496
   Rework dimensions for the deep section of the 3516 oil pan.

4. Drill and ream two interference-fit dowel holes in the joint face of the deep section of the oil pan.
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   Table 5

   3516 Engine Oil Pan Deep Section Dimensions
   Item	Dimension or Description
   6	Reamed Hole. Drill a 5.79 mm (0.228 inch) diameter hole that is 12.00 mm (0.472 inch) deep. Ream the hole to 5.947 ± 0.020 mm (0.2341 ± 0.0008 inch) diameter to a depth of 8.25 mm (0.325 inch.)
   7	Centerline of the pan to block bolts
   B	23.00 mm (0.906 inch)
   C	530.00 mm (20.866 inch)

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   Illustration 10	g06306498
   (D) Depth of dowel installation

5. Install two 101-2862 Dowels in the holes in the deep section of the oil pan to a depth of 12.00 ± 1.00 mm (0.472 ± 0.039 inch).

6. Apply Loctite 596 RTV Silicone High Temp to the following locations.

   • Both sides of 129-8433 or 142-4159 Integral Seal from the dowel holes up and position it in place over the dowels in the deep section of the oil pan. Bolt the halves of the pan together.

   • Location (14) in Illustration 11 and to the top of gasket joints.

   • Top of the integral seal tee joint at location (16) in Illustration 12, after the pan sections are bolted together, but before assembling to the bottom of the block.

7. Bolt the pan assembly to the bottom of the block.

Illustration 11	g06306502
Side view of a typical oil pan group and location of the prior to assembly. Refer to Table 6.

Table 6

Locations to Apply Prior to Assembly
Item	Description
8	Location of "tee-joint"
9	New 133-5926 Oil Pan
10	New 129-8433 or 142-4159 Integral Seal
11	New 133-5924 Oil Pan
12	Flywheel housing
13	Front accessory drive housing
14	Locations to apply s as required prior to assembly. Refer to Illustration 11
15	Gasket joints
16	Integral seal "tee-joint" on new 129-8433 or 142-4159 Integral Seal

Illustration 12	g02093233
(16) Integral seal "tee-joint"

Illustration 13	g06306505
Locations of the gasket joints (15)

3508 Two-Piece Oil Pan Rework Procedure

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Illustration 14	g06306507

1. Remove 2.47 mm (0.097 inch) from the surface (16) of the shallow section area of the oil pan.

2. Inspect the machined surface for porosity after machining. If porosity larger than 0.25 mm (0.010 inch) is found, fill the porosity with Belzona® 1111 Super Metal. This metal can be hand formed and machined after it has cured.

   Note: Dimension (J) from the newly machined end of the pan to the center of the last hole is 774.53 mm (30.493 inch).

3. Drill and ream two clearance dowel holes in the joint face of the shallow section of the oil pan. Refer to Table 7 for the sizes and the locations of the dowel holes.
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   Table 7

   3508 Engine Oil Pan Rear Section Rework Dimensions for Two-Piece Pans
   Item	Dimension
   16	Remove 2.47 mm (0.097 inch) from this surface.
   17	Reamed Holes. Drill two 6.00 mm (0.236 inch) diameter holes 12.00 mm (0.472 inch) deep. Ream the holes to 6.20 ± 0.05 mm (0.244 ± 0.002 inch) diameter to a minimum depth of 8.00 mm (0.315 inch)
   E	37.00 mm (1.457 inch) from centerline of oil pan mounting bolt holes to center of holes for the dowel
   F	497.00 mm (19.567 inch)
   G	41.00 mm (1.614 inch) from the mounting surface to the centerline of the dowel hole
   H	46.00 mm (1.811 inch) from the mounting surface to the centerline of the dowel hole
   J	774.53 mm (30.493 inch)

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   Illustration 15	g06306511

4. Drill and ream two interference-fit dowel holes (6) in the joint face of the deep section of the oil pan. Refer to Table 8 for the sizes and locations of the dowel holes.
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   Table 8

   3508 Engine Oil Pan Front Section Rework Dimensions for Two-Piece Pans
   Item	Dimension
   6	Reamed holes. Drill two 5.79 mm (0.228 inch) diameter holes 12.00 mm (0.472 inch) deep. Ream the holes to 5.974 ± 0.020 mm (0.2352 ± 0.0008 inch) diameter to a minimum depth of 8.25 mm (0.325 inch).
   E	37.0 mm (1.46 inch) from centerline of oil pan mounting bolt holes to center of holes for the dowel
   F	497.0 mm (19.57 inch) Oil pan mounting bolt holes to the furthest dowel centerline
   G	41.0 mm (1.61 inch) from the mounting surface to the centerline of the dowel hole
   H	46.0 mm (1.81 inch) from the mounting surface to the centerline of the dowel hole

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   Illustration 16	g06306515
   (D) 12.0 ± 1.0 mm (0.47 ± 0.04 inch)

5. Install two 101-2862 Dowels in the holes in the deep section of the oil pan to a depth of 12.00 ± 1.00 mm (0.472 ± 0.039 inch).

6. Apply Loctite 596 RTV Silicone High Temp to the following locations.

   1. Both sides of 132-6260 Integral Seal from the dowel holes up and position it in place over the dowels in the deep section of the oil pan. Bolt the halves of the pan together.

   2. Location (21) in Illustration 17 and to the top of gasket joints (15) in Illustration 17 and Illustration 19.

   3. Top of the integral seal tee joint at location (22) in Illustration 18, after the pan sections are bolted together, but before assembling to the bottom of block.

7. Bolt the pan assembly to the bottom of the block.

Illustration 17	g06306516
Side view of the typical oil pan group and location of the prior to assembly. Refer to Table 6.

Table 9

Locations to Apply Prior to Assembly
Item	Description
8	Location of "tee-joint"
18	New 133-5926 Oil Pan
19	New 129-8433 or 142-4159 Integral Seal
20	New 133-5924 Oil Pan
12	Flywheel housing
13	Front accessory drive housing
21	Locations to apply s as required prior to assembly. Refer to Illustration 17
15	Gasket joints
22	Integral seal "tee-joint" on new 129-8433 or 142-4159 Integral Seal

Illustration 18	g02115533
(22) Integral seal "tee-joint"

Illustration 19	g06306505
Locations of the gasket joints (15)

3508 Three-Piece Oil Pan Rework Procedure

1. Machine the rear section and add dowels.

   1. Remove 2.47 mm (0.097 inch) from the surface of the rear section of the oil pan.

   2. After machining, inspect the machined surface for porosity. If porosity larger than 0.25 mm (0.010 inch) is found in the machined surface, fill it with Belzona® 1111 Super Metal. This metal can be formed by hand and machined after it has cured.
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      Illustration 20	g06306523

   3. Drill and ream two interference fit dowel holes in the joint face of the rear section of the oil pan. Refer to Table (table below) for the dowel hole sizes and locations.
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      Table 10

      3508 Engine Oil Pan Rear Section Rework Dimensions for Three-Piece Pans
      Item	Dimension
      6	Reamed holes. Drill two 5.79 mm (0.228 inch) diameter holes 12.00 mm (0.472 inch) deep. Ream the holes to 5.974 ± 0.020 mm (0.2352 ± 0.0008 inch) diameter to a minimum depth of 8.25 mm (0.325 inch). Install two 101-2862 Dowels 12.00 ± 1.00 mm (0.472 ± 0.039 inch) deep.
      16	Remove 2.47 mm (0.097 inch) from this surface.
      E	37.00 mm (1.457 inch) from centerline of oil pan mounting bolt holes to center of holes for the dowel
      F	497.00 mm (19.567 inch)
      G	41.00 mm (1.614 inch) from the mounting surface to the centerline of the dowel hole
      H	46.00 mm (1.811 inch) from the mounting surface to the centerline of the dowel hole
      K	305.82 mm (12.040 inch)

2. Machine one side of the center section and add clearance holes.

   1. Remove 2.47 mm (0.097 inch) from the surface facing the deep sump. This face has the clearance holes. This face does not have threaded holes. Drill dowel holes in both sides.

   2. Inspect the machined surface for porosity. If porosity larger than 0.25 mm (0.010 inch) is found in the machined surface, fill them with Epoxy Resin. This metal can be hand formed and machined after it has cured.
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      Illustration 21	g06306578
      Rework dimensions for the center pan section

   3. Drill and ream two clearance dowel holes in each face of the center section of the oil pan. Refer to Table 11 for the sizes and the locations of the dowel holes.
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      Table 11

      3508 Engine Oil Pan Center Section Rework Dimensions for Three-Piece Pans
      Item	Dimension
      6	Reamed Holes. Drill four 6.00 mm (0.236 inch) holes 12.00 mm (0.472 inch) deep. Ream the holes 6.20 ± 0.05 mm (0.244 ± 0.002 inch) diameter to the minimum depth of 8.00 mm (0.315 inch).
      16	Remove 2.47 mm (0.097 inch) from this surface only (end with clearance holes).
      E	37.00 mm (1.457 inch)
      F	497.00 mm (19.567 inch)
      G	41.00 mm (1.614 inch)
      H	46.00 mm (1.811 inch)
      L	476.82 mm (18.772 inch)

3. Add dowels to the front section.
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   Illustration 22	g06306579

   1. Drill and ream two interference fit dowel holes in the joint face of the deep section of the oil pan.
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      Table 12

      3508 Engine Oil Pan Front Section Rework Dimensions for Three-Piece Pans
      Item	Dimension
      16	Reamed holes. Drill two 5.79 mm (0.228 inch) diameter holes 12.00 mm (0.472 inch) deep. Ream the holes to 5.974 ± 0.020 mm (0.2352 ± 0.0008 inch) diameter to a minimum depth of 8.25 mm (0.325 inch).
      E	37.00 mm (1.457 inch)
      F	497.00 mm (19.567 inch)
      G	41.00 mm (1.614 inch)
      H	46.00 mm (1.811 inch)

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      Illustration 23	g06306583

   2. Install two 101-2862 Dowels in the holes in the deep section of the oil pan to a depth of 12.0 ± 1.0 mm (0.47 ± 0.04 inch).

4. Apply Loctite 596 RTV Silicone High Temp to the following locations:

   • Both sides of 132-6260 Integral Seal from the dowel holes up and position it in place over the dowels in the front and rear sections of the oil pan. Bolt the three sections of the pan together.

   • Location (21) and to the top of gasket joints.

   • Top of the integral seal tee joint at location (22), after the pan sections are bolted together, but before assembling to the bottom of the block.

5. Bolt the pan assembly to the bottom of the block.

Table 13

Locations to Apply Sealant Prior to Assembly
Item	Description
8	Location of Tee Joint
23	New 137-8252 Oil Pan or 137-8255 Oil Pan
12	Flywheel Housing
21	Locations to apply sealants as required prior to assembly
15	Gasket joints
22	Integral seal tee joint on new 132-6260 Integral Seal

Illustration 24	g02139392
Side view of an oil pan group and location of sealant prior to assembly.

Illustration 25	g02115533
(22) Integral seal tee joint

Illustration 26	g06306505
(15) Gasket joints

3500 Deep Oil Pans

Illustration 27	g06306585
General Location of Possible Cracks

The 3500 engine oil pans may crack in certain applications. Although the rate of cracking is low, any cracking in the oil pan is unacceptable. The cracks primarily appear on Series 3500 deep sump oil pans. However, a few cracks have appeared on Series 3500 shallow oil pans. These cracks typically happen around the bosses on the sides and the corners of the oil pan.

The procedures in this guideline are designed to repair the cracks and the oil pan will also be strengthened.

This process has three steps.

1. Repair the crack location by grinding out the crack and then fill the crack by welding.

2. Weld a plate around the mounting pad that had the crack.

3. Weld in additional baffles to internal sections of the oil pans. This step is only for engines that are equipped with deep oil pans.

Warnings

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Define the Crack

Use the following procedure to define the crack location by using the 4C-4736 Dye Penetrant.

1. Use a wire brush to thoroughly clean any paint or grease from the surface that is to be inspected.

2. Use a cleaner on the part to remove any oil residue from the surface.

3. Apply the dye penetrant onto the surface. Allow the penetrant to dry for 3 to 5 minutes so that the penetrant is fully absorbed into the crack.

4. Wipe the dye penetrant from the surface by using a clean towel.

5. Apply a light coat of developer onto the surface that is to be inspected. A crack will appear as a red line in the developer.

6. Mark the complete outline of the crack or center punch the ends to make the crack visible after the developer and the penetrant is removed.

7. Make sure that the true ends of the crack have been identified to stop further progression of the crack.

Removing and Cleaning the Crack

1. Grind out the entire crack in a V-groove. Make sure that you grind the entire length and the entire depth of the crack.

2. Clean the entire length of the ground area.

3. Use a wire brush to clean the prepared groove. Enough area should be cleaned so that you can weld to bare base metal.

4. All oil, grease, and paint must be removed from the weld area. Surface oxides must be also removed from the weld area. Surface preparation is very important for a good repair.

Welding the Crack

1. Use a 1U-5232 or 221-1058 Welding Rod to fill the weld area along the entire length of the crack.

   Do not allow the temperature to exceed 260° C (500° F).

   Make sure that the surface is above 16° C (60° F).

2. After the entire crack has been filled, grind the weld so that the weld is level with the existing side of the oil pan. Several passes may be required to fill the crack.

Welding of Steel Plate Over Mounting Boss and the Repaired Weld Area

Illustration 28	g06306588
(1) Type 1 Design. (2) Type 2 Design.

There are two different types of side plates that are used. Type 1 design is used for cracks that appear around the mounting bosses that are located on the sides of the oil pan. Type 2 design is used for cracks that appear around the mounting bosses that are located on the corners of the oil pan. Two different designs of type 2 plates exist. Refer to the following illustrations for more information on fabricating the side plates.

Illustration 29	g06306590
The plate for the Sides of the Oil Tank should be made from 5 mm (0.20 inch) thick plate steel.

Table 14

Dimensions for Side Plates
Callout	Dimension
A	50 mm (1.97 inch)
B	104 mm (4.00 inch)
C	54 mm (2.125 inch)
D	225 mm (8.85825 inch)
E	171 mm (6.73227 inch)
F	5 mm (0.19 inch) X 45 Degree Chamfer
G	125 mm (4.90 inch)
H	65 mm (2.55 inch) Radius

Illustration 30	g06306593
The Plate for the Front Right Corner and the Back Left Corner should be made from 5 mm (0.20 inch) thick plate steel.

Table 15

Dimensions for Side Plates
Callout	Dimension
A	75 mm (2.95 inch)
B	5 mm (0.19 inch) X 45 Degree Chamfer
C	205 mm (8.00 inch)
D	47 mm (1.85 inch)
E	125 mm (4.92 inch)
F	65 mm (2.55 inch) Radius

Illustration 31	g06306597
The plate for the Back Right Corner and the Front Left Corner should be made from 5 mm (0.20 inch) thick plate steel.

Table 16

Dimensions for Side Plates
Callout	Dimension
A	75 mm (2.95 inch)
B	5 mm (0.19 inch) X 45 Degree Chamfer
C	205 mm (8.00 inch)
D	47 mm (1.85 inch)
E	125 mm (4.92 inch)
F	65 mm (2.55 inch) Radius

1. Determine the number of plates that are needed to repair the cracked locations. For further strengthening of the oil pan, you may add the plates to all bosses.

2. Before cutting the side plates, make sure that the recommended dimensions for the side plates will cover the entire length of all cracks by at least 20 mm (0.80 inch). This may require some modification to the dimensions. Rounded ends of the side plates need to be maintained. Any sharp corners will provide stress risers for the start of new cracks.

3. Cut all side plates that are required to update the oil pan.

4. Prepare each weld area by smoothing the surface after welding. The beveled edge of the plate may need to be ground to allow the plate to sit flush with the existing side wall.

5. Clean the entire length of the ground area.

6. Use a wire brush to clean the prepared groove. Enough area should be cleaned so that you can weld to bare base metal.

7. All oil, grease, and paint must be removed from the prepared groove and the weld area. Surface oxides must be also removed from the weld area. Surface preparation is important.

8. Use a 1U-5232 or 221-1058 Welding Rod E7018 to tack weld along the outer edge of the plate at 90 degree locations by using the following sequence Top, Bottom, Right and Left.

9. Use a 1U-5232 or 221-1058 Welding Rod E7018 to completely fill in the V-shaped area between the plate and the mounting boss. This may require multiple passes.

   Do not allow the temperature to exceed 260° C (500° F).

   Make sure that the welding surface temperature is above 16° C (60° F).

10. Use a 1U-5232 or 221-1058 Welding Rod E7018 to weld around the entire edge of the plate. This should be done with a single pass weld with a 3 mm (0.12 inch) fillet.

Adding Internal Baffles to Oil Pans (Deep Oil Pans Only)

This section applies to deep oil pans only. The number of internal baffles has been increased n order to strengthen deep sump oil pans on Series 3500 Series Engines. The Series 3508 Series has increased from 1 to 3 baffles. The Series 3512 Series has increased from 2 to 5 baffles. The Series 3516 Series has increased from 3 to 7 baffles. Two half sections of baffles need to be inserted into the oil pan and welded together to form one new baffle. To repair the Series 3508 Series engine, four half baffles would be required.

The following illustration shows the new 172-0915 Oil Pan Baffle Half.

Illustration 32	g06306599

Order the appropriate amount of 172-0915 Oil Pan Baffle Half for the model of oil pan you are reworking. Use the following illustrations to determine the approximate locations for the new baffles.

Illustration 33	g06306602
Series 3508 Series Engines with Deep Oil Pan using Four half baffles.

Table 17

Dimensions for Series 3508 Series Engines
Callout	Dimension
A	1021 ± 2 mm (40.2 ± 0.08 inch)
B	353 ± 2 mm (13.9 ± 0.08 inch)

Illustration 34	g06306604
Series 3512 Series Engines with Deep Oil Pan using Six half baffles.

Table 18

Dimensions for Series 3512 Series Engines
Callout	Dimension
A	1536 ± 2 mm (60.5 ± 0.08 inch)
B	904 ± 2 mm (35.6 ± 0.08 inch)
C	338 ± 2 mm (13.3 ± 0.08 inch)

Illustration 35	g06306606
Series 3516 Series Engines with Deep Oil Pan using Eight half baffles.

Table 19

Dimensions for Series 3516 Series Engines
Callout	Dimension
A	2078 ± 2 mm (81.8 ± 0.08 inch)
B	1444 ± 2 mm (56.8 ± 0.08 inch)
C	870 ± 2 mm (34.3 ± 0.08 inch)
D	345 ± 2 mm (13.6 ± 0.08 inch)

1. Use a 1U-5232 or 221-1058 Welding Rod E7018 3 mm (0.12 inch) to tack weld each baffle half to the pan side walls at the proper locations.

2. Use a 1U-5232 or 221-1058 Welding Rod E7018 3 mm (0.12 inch) to tack each baffle half to each other at the overlapping center.

3. Use a 1U-5232 or 221-1058 Welding Rod E7018 3 mm (0.12 inch) to complete a continuous weld of each baffle half to the pan sidewalls. The weld size should be 3 mm (0.12 inch) on both sides of the baffle.

4. Use a 1U-5232 or 221-1058 Welding Rod E7018 3 mm (0.12 inch) to complete a continuous weld of each baffle half to each other at the overlapping center. The weld size should be 3 mm (0.12 inch) on both sides of the baffle.

3600 Engine Oil Pans

There are two recommended methods to salvage oil pans with cracks and/or external damage: welding and Lock-N-Stitch procedure.

Note: If any drilling is used for the repair of the oil pan, use magnets or other collection systems to prevent metal shavings from entering the oil pan during the drilling operations.

Remove the side covers on both sides of the engine for inspection of the damaged area. Sometimes, a crack or other damage may be in line with the internal baffle plates. There is a possibility that the crack will progress at an angle through the oil pan. These types of damage should be repaired by welding with steel plate only.

Crack Inspection

1. Use a wire brush to clean any paint or grease from the surface to be inspected.

2. Spray or apply cleaner/remover fluid on the part to remove any oil and contaminants from the surface.

3. Spray or apply the dye penetrant on the surface. Let the surface dry for 3 to 5 minutes so that the dye absorbs into the crack.

4. Wipe dye penetrant from the surface using a clean towel.

5. Spray or apply a light coat of developer on the surface to be inspected. A crack will appear as a red line in the developer.

Mark the complete outline of the crack with a metal scribe or center punch the ends. This will make the crack visible after removing dye penetrant and developer. Additional repair procedures will require both ends of the crack to be identified and specially prepared.

Welding Procedures

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Cleaning

1. Before any welding is done on the oil pan, make sure the area to be repaired is thoroughly cleaned. Use a wire brush or grinding stone to clean the crack joint and the heat-affected zone.

2. All contaminants must be cleaned from the joint surfaces and the heat-affected zone. Surface oxides must be removed from the area to be welded.

3. Good cleaning and surface preparation of the area to be welded is important, if a good quality repair is to be made.

Correct Grounding Of The Welding Machine

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NOTICE
Before any welding is attempted on the oil pan, use correct grounding to prevent internal engine damage to bearings and corresponding components. Wire brush an area directly next to the repair on the oil pan. All paint, oil, and grease must be removed to ensure a correct ground for the welding machine. Incorrect grounding will result in an early engine failure.

Illustration 36	g06306620
Strip used for grounding the welding machine.

Use a wire brush or grinding stone to clean an area on both sides of the metal strip that is attached to the outside wall of the oil pan. The strip is located approximately 143.0 mm (5.63 inch) from the top of the pan. This strip is used for fixturing during the manufacture of the oil pan. Clean an area approximately 32.0 to 38.0 mm (1.26 to 1.50 inch) long to produce a correct ground. Clean and attach the ground wire from the welder at location (A). See Illustration 36.

Note: Before any welding is attempted on the oil pan, remove the access cover from both sides of the engine block for visual inspection of the damaged area. Remove oil from the pan until the level is at least 100.0 mm (4.00 inch) below the damaged area.

Using Steel Plate To Repair A Crack

The oil pan can be repaired using a piece of mild steel plate to seal the leakage. See the following procedure.

1. Use a wire brush or grinding stone to clean the complete surface where the steel plate will be installed.
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   Illustration 37	g06306621
   Drill holes at end of crack.

2. Locate the true ends of the crack and drill a 6.0 mm (0.24 inch) hole (B) at both ends of the crack as shown in illustration 37.

   Note: Use magnets or other methods to prevent metal shavings from entering the oil pan during drilling operation.

3. Visually inspect the inside surface to be sure that the drilled holes are beyond the ends of the crack. This will stop the progression of the crack during welding and engine operation.
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   Illustration 38	g06306623
   Recommended shape of plate is round or oval.

4. Fabricate a piece of mild steel plate approximately 3.8 to 4.7 mm (0.15 to 0.18 inch) thick as shown in Illustration 38.

   Note: The ideal shape for the piece of repair plate is either round or oval. If the recommended shape cannot be used and the plate must be rectangular, round off all corners of the plate as much as possible.

5. Tack weld the plate at points about 90 degrees apart using the following sequence- top, bottom, right, and left. Use a short weld bead to reduce heat build-up in the oil pan material.

6. Weld completely around the plate to seal the repair.

Note: Weld the rounded corners last when using a rectangular plate.

Using Only Filler Metal (Electrodes) To Repair A Crack

1. Identify the true ends of the crack to stop the progression of the crack.
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   Illustration 39	g06306626
   Stringer welds at each end of the crack.

2. If Length (C) in Illustration 39 is not longer than 76.0 mm (3.00 inch), weld a small bead (D) at a right angle across each end of the crack. Make these weld beads 25.0 to 38.0 mm (1.00 to 1.50 inch) long.

3. Start at the center and make light weld passes in alternate directions between the weld dams to seal the crack. See Illustration 40.
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   Illustration 40	g06306631
   Light weld passes starting from center of crack.

4. If length (C) is longer than 76.0 mm (3.00 inch), make stringer welds (D) at right angles across the ends.
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   Illustration 41	g06306635
   Divide crack into 76.0 mm (3.00 inch) segments with stringer welds.

5. Measure the length of the crack. Then, divide the crack with stinger welds (E) to ensure that no section of the crack is longer than dimension (F) of 76.0 mm (3.00 inch). This will help keep the crack from increasing in length.

6. Use the same welding procedures as previously outlined in step 3.

Note: Avoid over-heating of the heat-affected zone to prevent additional cracking.

Inspecting Weld Repair

After welding, inspect the repaired area with dye penetrant to locate any possible weld stress cracks. If any cracks are found, grind out the area of the stress crack and reweld the area where the crack appeared. Keep the heat buildup as low as possible when welding. Short weld passes will reduce heat build-up. Refill the oil pan to the correct level.

Lock-N-Stitch Procedure

Refer to Reuse And Salvage Guidelines, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair" for the Lock-N-Stitch procedures.

C175 Oil Pans

Deep Pan Inspection

Cracks in the oil pans should not be repaired. Cracks will continue to form even after repairs. Any oil pan that has a crack should be replaced.

Illustration 42	g03896333

Illustration 43	g03896335

Illustration 44	g03896336

Illustration 45	g03896356

Illustration 46	g03896357

Repairs should not be made to cracked oil pans. The cracks will return after repairing the casting.

Mid-Section Oil Pan Inspection

Mid-Section oil pans have been updated to include a deeper Press-In-Place (PIP) groove for the o-ring seal. To update the mid-section oil pans new hardware is also needed. See Table 20 for the hardware needed to install the new 471-9747 Oil Pan.

Table 20

Part Number	Description	Quantity	Callout
6V-4249	Bolt	2	(1)
6V-5230	Bolt	11	(3)
198-4766(1)	Washer	11	(4)
222-9151(1)	Washer	2	(2)
394-7231(1)	Stiffener Plate	1	(5)
471-9747	Oil Pan	1	(6)

(1)	May be reused from old configuration

Inspect the midsection oil pan for cracks in the seal groove. Do not reuse any cracked oil pans or attempt to salvage cracked oil pans. All cracked midsection oil pans should be replaced with 471-9747. If no cracks are present the midsection oil pan may be reused.

Illustration 47	g03896720
Location of midsection oil pan.

Illustration 48	g03896721
Location of the cracking within the PIP seal groove.

Illustration 49	g06306641
Graphic above shows locations of new hardware and the stiffener plate.

Refer to for the proper Disassembly and Assembly instructions for details on removing and installing the midsection oil pan.

Rear Oil Pan Inspection

Rear sections of the oil pan must be inspected for cracking and fretting. If the oil pan shows cracks at the location of the rear engine mount it must be replaced. If fretting damage is deeper than 0.5 mm (0.020 inch) the oil pan must be replaced. If the oil pan shows no cracks or fretting deeper than 0.5 mm (0.020 inch), it may be reused.

Illustration 50	g06306648
Example of cracks on the mounting area of the rear oil pan. Do not attempt to salvage cracked oil pans as the cracks will return.

Illustration 51	g06306644
Example of cracks on the mounting area of the rear oil pan. Do not attempt to salvage cracked oil pans as the cracks will return.

Illustration 52	g06306643
Fretting that is deeper than 0.5 mm (0.020 inch).

Illustration 53	g06024397
Fretting that is deeper than 0.5 mm (0.020 inch).

Crack Detection Methods

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NOTICE
Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.

Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components for cracks without damaging the component. Visual inspection (VT), Liquid Penetrant Testing (PT), Magnetic Particle Inspection (MT), Ultrasonic Testing (UT), Radiographic Testing (RT) and Eddy-Current Testing (ET) are recommended methods. There may be more than one acceptable crack detection method for the inspection of a given part, though the liquid penetrant is the most versatile. For example, the liquid penetrant method can be used when inspecting smooth machined components such as shafts, gear teeth, and splines, but using the Wet Magnetic Particle Inspection is more accurate. Refer to Table 21 for advantages and disadvantages and Table 22 for standards and requirements for these NDT methods.

Table 21

Crack Inspection Method Advantages vs. Disadvantages
Inspection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least expensive - Detects most damaging defects - Immediate results - Minimum part preparation	- Limited to surface-only defects - Requires inspectors to have broad knowledge of welding and fabrication in addition to non-destructive testing
Liquid Penetrant (PT)	- Inexpensive - Minimal training - Portable - Works on nonmagnetic material	- Least sensitive - Detects surface cracks only - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only - Less sensitive than Wet Magnetic Particle
Wet Magnetic Particle (MT)	- More sensitive than Liquid Penetrant - Detects subsurface as much as 0.13 mm (0.005 inch)	- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored
Ultrasonic Testing (UT)	- Most sensitive - Detects deep material defects - Immediate results - Wide range of materials and thickness can be inspected	- Most expensive - Requires operator training and certification - Surface must be accessible to probe
Eddy-Current Testing (ET)	- Surface and near surface flaws detectable -Moderate speed/Immediate results -Sensitive to small discontinuities	- Difficult to interpret - Only for metals -Rough surfaces interfere with test - Surface must be accessible to probe
Radiographic Testing (RT)	-Detects surface and internal flaws - Minimum part preparation - Can inspect hidden areas	- Not for porous materials - Radiation protection needed - Defect able to be detected is limited to 2% of thickness

Table 22

Applicable Crack Detection Standards
Inspection Method	Standard	Acceptance Criteria	Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Magnetic Particle Testing (MT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Ultrasonic Testing (UT)	EN-ISO 17640 - Level B AWS D1.1	EN-ISO 11666 Technique 2 - Level 2 AWS D1.1 - Class A - Table 6.3	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Eddy-Current Testing (ET)	EN-ISO 15549 ASTM E426	EN-ISO 20807	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2
Radiographic Testing (RT)	EN-ISO 5579 ASTM E94	EN-ISO 10657-1	EN-ISO 9712 - Level 2 ANSI-ASNT SNT-TC-1A Level 2

Visual Surface Inspection (VT)

Illustration 54	g06085008
Example of Visual Inspection Tools (A) Flashlight or adequate light source (B) Magnifying eye loupe (C) Tape measure or other measuring device (D) Inspection mirror (E) Weld size inspection gauges

Components and welds that are to be inspected using PT, MT, or UT shall first be subject to Visual Surface Inspection (VT). Visual Inspection is often the most cost-effective inspection method and requires little equipment as seen in Illustration 54. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient experience and knowledge with regard to the components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test regularly.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

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Illustration 55	g06107074
Typical example of pre-cleaning area.

1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry. If there is visible crack remove paint using paint remover or wire brush.
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   Illustration 56	g06107081
   Typical example of applying penetrant.

2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.
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   Illustration 57	g06107088
   Typical example of removing excess penetrant oil.

3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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   Illustration 58	g06107094
   Typical example of applying developer.

4. Before using Developer, ensure that it is mixed thoroughly by shaking can. Holding can approximately 203.20 - 304.80 mm (8.00 - 12.00 inch) away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.
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   Illustration 59	g06084042
   Typical example of cracks found during a liquid penetrant testing.

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 59. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 60	g06085930
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (C) Dry powder bulb.

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 61	g06085937
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process.

Illustration 62	g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 62. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

   5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
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   Illustration 63	g03536210

3. For case hardened and ground surfaces:

   • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 63 for an example of yoke placement.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. Record the size and shape of any discontinuities found.

Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician.

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NOTICE
All personnel involved in ultrasonic testing shall be qualified to Level 2 in accordance to standards stated in Table 22.

Refer to Tooling and Equipment Table 3 for part numbers.

1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.

2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

   1. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect form the backsurface of the material to project the thickness of the material.

   2. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.

Eddy-Current Testing (ET)

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NOTICE
All personnel involved in Eddy-Current Testing shall be qualified to Level 2 in accordance to standards stated in Table 22.

Illustration 64	g06090873
Eddy-Current Testing

Eddy-Current Testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the flow caused by variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. Major applications of eddy-current testing are surface inspection and tubing inspections.

Radiographic Testing (RT)

Note: CAUTION: This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.

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NOTICE
All personnel involved in radiographic testing shall be qualified to Level 2 in accordance to standards stated in Table 22.

Illustration 65	g06090892
Radiographic Testing

Radiographic Testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to penetrate materials to find hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source and the film, or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will project onto the film any indications that have been in the path of the radiation waves.