Reuse and Salvage For 3500, 3600 & C175 Engine Oil Pans

1/30/24, 3:29 PM SIS 2.
Reuse and Salvage for 3500, 3600 & C175 Engine Oil Pans {1302} (SEBF8304-22)
SMCS - 1302 i08480718

Caterpillar Products
All 3500 Engines
PIP
All 3600 Engines
All C175 Engines -

202 1046
All G3500 Engines
4
12: 01/3 666
/ 4
2
All G3600 Engines
Revision History:
SEB 9:54+ 0
© 2 F830 03:00
Table 1
Revision Summary of Changes in SEBF8304
22 0
Cat 4 C2 4
Added media to the "References" Section.
Added the "Salvage Welding" Section.
21 e
Con rpilla aterpi
Added Images 45 through 48.
Added new serial number prefixes.
20
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Added new serial number prefixes. Updated RTV information
19
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Combined information from M0067418 and SEBF8160, added 3 part numbers, and repaired
34 pixelated illustrations.
17–18
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Added new serial number prefixes. .
Introduction llow
© 2021 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).
Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair
options or modifications to reuse and salvage techniques and/or methods.
https://sis2.cat.com/#/print-preview/service/fc12efdf-b424-4708-a0d4-0526e8b45dc7 1/56
1/30/24, 3:29 PM SIS 2.0
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 may include canceled part numbers and replaced part numbers. Use the Numerical Part
Record (NPR) on the Service Information System website (SIS web) 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. Ensure that the product will
not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that
are used. Ensure that the product will not be damaged or made unsafe by any operation, lubrication,
maintenance, or the repair procedures used.
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.
1/30/24, 3:29 PM SIS 2.0
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”. Refer to Illustration 2 for an example of a “WARNING” Safety
Alert Symbol.
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, 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 oil pans for 3500, 3600, and C175 Family Series
engines. Life will vary depending on application, load, lubrication, and environment.
This guideline contains the latest standards of engineering, which will help minimize owning and
operating costs. Parts are expected to reach the next Planned Component Rebuild (PCR) if the parts
1/30/24, 3:29 PM SIS 2.0
meet the specifications within this guideline and are intended for similar applications. Do not install a
part that is not reusable. During reconditioning, correct any condition that might have caused the
original failure.
The dimensions and tolerances provided are to return a part / component to specification. The
dimensional information alone is not solely used to condemn a part from reuse. Follow visual inspections
and the "Crack Detection Methods" section for further guidance.
References
Table 2
References
Media
Publication Type and Title
Number
"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Service Information
REHS1841
"General Welding Procedures"
Engine News
SEBD9276
"Summary of Improvements to Deep Sump Oil Pans"
Reuse and Salvage Guidelines
SEBF8187
"Standardized Parts Marking Procedures"
Reuse and Salvage Guidelines
SEBF8728
"Specifications for Inspection of Driveline Fasteners"
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"
Service Advisories, Service Letters, and Technical Service

Bulletins
NOTICE
1/30/24, 3:29 PM SIS 2.0
The most recent Service Advisories, Service Letters, and

Technical Service Bulletins that are related to this component
should be reviewed before beginning work. Often Service
Advisories, Service Letters, and Technical Service Bulletins
contain upgrades in repair procedures, parts, and safety
information which pertain to the components being repaired.
Tooling and Equipment
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
(1)
Description Designation
Personal
— (2) Personal Protective Equipment (PPE)
Protection
Component
— (3)
Lifting Eye Assemblies Repositioning
and Movement
Component
— (3) Tool (Cribbing) Repositioning
and Movement
Component
— Suitable Lifting Device Repositioning
and Movement
1U-7262 Telescoping Magnet General Tooling
1U-5232
Welding Electrode Ø 3.20 mm (0.126 inch) E7018 Welding
221-1058
1U-6484
Welding Electrode Ø 2.38 mm (0.0937 inch) E6011 Welding
1U-5285
Surface
1U-5516 Disc (Coarse) Preparation
/ De-burring
1/30/24, 3:29 PM SIS 2.0
Surface
1U-5518 Shaft, Threaded Preparation
/ De-burring
Surface
1U-5519 Disc Pad Holder Preparation
/ De-burring
Surface
4C-3770 Grinding Wheels Preparation
/ De-burring
4C-5831 Tip Tube As needed
Surface
Flapper Wheel
4C-8514 Preparation
(2" x 1" 60 grit)
/ De-burring
Surface
Flapper Wheel
4C-8515 Preparation
(2" x 1" 120 grit)
/ De-burring
External
4S-9405 Caliper Measurement
Checks
Tool Measurement
5P-3920
304.8 mm (12.00 inch) Steel Rule Checks
Thickness
8H-8581 Feeler Gauge Measurement
Checks
Flatness/
386-3364 Straight Edge Straightness
Checks
1U-9915 Curved Handle Wire Brush General Cleaning
8T-7765 Surface Reconditioning Pad (180 Grit) General Cleaning
162-5791 Towel General Cleaning
Surface Texture
9A-1593 Comparison Gauge
Tester
Process
5P-7414 or
Seal Pick Specific
480-0738
Application
Process
6V-4249 Bolt Specific
Application
Process
6V-5230 Bolt Specific
Application
Process
Loctite Superflex 596 High Temp RTV Silicone Adhesive - Red
— (4) (5) Specific
Application
1/30/24, 3:29 PM SIS 2.0
Process
222-9238 Dowels Specific
Application
Process
101-2862 (6) Pin Specific
Application
Process
129-8433
Integral Seal Specific
142-4159
Application
Process
132-6260 Integral Seal Specific
Application
Process
133-5924 Oil Pan Specific
Application
Process
Application
Process
Application
Process
Application
Process
172-0915 Half Baffle Specific
Application
Process
198-4766 Washer Specific
Application
Process
222-9151 Washer Specific
Application
Process
394-7231 Stiffener Plate Specific
Application
Process
Application
Surface
222-3071 Portable Angle Grinder Group Preparation
/ De-burring
Surface
222-3074 Wheel Grinder Group Preparation
/ De-burring
222-3076 Die Grinder Surface
(Right Angle) Preparation
1/30/24, 3:29 PM SIS 2.0
/ De-burring
222-3080 Air Hammer Weld Cleanup
Welding
Preparation
236-8097 Carbide Burr
Weld Removal/
Crack Excavation
Crack/
Microscope, Pocket
262-8390 Measurement
40x
Inspection
263-7147(7) Lock-N-Stitch Kit Casting Repair
— GO/NO-GO Thread Gauge Set, Metric Threaded Hole
and /or
GO/NO-GO Thread Gauge Set, SAE Inspection
—
Paint
458-9587 (8) Touch Up
Yellow
Paint
479-5400 (9) Touch Up
Yellow
Automatic Tape Measure (1-inch X 26- ft)
1U-9367 Visual Testing (VT)
25.4- mm x 8- m
8S-2257 Magnifying Glass Visual Testing (VT)
9U-6182 Mirror (Telescoping) Visual Testing (VT)
9U-7231 Flashing Lights Conversion Kit Visual Testing (VT)
4C-9442 Light Visual Testing (VT)
— (3) Bright Incandescent Light Visual Testing (VT)
— Reflective Surface for Inspection Visual Testing (VT)
Crack/
Microscope (40-Power)
262-8390 Measurement
Pocket
Inspection
Liquid Penetrant
605-2193 Wiper
Testing (PT)
General Cleaning/
Brush
1U-9915 Liquid Penetrant
Curved Handle Wire
Testing (PT)
Liquid Penetrant
— Developer
Testing (PT)
Liquid Penetrant
— Penetrating Oil
Testing (PT)
General Cleaning/
— Solvent Cleaner Liquid Penetrant
Testing (PT)
Dry Magnetic
263-7184 Crack Detection Kit (Magnetic Particle) Particle Testing
(MT)
1/30/24, 3:29 PM SIS 2.0
Wet Magnetic
Lamp Group
459-0184 Particle Testing
Ultraviolet
(MT)
PIP
(1) The most current part number is identified in bold font when multiple part numbers are in a cell.
(2) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part
-
202 1046
numbers suitable by geographic location and local safety standards.
(3) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(4) Available in North America, Australia, Asia Pacific, and Americas South.
12: 4 / 0 4 6
(5) Europe, Africa, and Middle East equivalent is Silicone 598.
6
(6) Service replacement pin for dowel 222–9238
1 / 6
(7) Additional tooling required is listed in SEBF8882. Review the list and obtain the tooling to complete the salvage operation
2 3
SEB 9:54+ 0
correctly.
(8) Available in North and South America (except Canada).
(9) Available in Canada, APD, and EAME.
© 2 F830 03:00
Replacement Parts
0 4
Consult the applicable Parts Identification manual for your engine.
Cat 4 C 2
e
Con rpilla aterpi
When replacement parts are required for this product Caterpillar
fide r: llar
recommends using Caterpillar replacement parts or parts with
equivalent specifications including, but not limited to, physical
ntia Inc
dimensions, type, strength and material.
l Ye .
Failure to heed this warning can lead to premature failures,
product damage, personal injury or death.
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Measurement Requirements
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
1/30/24, 3:29 PM SIS 2.0
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.
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.
Note: Clean exterior of the engine oil pan prior to disassembly to minimize cross-contamination.
Before you inspect a part, clean the part 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.
3500 Standard Oil Pans

Early 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.
1/30/24, 3:29 PM SIS 2.0
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
Typical two-piece oil pan
(1) Front section
(2) Rear section
(3) Location of the integral seal and dowels
Typical three piece oil pan
(1) Front section
(2) Locations of integral seals and dowels
(3) Rear section
(4) Center section
3508 Two-Piece Oil Pan Rework Procedure
1/30/24, 3:29 PM SIS 2.0
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 4 for the sizes and the locations of the dowel holes.
Table 4
3508 Engine Oil Pan

Rear Section Rework Dimensions for Two-Piece Oil Pans
Location Dimension
16 Remove 2.47 mm (0.097 inch) from this surface.
Reamed Holes. Drill two 6.00 mm (0.236 inch) diameter holes 12.00 mm (0.472 inch)
deep.
17
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)
37.00 mm (1.457 inch) from centerline of oil pan mounting bolt holes to center of holes
E
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)
1/30/24, 3:29 PM SIS 2.0
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 5 for the sizes and locations of the dowel holes.
Table 5
3508 Engine Oil Pan

Front Section Rework Dimensions for Two-Piece Oil Pans
Location Dimension
Reamed holes. Drill two 5.79 mm (0.228 inch) diameter holes 12.00 mm (0.472 inch)
6 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).
37.0 mm (1.46 inch) from centerline of oil pan mounting bolt holes to center of holes
E
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
1/30/24, 3:29 PM SIS 2.0
(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 Superflex 596 High Temp RTV Silicone Adhesive - Red to the following locations.
a. 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.
b. Location (21) in Illustration 8 and to the top of gasket joints (15) in Illustration 8 and Illustration
10.
c. Top of the integral seal tee joint at location (22) in Illustration 9, 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.
Side view of the typical oil pan group and location of the prior to assembly. Refer to Table 13.
Table 6
Locations to Apply Prior to Assembly
Location 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 sealant as required prior to assembly. Refer to Illustration 8
1/30/24, 3:29 PM SIS 2.0
15 Gasket joints
22 Integral seal "tee-joint" on new 129-8433 or 142-4159 Integral Seal
(22) Integral seal "tee-joint"
Locations of the gasket joints (15)
3508 Three-Piece Oil Pan Rework Procedure

1. Machine the rear section and add dowels.
a. Remove 2.47 mm (0.097 inch) from the surface of the rear section of the oil pan.
1/30/24, 3:29 PM SIS 2.0
b. 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.
c. 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.
Table 7
3508 Engine Oil Pan

Rear Section Rework Dimensions for Three-Piece Oil Pans
Location Dimension
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)
6
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.
37.00 mm (1.457 inch) from centerline of oil pan mounting bolt holes to center of
E
holes for the dowel
F 497.00 mm (19.567 inch)
41.00 mm (1.614 inch) from the mounting surface to the centerline of the dowel
G
hole
46.00 mm (1.811 inch) from the mounting surface to the centerline of the dowel
H
hole
K 305.82 mm (12.040 inch)
2. Machine one side of the center section and add clearance holes.
1/30/24, 3:29 PM SIS 2.0
PIP
a. 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.
-
202 1046
b. Inspect the machined surface for porosity. If porosity larger than 0.25 mm (0.010 inch) is found
4 4 666
in the machined surface, fill them with Epoxy Resin. This metal can be hand formed and
12: / 0 1
machined after it has cured.
2 / 3
SEB :54+ 0
9
© 2 F830 03:00
Cat 024 C 4
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Con illa terpi
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.
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Rework dimensions for the center pan section
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c. Drill and ream two clearance dowel holes in each face of the center section of the oil pan. Refer
to Table 8 for the sizes and the locations of the dowel holes.
Table 8
3508 Engine Oil Pan

Center Section Rework Dimensions for Three-Piece Oil Pans
Location Dimension
Reamed Holes. Drill four 6.00 mm (0.236 inch) holes 12.00 mm (0.472 inch)
6 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.
1/30/24, 3:29 PM SIS 2.0
a. Drill and ream two interference fit dowel holes in the joint face of the deep section of the oil pan.
Table 9
3508 Engine Oil Pan

Front Section Rework Dimensions for Three-Piece Oil Pans
Location Dimension
Reamed holes. Drill two 5.79 mm (0.228 inch) diameter holes 12.00 mm
16 (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)
1/30/24, 3:29 PM SIS 2.0
b. 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 Superflex 596 High Temp RTV Silicone Adhesive - Red 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.
Table 10
Locations to Apply Sealant Prior to Assembly
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
1/30/24, 3:29 PM SIS 2.0
Side view of an oil pan group and location of sealant prior to assembly.
(22) Integral seal tee joint
1/30/24, 3:29 PM SIS 2.0
(15) Gasket joints
3516 Rework Procedure

1. Remove 3.20 mm (0.126 inch) from the front section of the oil pan in Illustration 24.
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.
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.
1/30/24, 3:29 PM SIS 2.0
Table 11
3516 Engine Oil Pan Shallow Section Dimensions
Location Dimension or Description

Reamed hole. Drill a 6.00 mm (0.236 inch) diameter hole that is 12.00 mm
(0.472 inch) deep.
6
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
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.
Table 12
3516 Engine Oil Pan Deep Section Dimensions
Location Dimension or Description

Reamed Hole. Drill a 5.79 mm (0.228 inch) diameter hole that is 12.00 mm
(0.472 inch) deep.
6
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)
1/30/24, 3:29 PM SIS 2.0
C 530.00 mm (20.866 inch)
(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 Superflex 596 High Temp RTV Silicone Adhesive - Red 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 21 and to the top of gasket joints.
Top of the integral seal tee joint at location (16) in Illustration 22, after the pan sections are
bolted together, but before assembling to the bottom of the block.
1/30/24, 3:29 PM SIS 2.0
Side view of a typical oil pan group and location of the prior to assembly. Refer to Table 13.
Table 13
Locations to Apply Prior to Assembly
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 21
15 Gasket joints
16 Integral seal "tee-joint" on new 129-8433 or 142-4159 Integral Seal
(16) Integral seal "tee-joint"
1/30/24, 3:29 PM SIS 2.0
Locations of the gasket joints (15)
3500 Deep Oil Pans
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. Cracks primarily appear on Series 3500 deep sump oil pans.
However, a few cracks have appeared on Series 3500 shallow oil pans around the bosses on the sides
and 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.
1/30/24, 3:29 PM SIS 2.0
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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4
Personal injury can result from flame cutting or welding on
painted areas.
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/
2
The effect of gasses from burned paint is a hazard to the person
SEB 9:54+ 0
doing the cutting or welding.
Do not flame cut or weld on painted areas.
© 2 F830 03:00
0
Cat 4 C 2 4
e r
Con illa terpi
p a
Personal injury or death can result from fumes, gases and
ultraviolet rays from the weld arc.
fide r: llar
Welding can cause fumes, burn skin and produce ultraviolet
rays.
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Keep your head out of the fumes. Use ventilation, exhaust at the
arc, or both, to keep fumes and gases from your breathing area.
llow
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

1/30/24, 3:29 PM SIS 2.0
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.
Salvage Welding
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
1/30/24, 3:29 PM SIS 2.0
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
NOTICE
Weld repair should be done cautiously in certain locations as
the heat can cause distortion in the case and pull components
out of alignment. Generally, the larger the crack and weld repair,
the more chance for developing distortion.
NOTICE
Refer to the latest version of the American National Standards
Institute/ American Welding Society "ANSI/AWS D1.1 - Structural
Welding Code -".
Weld repairs that do not get machined should be ground flush or shaped to match the profile of the
surrounding material of gear case. There should be no visible defects present such as rollover, undercut,
porosity, or slag inclusions. Ensure that each repair is inspected after the metal cools using either Liquid
Penetrant Testing (PT) or Dry Magnetic Particle Testing (MT) methods. Refer to the "Crack Detection
Methods" section.
Welder Qualifications
Note: Personal breathing protection should be worn by the personnel that are welding. Personal
breathing protection will prevent fumes from entering the lungs of the person that is welding. Use
a respirator for breathing protection.
Welders must be qualified for the appropriate type of weld that is being performed:
1/30/24, 3:29 PM SIS 2.0
Shielded Metal Arc Welding (SMAW)
Flux Cored Arc Welding (FCAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)/ Tungsten Inert Gas (TIG)
Welders must be qualified for the appropriate position of weld that is being performed. Refer to AWS
Specifications D1.1 and D14.3 or comparable standards for information that regards qualification
requirements. The welders must have used the process at some time within the last 6 months. The
welders must complete the process of certification if the welders have not used the welding processes for
6 months. The welding operator must hold a current certification for this process. The operator must wear
the appropriate equipment. The operator must also install all appropriate equipment. All equipment must
maintain the amount of fumes, heat, and ultraviolet radiation at a safe limit.
References:
Reuse & Salvage Guidelines, SEBD0512 , "Caterpillar Service Welding Guide"
ANSI/ AWS D1.1, D14.3
Caterpillar Manufacturing Practice MC1000-105
Welding Preparation
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.
Note: Cover all exposed machined surfaces before beginning defect removal.
Defect Removal Techniques

Once a defect has been detected the defect shall be removed by grinding, air carbon/ plasma arc
gouging, or machining. Cavities which have been gouged shall be chipped or ground to remove the
gouging slag. Grind smooth all uneven areas caused by gouging which present pockets to trap slag.
Non-Destructive Testing (NDT) shall be used to ensure that cracks have been removed, refer to the "Dry
Magnetic Particle Testing (MT)" section.
Welding the Crack

1/30/24, 3:29 PM SIS 2.0
(K) Infrared Thermometer
(L) Temperature Indicating Crayon
1. Do not allow the temperature to exceed 260° C (500° F).

Make sure that the surface is above 16° C (60° F).
Use a 1U-5232 or 221-1058 Welding Rod to fill the weld area along the entire length of the crack.
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
(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 on the sides of the oil pan. Type 2 design is used for cracks that
appear around the mounting bosses that are 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.
1/30/24, 3:29 PM SIS 2.0
The plate for the Sides of the Oil Tank should be made from 5 mm (0.20 inch) thick plate steel.
Table 14
Acceptable Dimensions and Tolerances for Side Plates

Location 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° Chamfer
G 125 mm (4.90 inch)
H 65 mm (2.55 inch) Radius
1/30/24, 3:29 PM SIS 2.0
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

Location Dimension
A 75 mm (2.95 inch)
B 5 mm (0.19 inch) X 45° 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
1/30/24, 3:29 PM SIS 2.0
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
Location Dimension
A 75 mm (2.95 inch)
B 5 mm (0.19 inch) X 45° 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.
1/30/24, 3:29 PM SIS 2.0
4. Prepare each weld area by smoothing the surface after welding. The beveled edge of the plate may
PIP
need to be ground to allow the plate to sit flush with the existing side wall.
202 1046-
5. Clean the entire length of the ground area.
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weld to bare base metal.
/ 4
6. Use a wire brush to clean the prepared groove. Enough area should be cleaned so that you can
2
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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.
© 2 F830 03:00
8. Use a 1U-5232 or 221-1058 Welding Rod E7018 to tack weld along the outer edge of the plate at
90° locations by using the following sequence Top, Bottom, Right and Left.
Cat 4 C 0 2 4
9. Use a 1U-5232 or 221-1058 Welding Rod E7018 to completely fill in the V-shaped area between the
e
Con rpilla aterpi
plate and the mounting boss. This may require multiple passes.
Do not allow the temperature to exceed 260° C (500° F).
fide r: llar
Make sure that the welding surface temperature is above 16° C (60° F).
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10. Use a 1U-5232 or 221-1058 Welding Rod E7018 to weld around the entire edge of the plate. This
l Ye .
should be done with a single pass weld with a 3 mm (0.12 inch) fillet.
Adding Internal Baffles to Oil Pans (DeeplOil

loPans Only)
w
This section only to deep oil pans without the additional baffles or thick walls described in SEBD9276,
"Summary of Improvements to Deep Sump Oil Pans". 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.
1/30/24, 3:29 PM SIS 2.0
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.
Series 3508 Series Engines with Deep Oil Pan using Four half baffles.
Table 17
Acceptable Dimensions and Tolerances for Series 3508 Series Engines
Location Dimension
A 1021 ± 2 mm (40.2 ± 0.08 inch)
B 353 ± 2 mm (13.9 ± 0.08 inch)
1/30/24, 3:29 PM SIS 2.0
Series 3512 Series Engines with Deep Oil Pan using Six half baffles.
Table 18
Location 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)
Series 3516 Series Engines with Deep Oil Pan using Eight half baffles.
Table 19
1/30/24, 3:29 PM SIS 2.0

Location 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.
1/30/24, 3:29 PM SIS 2.0
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.
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
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.
1/30/24, 3:29 PM SIS 2.0
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 34.
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.
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 35.
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.
1/30/24, 3:29 PM SIS 2.0
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 36.
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° 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.
Stringer welds at each end of the crack.
1/30/24, 3:29 PM SIS 2.0
2. If Length (C) in Illustration 37 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 38.
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.
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.
1/30/24, 3:29 PM SIS 2.0
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 C175 oil pans should not be repaired. Cracks will continue to form even after repairs. Any oil
pan that has a crack should be replaced.
Typical example of a C175 engine oil pan crack.
1/30/24, 3:29 PM SIS 2.0
PIP
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202 1046
12: 4 / 0 4 666
2 1 / 3
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9
© 2 F830 03:00
0
Cat 4 C 2 4
Illustration 42
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g03896336
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llow
1/30/24, 3:29 PM SIS 2.0
Repairs should not be made to cracked oil pans. The cracks will return after repairing the casting.
C175 Mid-Section Oil Pan Replacement

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.
1/30/24, 3:29 PM SIS 2.0
Location of midsection oil pan.
Location of cracking in Detail - Y.
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.
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
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.
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.
1/30/24, 3:29 PM SIS 2.0
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.
Fretting that is deeper than 0.5 mm (0.020 inch).
Crack Detection Methods
NOTICE
1/30/24, 3:29 PM SIS 2.0
Regardless of which crack detection method is used, close

adherence to instructions furnished with the detection
equipment is important when checking any component. Failure
to do so may cause inaccurate results or may cause injury to
the operator and/or surroundings.
There are four major crack detection methods or Non-Destructive Testing (NDT) listed in this section:
Visual Testing (VT), Liquid Penetrant Testing (PT), Dry / and Wet Magnetic Particle Testing (MT).
Crack detection methods or NDT is methods for testing components for cracks without damaging the
component. VT, PT, and Dry/ Wet MT are methods recommended. There may be more than one
acceptable crack detection method for the testing of a given part, although PT is the most versatile. For
example, PT can be used when testing smooth machined components such as shafts, gear teeth, and
splines, but using Wet MT 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 Detection Methods Advantages and Disadvantages
Detection
Advantages Disadvantages
Method
- Least Expensive
- Limited to surface-only defects.
- Detects most damaging
Visual Testing - Requires inspectors to have broad knowledge of
defects.
(VT) welding and fabrication in addition to Non-
- Immediate Results
Destructive Testing (NDT).
- Minimum part preparation
- Inexpensive
- Minimal Training - Least Sensitive
Liquid Penetrant
- Portable - Detects surface cracks only.
Testing (PT)
- Works on nonmagnetic - Rough or porous surfaces interfere with test
material.
- Portable
- Works on magnetic material only.
Dry Magnetic - Fast/Immediate Results
- Less sensitive than Wet Magnetic Particle Testing
Particle (MT) - Detects surface and
(MT).
subsurface discontinuities
- More sensitive than Liquid
- Requires power for light.
Penetrant Testing (PT).
Wet Magnetic - Works on magnetic material only.
- Detects subsurface as
Particle (MT) - Liquid composition and agitation must be
much as 0.13 mm
monitored.
(0.005 inch).
Table 22
Applicable Crack Detection Standards
Detection Method Standard Acceptance Minimum

Criteria Required
1/30/24, 3:29 PM SIS 2.0
Personnel
Qualifications
EN-ISO 5817 EN-ISO 5817 - Level B EN-ISO 9712
Visual Testing (VT)
AWS D1.1 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A
EN-ISO 3452 EN-ISO 23277 EN-ISO 9712
Liquid Penetrant Testing (PT)
ASTM E165 AWS - D1.1 ANSI-ASNT SNT-TC-1A
EN-ISO 17638 EN-ISO 23278 - Level 1 EN-ISO 9712
Magnetic Particle Testing (MT)
ASTM E709 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A
Visual Testing (VT)
Example of Visual Testing (VT) Tooling
(A) Flashlight (or adequate light source)
(B) Magnifying Glass
(C) Tape Measure (or other measuring device)
(D) Inspection Mirror
(E) Weld Size Inspection Gauges
Refer to Tooling and Equipment Table3 for part numbers.
Components and welds that are to be tested using PT or MT shall first be subject to Visual Testing (VT).
VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration
49. Personnel performing VT shall either be trained to a company standard or have sufficient experience
and knowledge regarding the components being inspected. Personnel performing VT shall take routine
eye exams.
Liquid Penetrant Testing (PT)
Personal injury can result from improper handling of chemicals.

1/30/24, 3:29 PM SIS 2.0
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

Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe
the surface clean.
Penetrating Oil: 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 penetrating oil indications.
Wire Brush: Removes dirt and paint.
Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
Typical example of pre-cleaning the testing area.
1/30/24, 3:29 PM SIS 2.0
1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe
the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to
dry. Remove paint where there are visible cracks using paint remover or a wire brush.
Typical example of applying penetrating oil to areas to be tested.
2. Apply penetrant by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrant to
soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with
clean, dry wipe.
Typical example of removing penetrating oil with a cloth.
1/30/24, 3:29 PM SIS 2.0
3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or
wipe. Allow the area to dry thoroughly.
PIP
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Typical example of applying the developer.
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4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container.
llow
Hold the container approximately 203 - 305 mm (8.0 - 12.0 inch) away from the testing area. Apply
an even, thin layer of developer over the testing area. A few thin layers are a better application
method than one thick layer.
Typical example of cracks found during Liquid Penetrant Testing (PT).
1/30/24, 3:29 PM SIS 2.0
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 54. Clean the area of
application of the developer with solvent cleaner.
Dry Magnetic Particle Testing (MT)

Materials and Equipment Required
(A) Indications shown by Dry Magnetic Particle Testing (MT).
(B) 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
1/30/24, 3:29 PM SIS 2.0
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
1/30/24, 3:29 PM SIS 2.0
(A) Indications shown by Wet Magnetic Particle Testing (MT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp
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:
a. The concentration of the suspended magnetic particles shall be as specified by the

manufacturer and be checked by settling volume measurements.
b. Determine concentrations by measuring the settling volume. Use an ASTM pear shaped
centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) divisions. Refer to the
example in Illustration 57. 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.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
d. The oil shall have the following characteristics:
Low viscosity not to exceed 5 mm2/s (5 cSt) at any temperature at which the vehicle is to be
used.
Low inherent fluorescence and be non-reactive.
e. The conditioning agents used in the conditioned water shall have the following characteristics:
1/30/24, 3:29 PM SIS 2.0
Impart good wetting characteristics and good dispersion.
Minimize foaming and be non-corrosive.
Low viscosity shall not exceed a maximum viscosity of 5 mm2/s (5 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.
3. For case hardened and ground surfaces:
Locating grinding cracks on case hardened and ground surfaces is a highly sensitive process.
Inspection requires that the yoke is applied so 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. Refer to Illustration 58 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.
PIP-10464666
2024/01/30
12:29:40+03:00
i03839550
1/30/24, 3:29 PM ntia SIS 2.0
nc.
© 2024 Caterpillar Inc.
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Caterpillar:
Confidential Yellow llow

Reuse and Salvage For 3500, 3600 & C175 Engine Oil Pans

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1/30/24, 3:29 PM SIS 2.

SMCS - 1302 i08480718

All C175 Engines -

Revision Summary of Changes in SEBF8304

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

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is Involved.

TIBU2809 Technical Information Bulletin, "Oil Pan Cracking"

Service Advisories, Service Letters, and Technical Service

The most recent Service Advisories, Service Letters, and

Tooling and Equipment

To avoid component damage, follow the recommended

Required Tooling and Equipment

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

During cleaning, do not damage machined surfaces.

Use appropriate thread taps to chase all threaded holes.

3500 Standard Oil Pans

3508 Two-Piece Oil Pan Rework Procedure

3508 Engine Oil Pan

3508 Engine Oil Pan

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

Locations to Apply Prior to Assembly

3508 Three-Piece Oil Pan Rework Procedure

3508 Engine Oil Pan

3508 Engine Oil Pan

3508 Engine Oil Pan

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

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

Locations to Apply Sealant Prior to Assembly

3516 Rework Procedure

3516 Engine Oil Pan Shallow Section Dimensions

Location Dimension or Description

3516 Engine Oil Pan Deep Section Dimensions

Location Dimension or Description

C 530.00 mm (20.866 inch)

Location (14) in Illustration 21 and to the top of gasket joints.

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

Locations to Apply Prior to Assembly

3500 Deep Oil Pans

This process has three steps.

Do not flame cut or weld on painted areas.

Protect yourself and others; read and understand this warning.

Read and understand the manufacturer's instructions and your

See "American National Standard Z49.1, Safety in Welding and

American Welding Society

See "OSHA Safety and Health Standards, 29 CFR 1910",

U.S. Department of Labor

Define the Crack

Removing and Cleaning the Crack

2. Clean the entire length of the ground area.

Personal injury or death can result from fumes, gases and