56120-ZW1-703 Honda ROD, PISTON (Honda Code 8425662).

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Program must be administered as soon as possible. When reporting the repair, use "PI3171" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3171" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.
Completion Date
December 31, 1998Termination Date
June 30, 1999Problem
Some Caterpillar Engines with less than 300 hours, in certain vehicular applications built between January 28 and February 06, 1998 may have incorrectly installed injector sleeves in the cylinder head. Incorrectly installed sleeves could result in early hour loosening causing combustion gas leakage in the fuel, combustion gas leakage in the coolant and/or coolant leakage in the oil and piston cavity.
Affected Product
Model & Identification Number
CLAAS CH55 (5DK1357, 5DK1361-1363, 5DK1366-1369, 5DK1376, 5DK1378, 5DK1381, 5DK1383, 5DK1391)
120H (4MK484, 4MK486 5FM1149 , 5FM1151, 5FM1154-1156, 5FM1158, 5FM1159, 5FM1160, 5FM1163, 5FM1168, 5FM1171, 5FM1175, 5FM1176, 5FM1180, 5FM1181, 5FM1190, 6TM417-420 , 6TM422 9YR344 , 9YR347, 9YR352)
135H (3YK308 8WN448-451 , 8WN453-455, 8WN456, 8WN458, 8WN470)
928G (6XR839, 6XR840, 6XR842, 6XR845-849, 6XR852, 6XR855, 6XR857-866, 6XR873, 6XR874, 6XR877, 6XR878, 6XR882, 6XR950)
IT28G (8CR900, 8CR911, 8CR913, 8CR918-924, 8CR926, 8CR927, 8CR930, 8CR932, 8CR934, 8CR936-938, 8CR948, 8CR952, 8CR954, 8CR1069)
938G (4YS511-515, 4YS517, 4YS518, 4YS521, 4YS522)
IT38G (7BS405, 7BS407, 7BS412, 7BS413)
950G (3JW194, 3JW202, 3JW203, 3JW210)
613C (8LJ1708, 8LJ1710, 8LJ1712, 8LJ1737, 8LJ1746, 8LJ1747)
322B (1YS737, 1YS739, 1YS741, 1YS742, 1YS744)
325B (2JR1667, 2JR1671, 2JR1673-1676, 2JR1678-1684, 2JR1687-1689, 2JR1694)
CS-563C (4KN1018, 4KN1026-1032, 4KN1034, 4KN1036-1039, 4KN1042, 4KN1047, 4KN1052, 4KN1059)
CP-563C (5JN685, 5JN687, 5JN688, 5JN691, 5JN693, 5JN695-705, 5JN707, 5JN708, 5JN712, 5JN792)
CS-583C (7MN161)
AP-1055B (8BM295, 8BM298, 8BM299)
BG-245C (4XN118)
Spare Engines
98Z26941, 26957, 26963, 26996, 27005, 27050, 27056
Parts Needed
1 - 1192940 Gasket1193061 Sleeve (as required)5F6199 Ball (as required for each branch dealer completing evasive evaluations)Action Required
This program only applies to engines with less than 300 hours.
1. Visually inspect the engine in the machine serial number list noted and determine if the cylinder head on the engine is a suspect for additional evaluation.2. If the cylinder head is determined to be suspect, follow the NON-EVASIVE evaluation outlined in the Rework Procedure and determine if an evasive evaluation is required.3. If the non-evasive evaluation indicates that injector sleeve installation is questionable, complete the EVASIVE evaluation outlined in the Rework Procedure.4. Using the evasive sleeve evaluation, identify the injector sleeve(s) that require replacement.5. Order the number of sleeves required and install them in accordance to the Special Instruction for the appropriate injector sleeve removal installation tooling you have.Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
This program only applies to engines with less than 300 hours.
For Claas CH55 Parts will be allowed at C/L price.
Use the appropriate 99Z----- Code when submitting a claim against a spare component.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
This program only applies to engines with less than 300 hours. If an engine has more than 300 hours, a SIMS entry must be completed stating that this program does not need to be performed.
1. Inspect machine engine Cylinder Head part number and determine if the Cylinder Head is Suspect for incorrectly installed injector sleeves.a) The head part number is located on the front of the cylinder head, governor side of the engine, beside the engine lifting eye.See Illustration 1.b) If the part number is a dot matrix type number, as shown in Illustration 1, the injector sleeve installation is not suspect.If the part number is a stamping, the head is suspect and the non-evasive sleeve evaluation is required.Time allowed for inspection only - .5hrs
2. If the head is determined to be a suspect head, has a stamped part number, remove the engine valve cover for further evaluation.Add time for Valve Cover R&I - .8hrs
3. NON-EVASIVE Evaluation -Using a sliding Caliper that is capable of measuring depth, measure the dimension from the injector timing ledge to the top of the cylinder head. Align the caliper vertically using the edge of the injector spring as a guide, measure and record the distance from the top of the injector timing ledge to the top face of the cylinder head on each cylinder. This measurement will be in the range of 8.39mm, but can vary from engine to engine. See Illustration 2.If the variation from cylinder to cylinder on the same engine is Less0.40mm (.016 in.), and the maximum measurement is less than 8.85mm (.348 in.), then the injector sleeves are correctly installed and no further evaluation is needed.
If the variation from cylinder to cylinder on the same engine is Greaterthan 0.40mm (.016 in.), or the maximum measurement from the injector timing ledge to the top of the head is greater than 8.85mm, recheck to verify that the measurements are correct. If the results are the same, proceed to step 4.Add time for non-evasive evaluation - .6hrs
4. EVASIVE EVALUATION - Remove all 6 injectors. Using a depth gage or depth micrometer with a flat end and a 19.05mm (.750 in) steel ball (ref. pt no. 5F6199) dropped in the sleeve, check and record the distance from the top face of the cylinder head to the top of the steel ball on each cylinder. This measurement should be 65.61 .46mm (2.583 .018 in.). If a sleeve(s) do not measure within the specifications provided, recheck the measurements. If measurements are verified, proceed to step 5. See Illustration 3.add time for the evasive evaluation - 6.0hrs
5. Remove and replace any injector sleeve that is found out of the specification provided in step 4.Add time for the first sleeve replaced - 1.0hrs
Add time for each additional sleeve replaced - 0.7hrs
6. When replacing