PIN AS 1386685 - Caterpillar

ENGINES
3500 DIESEL COMMERCIAL ENGINESProblem:
Some 3500 oil pans may crack in certain applications. The rate of cracking is very low. However, any oil pan cracking is unacceptable. The cracks primarily happen on 3500 deep sump oil pans with a few cracks on 3500 shallow oil pans. These cracks typically happen around the mounting bosses that attach the oil pan to the engine rails.Solution:
The following guideline is designed to both repair cracks and strengthen the oil pans in applications that are cracking oil pans. In general this is a three step process:* Repair crack location by grinding out crack and filling with weld* Weld plate around mounting pad from which crack initiated* Weld additional baffles to internal sections of the oil pans (Deep Sump Oil Pans Only) WELD REPAIR OF CRACK LOCATION:1. Define the ends of the crack by using 4C(4736 Penetrant Kit:a. Use a wire brush to thoroughly clean any paint or grease from the surface to be inspected.b. Spray or apply cleaner/remover fluid on the part to remove any oil contaminants from the surface.c. Spray or apply the dye penetrant on the surface. Let it dry for three to five minutes so that the dye absorbs into the crack.d. Wipe the dye penetrant from the surface using a clean towel. e. Spray or apply a light coat of the developer on the surface to be inspected. A crack will appear as a red line in the developer.f. Mark the complete outline of the crack with a metal scribe or center punch the ends to make the crack visible after removing dye penetrant and developer.g. Be careful to make sure the true ends of the crack have been defined in order to stop the progression of the crack. Before any grinding or 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 mm (4in) below the damaged area.2. Grind out entire crack in a V shape. Make sure to grind entire length and depth of crack.3. Clean entire length of ground area:a. Before any welding on the oil pan is started make sure the area to be repaired is thoroughly cleaned. Use a wire brush or grinding stone to clean the prepared groove and enough area to weld to bare base material.b. All oil, grease, paint, etc. must be cleaned from the prepared groove surfaces and enough area to weld to bare base material. Surface oxides must be removed from the area to be welded. c. Good cleaning and surface preparation of the area to be welded is very important, if a quality repair is to be made. Before any welding is attempted on the oil pan, use correct grounding to prevent internal engine damage to bearing 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