KIT-SERVICE 1960400 - Caterpillar

This is a 10.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
10 hours trouble shooting time will be allowed to indentify cylinders with broken piston rings.
40 hours of repair time will be allowed for the first cylinder pack.
35 hours for each subsequent per cylinder pack replacement for those pistons found with broken rings
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Checking Crankcase Pressure Changes to Detect Failed Piston Rings
Introduction:
This test can detect a single cylinder that has worn/broken piston rings and is not performing correctly.
The test kit can be assembled from common material that will be found in most shops.
This test uses the crank case breathers or T-hoses, where all venting locations are fitted with caps or plugs. One plug is drilled to 3/4 inch to provide exhaust restriction, one is fitted with a 1/8 inch hose barb fitting affixed to it, and all the others are capped off. A manometer is then used in conjunction with the cylinder cutout function in Caterpillar ET to determine the crank case pressure drop, as each cylinder is cut out during idling.
Needed for the Test Kit
3 ABS Black Plastic Caps, one 1/2 inch ID / two 1/4 inch OD used at plugs or 6 similar caps to seal off the individual breathers.
Drill a 3/4 inch hole in one plug or cap to provide restriction and amplify the signal to the manometer.
Install a threaded fitting into one cap that will allow a 1/8 inch hose barb fitting to be installed.
3 to 6 hose clamps (used to hold plugs or caps on breathers)
20 to 25 feet of 1/8" rubber hose that will not easily kink
1 digital manometer with a resolution of 0.01 inches of water
Example of part of a test kit and installation
Image1.1.1
Installation of the Test Kit
Place the plug or cap with the 3/4 inch hole on one breather or T-hose to provide restriction and amplify the signal to the manometer.
Use a different breather or T-hose with the cap or plug containing the 1/8 inch barb fitting installed. Run the 1/8 inch tube to the cab. Install the tube on the manometer and plug or cap the remaining T-hose or breathers as shown.
Examples of how to cap breathers
Image1.2.1
Testing of the Engine
At idle, with truck at operating temp of 170F or greater, take a stabilized pressure reading as indicated on the digital manometer, Record this value. This is the reference value for the whole engine. If the value exceeds 4 inched of water, there is excessive blowby. During the test you will want to verify that this reference value does not change significantly.
Perform a single cylinder cut out tests for each cylinder and allow the value to stabilize. Record the values from the manometer and list the values in the included chart.
The contribution to