PARTS STOCK ACTION NEEDED - PSP FOR UPDATING OR REPLACING THE ENGINE ON 950F WHEEL LOADERS - COSA LETTER NO. 4.1 - PS8016 - MAI LED COSA Caterpillar

HEBE1414
AUGUST 6, 1993
COSA LETTER No. 4.1
*****************
* PARTS STOCK * PRODUCT SUPPORT PROGRAM FOR UPDATING OR
* ACTION NEEDED * REPLACING THE ENGINE ON 950F WHEEL LOADERS
*****************
1000, 1052  PS8016
NOTE: This Program can be administrated either before or
after a failure. In either case the decision whether to
apply the Program is made by the dealer. When reporting
the repair, use "PS8016" as the Part Number, and "7755"
as the Group Number. If administered before failure,
use "56" as the Warranty Claim Description Code, and if
administered after failure, use "96" as the Warranty
Claim Description Code.
NOTE: This Program replaces two recently released Support
Programs:
PS4903 - Service Letter dated April 16, 1993
New engine oil pan, oil level gauge, and
turbocharger, and adjusting the injection
fuel timing
PS4981 - Service Letter dated April 17, 1993
Adjusting the fuel governor
NOTE: Please refer to following documentation as needed:
TIB dated May 6, 1993 - Comp code 1060
Machining burr in turbocharger compressor
housing
TIB dated May 20, 1993 - Comp code 1302
Oil pan interference with oil pump gear
TIB dated May 6, 1993 - Comp code 1000
Engine low idle setting on 950F
NOTE: This program does not apply to dealers M142, M450.

December 31, 1995 (exception: see Rework 7)
INTRODUCTION
AVSpare is committed to providing fair customers value on all
products sold. In the case of the 950F some users working in
specific conditions have experienced a series of problems they
would not normally expect from a AVSpare product. The result
is a level of satisfaction below that which AVSpare strives
for. When forced with such a challenge it is AVSpare aim to
restore customer satisfaction in as fair and equitable manner as
possible.
It is with this in mind the Product Support Program covering the
3116 engine fitted in the 950F has been initiated. This PSP
provides solutions to customers to ensure that they obtain fair
and equitable value from the product irrespective of when it was
purchased.
The technical solutions provided combined with the extended
warranty coverage are intended to restore any customer confidence
that may have been lost. As this program is implemented with our
customer we count on your support to ensure that the full value
of AVSpare product purchased is realized.
I. GUIDELINES ON HOW TO APPLY THIS PROGRAM
1. NEW UNITS IN DEALER'S INVENTORY
Update the engine of the new units in dealer inventory to
today's configuration with Rework 1 - Governor, Rework 2 -
Turbocharger, Rework 3 - Oil Pan, Rework 4 - Turbocharger
Compressor Housing, and Rework 6 - Pistons. Perform the
appropriate reworks needed according to unit Serial Number.
2. RECENT UNITS
Update the engine of field machines with Serial Numbers
6YG2229, 2234, 2235, 2240, 2247, 2250-2252, 2254-2256,
2258-2264, 2266-up (all these units should have engine
Serial Numbers in the range 4TF6626-up) to today's
configuration with Rework 3 - Oil Pan, and Rework 4 -
Turbocharger Compressor Housing.
IMPORTANT
The units listed above have all the improvements related to
the oil sooting except the larger oil pan. As they are
recently sold units, and have not yet accumulated a high
number of working hours, it is strongly recommended to
install the new larger oil pan as soon as possible, but no
later than next time the machine is in a workshop.
3. EARLY UNITS
These are units with Serial Numbers 6YG1-2228, 2230-2233,
2236-2239, 2241-2246, 2248, 2249, 2253, 2257, 2265, and
5PJ1-45 (all these units should have engine Serial Numbers
in the range 4TF1-6625).
The more recent delivered units should be treated with
priority.
Before any other action, check engine blowby using the
8T2700 Blowby/Air Flow Indicator Group (refer to Special
Instruction SEHS8712). Refer to guidelines given in chapter
IV on evaluating the engine cylinder block wear by using
blowby measurements and oil consumption.
If readings show the engine cylinder block is worn, apply
Rework 5 - Exchange Engine, provided proper maintenance
according to the Operation and Maintenance Manual was
performed, and no evidence of misuse or abuse is present.
Refer to chapter IV for special instructions related to the
replacing engine content, installation, pricing and
availability.
If readings show the engine cylinder block is in acceptable
conditions, proceed according to the unit Serial Number and
SMU (see below).
3A. Units with 0-1500 SMU
It is strongly recommended to apply the appropriate reworks
according to given guidelines as soon as possible, but no
later than next time the unit is in a workshop. Reworks
applicable are Rework 1 - Governor, Rework 2 - Turbocharger,
and Rework 3 - Oil Pan.
3B. Units with 1501-6000 SMU
Use proper judgement according to unit SMU to evaluate if
benefits of having an improved engine justify the machine
down time.
If the engine can be expected to reach regular overhaul
engine life, it is recommended to wait until the time of the
first overhaul to update the engine. In this case,
AVSpare participation is as described in point 3C below.
3C. Machines over 6000 SMU
For customers who have engines which did run to their full
satisfaction without being updated, it is recommended to
update these engines at the time of the first engine
overhaul. For these customers we created the Rework 7.
During an engine overhaul, normally the piston rings are
replaced, the governor adjusted to new specs, and the
turbocharger replaced or reconditioned. These activities are
considered as part of a normal engine overhaul. These items
are NOT claimable.

To ensure that customers obtain fair value from their 950F
with serial numbers listed under point 3, AVSpare
extends the warranty period up to 6000 vehicle hours or
December 1995, whichever comes first against failures of oil
lubricated parts in basic engine, including fuel system
components, but excluding the air compressor as possible
failures are covered by PS0676 - Service Letter dated May
26, 1993.
This guarantee is offered provided AVS filters are used and
proper maintenance practices have been applied as per
Operation and Maintenance Manual. This extended warranty
will cover parts ONLY.
The extended Warranty period starts with the date of this
Service Letter, and is not retroactive.
Dealer must enter "Extended Warranty Coverage" in the claim
comments.
4. 

Handle the parts, except the engine, in accordance with your
Warranty Bulletin on warranty parts handling.
The old engines removed from units will have to be returned
to the Gosselies plant. Dealers will organize the return of
old cores by batches at their best convenience to minimize
the transportation costs, or at least once a year.
The balance between replacement engines supplied to each
dealer and the old engines returned to the plant will be
established at the end of the program. Dealers will be
re-invoiced USD 3000.-- for each core not returned.
Should the return of engines to Gosselies not be practical
for custom or cost reasons, contact the Support engineer at
Gosselies for further instructions.
Address for engine shipment:
AVSpare GOSSELIES SA
AVENUE DES ETATS-UNIS, 1
B-6041 GOSSELIES - BELGIUM
Attention: Mr. Pierre LECOMTE
WL Product Support
II. 

Below listed Serial Number ranges indicate which rework should be
applied.
Model S/N Range Rework No. S/N Range Rework No.
950F 6YG0001-1570 1 2 3 5 6 7 6YG2254-2256 3 7
1571 2 3 5 6 7 2257 3 5 6 7
1572 1 2 3 5 6 7 2258-2264 3 7
1573-1575 2 3 5 6 7 2265 3 5 6 7
1576 1 2 3 5 6 7 2266-2399 3 7
1577 2 3 5 6 7 2401-2405 3 7
1578-1583 1 2 3 5 6 7 2407-2422 3 7
1584-1588 2 3 5 6 7 2423-2424 3 4 7
1589-1595 1 2 3 5 6 7 2425-2428 3 7
1596-1602 2 3 5 6 7 2429-2435 3 4 7
1603 1 2 3 5 6 7 2436-2437 3 7
1604-1608 2 3 5 6 7 2439 3 7
1609-1612 1 2 3 5 6 7 2440 3 4 7
1613-1614 2 3 5 6 7 2441 3 7
1615-1616 1 2 3 5 6 7 2442-2447 3 4 7
1617 2 3 5 6 7 2448 3 7
1618 1 2 3 5 6 7 2449-2522 3 4 7
1619-1620 2 3 5 6 7 2523 3 7
1621-1634 1 2 3 5 6 7 2524-2637 3 4 7
1635-1640 2 3 5 6 7 2638 3 7
1641 1 2 3 5 6 7 2639-2640 3 4 7
1642-1652 2 3 5 6 7 2641 3 7
1653 1 2 3 5 6 7 2642 3 4 7
1654 2 3 5 6 7 2643 3 7
1655-1656 1 2 3 5 6 7 2644 3 4 7
1657 2 3 5 6 7 2645 3 7
1658-1659 1 2 3 5 6 7 2646 3 4 7
1660-1662 2 3 5 6 7 2647 3 7
1663-1665 1 2 3 5 6 7 2648-2697 3 4 7
1666-1876 2 3 5 6 7 2698  4
1877 3 5 6 7 2699-2701 3 4 7
1878-1892 2 3 5 6 7 2702-2705 4
1893-1905 3 5 6 7 2707  4
1906 2 3 5 6 7 2709  4
1907-2228 3 5 6 7 2711  4
2229 3 7 2713-2715 4
2230-2233 3 5 6 7 2717-2719 4
2234-2235 3 7 2722-2739 4
2236-2239 3 5 6 7 2741  4
2240 3 7 2744-2759 4
2241-2246 3 5 6 7 2761-2763 4
2247 3 7 2765-2772 4
2248-2249 3 5 6 7 2774  4
2250-2252 3 7 2776-2777 4
2253 3 5 6 7 2779  4
2781  4
950F 5PJ0001-0045 3 4 5 6 7
NOTE: Once Rework 5 has been applied, the unit is no
longer eligible for any of the other reworks of
this Program.
NOTE: Rework 6 is restricted to NEW machines in dealer's
inventory.
NOTE: Rework 7 is applicable ONLY at first engine
overhaul, and if Reworks 3, 4 or 5 have not been
applied before.
III. APPLICABLE DETAILS FOR REWORKS 1 TO 7
REWORK 1 - ADJUST TORQUE CAM IN FUEL GOVERNOR
This rework applies to the 950F's (Serial Number Prefix 6YG) with
engine Serial Number range 4TF1-4420. It was covered by former
PS4981. Main improvement achieved will be elimination of black
smoke at low idle rpm.

1 - 7C6204 Plug (governor housing)
1 - 8C8418 Lock Wire (for governor and fuel setting seal)
1 - 1T1068 Seal (front of governor to front housing)
1 - 8T1460 Ring-Retaining (clip for linkage connecting pin)
1 - 7W5614 Seal (between front and rear half of governor)
2 - Dealer's governor Seal (for governor and fuel setting)

See rework procedure in Annex A.

Product AVSpare Dealer Suggested Customer Suggested
SMU (no Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
age (D/N) (Cost)  (C/L) (Sell)
limit)
0-6000 100% 3.0 0 0 0  0
NOTE: When reporting the repair, indicate "Rework 1" in
the claim comments.
REWORK 2 - INSTALL NEW TURBOCHARGER AND ADJUST FUEL INJECTION
TIMING
This rework applies to the 950F's (Serial Number Prefix 6YG) with
engine Serial Number range 4TF1-5321. It was covered by former
PS4903 - Group 1. Main improvement achieved will be better engine
starting performance and reduction of oil sooting.

1 - 7C7431 Gasket-Turbocharger Mounting
1 - 5P1263 Hose Stock (15 cm long)
1 - 1S7057 Gasket-Turbocharger Oil Supply
1 - 4W5140 Plate-Engine Information
1 - 7W2398 Gasket-Turbocharger Oil Drain
1 - 100-5865 Turbocharger Group
1 - 105-1542 Gasket-Valve Cover

See rework procedure in Annex B.
Make sure Parts Stock has been checked, see Rework 4.

Product AVSpare Dealer Suggested Customer Suggested
SMU (no Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
age (D/N) (Cost)  (C/L) (Sell)
limit)
0-6000 100% 4.0 0 0 0  0
NOTE: When reporting the repair, indicate "Rework 2" in
the claim comments.
REWORK 3 - INSTALL NEW ENGINE OIL PAN AND OIL LEVEL GAUGE
This rework applies to the 950F's (Serial Number Prefixes 6YG and
5PJ) with engine Serial Number range 4TF1-8415. It was covered by
former PS4903 - Group 2. Main improvement achieved will be longer
oil life, reduced oil sooting and consequent reduction of engine
wear.

1 - 5P1506 Hose Stock (60 cm long)
1 - 1R0739 Filter Assembly
1 - 7W8860 Gasket-Oil Pan
1 - 105-1542 Gasket-Valve Cover (if needed - See Rework 2)
1 - 105-1556 Oil Pan
1 - 105-9776 Oil Level Gauge (for engine S/N 4TF1-5321)
or
1 - 105-8919 Oil Level Gauge (for engine S/N 4TF5322-up)
1 - 106-6584 Tube Assembly
1 - SEES6492 Chart-Refill Capacities (to be ordered from
Corporate Literature)

See rework procedure in Annex C.
New oil pans must be checked as per instructions given in TIB
dated May 20,1993. Suspect pans will be reworked according to
instructions given in the TIB. All oil pans supplied from Parts
after June 1, 1993 are NOT suspect and may be used without any
rework.

Product AVSpare Dealer Suggested Customer Suggested
SMU (no Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
age (D/N) (Cost)  (C/L) (Sell)
limit)
0-6000 100% 10.0* 0 0 0  0
* Labor shown is claimable ONLY if units are equipped with the
Sound Suppression Package, which includes a rubber mat
underneath the engine. This mat makes the oil pan change
more difficult and more time consuming. For units not
equipped with the Sound Suppression Package, ONLY 8 labor
hours can be claimed for this rework.
NOTE: When reporting the repair, indicate "Rework 3" in
the claim comments.
NOTE: Units updated per this rework are not eligible for
Rework 7 - Group 1.
REWORK 4 - REPLACE TURBOCHARGER COMPRESSOR HOUSING
The purpose of this rework is to eliminate housing having an
internal burr which could potentially loosen into the compressor
wheel.
NOTE: If dealers have replaced turbochargers on 950F
Wheel Loaders with the 100-5865 Turbocharger Group
before May 1993, the units should also be
considered for this rework (refer to TIB dated
May 6, 1993).

1 - 100-5879 Housing

See rework procedure in Annex D.

***** Parts Stock *****
Submit one claim for all 100-5879 Housing used for the rework of
each 100-5865 Turbocharger Groups in parts stock. For each
reworked Turbocharger claim 1 - 100-5879 Housing and 0.5 labor
hour at your cost rate.
***** Affected Product *****
Product AVSpare Dealer Suggested Customer Suggested
SMU (no Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
age (D/N) (Cost)  (C/L) (Sell)
limit)
0-6000 100% 1.0 0 0 0  0
NOTE: When reporting the repair, indicate "Rework 4" in
the claim comments.
NOTE: If a complete turbocharger replacement is needed
due to a damaged compressor wheel, the labor
allowance is 2 hours.
REWORK 5 - EXCHANGE ENGINE
This rework applies to the 950F's (Serial Number Prefixes 6YG and
5PJ) with engine S/N 4TF1-6625. - The main purpose of this rework
is to regain customer confidence and insure fair value for engine
life is obtained.
The replacement engine has been manufactured to the latest
standards providing all improvements mentioned in the other
reworks. An additional benefit is the increased effective engine
life.

1 - 110-9010 Engine Arrangement

Follow Service Manual procedures for exchanging the engine. See
additional information in chapter IV, item 2 (Engine Exchange).

Product AVSpare Dealer Suggested Customer Suggested
SMU (no Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
age (D/N) (Cost)  (C/L) (Sell)
limit)
0-1500 100% 30.0 0 0 0  0
1501-3000 100% 15.0 0 0 0 15.0
3001-6000 100% 0 0 0 0 30.0
NOTE: When reporting the repair, indicate "Rework 5" in
the claim comments.
NOTE: List the serial number of the old and the new
engines, along with the measured blowby and
reported oil consumption in the claim comments.
NOTE: Make a SIMS entry for each engine replacement, use
the new engine Arrangement Number (110-9010) as
the Part Number, Substitute Group Number 1000, and
list the new engine Serial Number in the comments
field. This additional SIMS entry will help track
engine exchanges.
NOTE: This rework is applicable ONLY if engine cylinder
block wear has been demonstrated through blowby
measurements and/or engine oil consumption. -
Refer to attached guidelines for more information.
NOTE: Machines repaired per this rework are no longer
eligible for any other rework of this Program.
NOTE: The allowances shown are "maximum" allowed. If it
can be demonstrated the customer has poor
maintenance practices, such as extended service
intervals, allowing dirt to enter the engine,
running the engine with too little oil or coolant,
etc., then it may be appropriate to charge the
customer for 100% of Part and Labor costs.
REWORK 6 - INSTALL NEW PISTONS AND PISTON RINGS
This rework applies to the 950F's (Serial Number Prefixes 6YG and
5PJ) with engine Serial Number Range 4TF1-6625. - It is limited
to new units in dealer inventory. Main improvement achieved will
be a reduction of oil sooting by having the top ring moved away
from upper face of piston.

6 - 6I1210 Crown As
6 - 4P1549 Skirt
6 - 7E5214 Kit - Piston Rings
1 - 9X6533 Kit - Gaskets

Replace existing piston crowns, skirts and rings with new parts.
Follow Service Manual procedures for installing the new parts.
Note: This rework must be done at the same time the oil
pan is changed to reduce disassembly and assembly
labor time.

Product AVSpare Dealer Suggested Customer Suggested
SMU (no Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
age (D/N) (Cost)  (C/L) (Sell)
limit)
0-500 100% 13.0 0 0 0  0
NOTE: When reporting the repair, indicate "Rework 6" in
the claim comments.
NOTE: Units updated per this rework are not eligible for
Rework 7 - Group 2.
REWORK 7 - UPDATE NON REPAIRED/REPLACED ENGINES AT TIME OF ENGINE
OVERHAUL
This rework is designed to encourage the customer to upgrade the
engine at first overhaul.

***** Group 1 *****
To apply on units with engine Serial Number Range 4TF1-8415 ONLY
if Rework 3 or Rework 5 have not been applied before.
1 - 105-1556 Oil Pan
1 - 105-9776 Oil Level Gauge (for engine S/N 4TF1-5321)
or
1 - 105-8919 Oil Level Gauge (for engine S/N 4TF5322-up)
1 - 106-6584 Tube As
1 - 5P1506 Hose Stock (60 cm long)
***** Group 2 *****
To apply on units with engine Serial Number Range 4TF1-6625 ONLY
if Rework 5 or Rework 6 have not been applied before.
6 - 6I1210 Crown As
6 - 4P1549 Skirt

If the engine of eligible units has not been updated with the
larger oil pan and/or the new piston crowns and skirts, or if the
engine has not previously been replaced, it must be updated at
the time of the first overhaul.

***** Group 1 *****
No SMU/ AVSpare Dealer Suggested Customer Suggested
age Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
limit (D/N) (Cost)  (C/L) (Sell)
100% 0 0 0 0  0
***** Group 2 *****
No SMU/ AVSpare Dealer Suggested Customer Suggested
age Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
limit (D/N) (Cost)  (C/L) (Sell)
33 1/3% 0 0 0 50% 0
NOTE: When claiming these parts, indicate "Rework 7" in
the claim comments.
NOTE: There is NO termination date for this Rework. -
Support for changing the oil pan and the pistons
at the first engine overhaul is offered WITHOUT
limit in SMU and age of the unit.
IV. ADDITIONAL INFORMATION
1) EVALUATING ENGINE CYLINDER BLOCK WEAR
1A) Crankcase Blowby
Blowby will be evaluated using the 8T2700 Blowby/Air Flow
Indicator Group (refer to Special Instruction SEHS8712).
Measurements will be made in torque converter stall
conditions (engine speed at 2120 +/- 65 rpm).
A blowby rate of less than 200 liters per minute is
considered as normal, at any engine age. Such engines do not
have the cylinder walls worn.
A blowby rate of more than 240 liters per minute is
considered as excessive. Such engines have the cylinder
walls and rings worn.
If blowby readings are between 200 and 240 liters per
minute, the oil consumption criteria must be used to
evaluate the wear in the engine.
1B) Oil Consumption
The following fuel to oil ratios will be used to evaluate
the wear in the engine. This criteria is to be considered as
complementary to the blowby measurements described here
above.
These values represent the point at which oil consumption is
considered to be excessive. Customer should monitor and
document the fuel and oil consumption for at least 2-3 weeks
in order to establish a good "average" consumption, instead
of relying on consumption estimate of only a few days. A
report showing daily fuel and oil consumptions should be
retained in the dealer file.
Engine Hours Liters of Fuel per Liter of Oil
0 - 1000  200 or less
1001 - 2000  180 " "
2001 - 3000  160 " "
3001 - 4000  140 " "
4001 - 5000  120 " "
5001 - 6000  100 " "
In evaluating oil consumption, servicemen must first make
sure that the oil is not being lost by leakage at gaskets
and seals, etc.
If oil consumption is excessive, the engine is worn.
If oil consumption is below the limits given, the blowby and
the oil consumption will be monitored for the next 1000
hours. If readings remain stable, the engine can be
considered as not suffering of excessive wear rate and it
would be appropriate to update it as per instructions given
in chapter I, item 3.
2) ENGINE EXCHANGE
The exchange engine is a standard size running engine, factory
tested and adjusted, ready for installation on vehicle. This will
significantly reduce rework time and machine down time. After the
new engine has been installed on unit, check and adjust if
required the engine low idle at 825 +/- 30 rpm.
This engine has been specially created for the purpose of this
program. Some components will have to be transferred by the
Dealer from the old to the new engine. None of these parts are
affected by the oil sooting and engine wear problem.
This special engine does not include the Flywheel, the Flywheel
Housing, the Front Support, the Fan Drive, the Front Damper, the
Shut-off Solenoid, the Sound Cover, the Air Inlet Heater, the Air
Compressor and the Air Lines. These components will have to be
removed from the replaced engine, and re-installed on the
replacing engine.
Special care must be given when installing the Flywheel Housing.
The 8C3091 Seal-O-Ring, part of the 7C1770 Seal Group-Flywheel
Housing, must be placed in the radius of the 2W6546 Cover. Do not
install it in the groove on the outside diameter of the Cover.
Failure to install this seal correctly will result in a
transmission/torque converter oil leak. See Illustration 7.
This special engine can ONLY be used for this Program. It is
purposely covered by a special action price. Dealers using this
special engine for revenue repairs or any use outside of this
Program will be re-invoiced for an additional USD 4,500.--.
The engine identification plate will show 7E0576 as Arrangement
Number with 0T9508 as Specification Number. The engine has a new
Serial Number (prefix 4TF) according to production sequence. The
new engine Serial Number has to be indicated in the claim
comments when reporting the repair. It could be appropriate to
update the Product Identification Plate in the cab with the new
engine Serial Number.
3) AVAILABILITY OF ENGINES
This Service Letter is released without waiting for engines to
become available in large quantities at the start of the Program.
The replacing engines (ref 110-9010) will start to be available
through the Parts Distribution Center (Grimbergen) by mid-August
1993, and in limited quantity. They will be manually allocated
until the end of 1993.
Dealers are requested to place priority on updating latest built
units with the larger oil pan. Exchanging the engine must be
reserved ONLY to those units showing obvious signs of engine
cylinder block wear through excessive blowby and unacceptable oil
consumption.
ANNEX A
PAGE 1 OF 2

 FOR ADJUSTING THE GOVERNOR ON CERTAIN 950F
LOADERS
1. Remove Governor From Engine.
NOTE: The governor must be taken to the dealer shop for
the internal torque cam adjustment. The governor
must be tested on the 1U7326 Governor Calibration
Bench before being installed on the engine.
2. Separate the governor rear housing. See the Service Manual
Disassembly and Assembly section. Do not disassemble the
internal parts of the governor.
3. Adjust the governor torque cam to a new specification of .16
+/- .08 mm. See adjustment procedure, and required tools, in
the Disassembly and Assembly topic, "Disassemble and
Assemble Torque Cam", beginning with Step 11.
4. Test governor on 1U7326 Governor Calibration Bench. Refer to
Special Instruction SEHS8868 for procedure. Governor test
specifications are provided on page 12 of the September 7,
1992 Service Magazine.
NOTE: Only the torque cam adjustment has changed. The
governor bench test specifications did not change.
Calibrate each governor to the bench
specifications given.
5. Install governor on engine. After governor is installed,
check the Fuel Setting, and adjust it to the specification
shown on the Engine Information Plate (Full Load Static
Fuel). Do not adjust Fuel Settings "to the high side" of
tolerance. After the Fuel Setting is adjusted, install a new
lockwire and dealer seal.
6. Start the engine when rework is completed.
7. Adjust the Low Idle to 950 +/- 30 rpm. Check High Idle. The
High Idle rpm (in chassis with no load) should be 2360 +/-
30 rpm. Shut off the engine. Install a new lockwire and
dealer governor seal on the high idle adjustment screw.
NOTE: The engine low idle may be lowered at a minimum of
825 rpm. Refer to TIB dated May 6, 1993 for
conditions in which low idle can be lowered.
ANNEX A
PAGE 2 OF 2
NOTE: The procedure above assumes that the same governor
will be installed on the engine for units being
reworked in dealers shops. However, for reworks
100% 6 0 0 0 0
"exchange" governor. If so, it will be necessary
for the dealer to purchase a new 4P5729 Governor
and a 7E9912 Control Group to begin the exchange.
When removing a governor, always keep the same
control group parts (levers) with the governor.
This is necessary because of slight differences
between some of the governors and control groups
used.
ANNEX B
PAGE 1 OF 2
INSTALLATION OF THE NEW TURBOCHARGER AND ADJUST TIMING ON CERTAIN
950F LOADERS
A. Install Turbocharger
NOTE: Before removing the existing turbocharger, check
the part number on the turbocharger identification
plate (refer to Illustration 1).
- If a unit has a turbocharger with a part
number of 4P4677, 9Y4230, or the
identification plate is missing, install a
new turbocharger.
- If the part number is 1005865, check service
history whether it has been installed as
service replacement. If so, handle
turbocharger as per Annex D, if not, DO NOT
install a new turbocharger.
- If the part number is 1005864, DO NOT install
a new turbocharger.
1. Remove the former turbocharger and air intake hose. Inspect
hose and piping for signs of dirt entry, and correct as
needed. Inspect condition of 8T7044 mounting studs and
8C8734 Locknuts and replace if needed.
2. Install the new 1005865 Turbocharger. Use 5P3931 Antiseize
Compound on the threads of the mounting studs. Install the
new mounting gasket and oil supply/drain gasket. Tighten the
locknuts to 54 +/- 5 N.m (40 +/- 4 lb. ft).
3. Install the new air inlet hose (15 cm of 5P1263 Hose). The
hose is slightly shorter than the former air inlet hose
because the compressor housing of the new turbo is slightly
longer. Tighten the 8T6675 Constant-Torque-Type Clamps to
11 +/- 2 N.m (9 +/- 2 lb. ft). Refer to the Service Manual,
Engine Disassembly & Assembly section concerning the
Turbocharger removal and installation.
B. Adjust Fuel Injector Timing - Check/Adjust Fuel Setting
- Check/Adjust Low Idle rpm
NOTE: Refer to the Service Manual, Engine Section,
Testing and Adjusting for the correct procedure to
set injector Fuel Timing and valve clearance, and
the Fuel Setting procedure.
1. Remove the valve cover sound suppression cover and valve
cover.
2. Check the Fuel Setting. The correct Fuel Setting is shown on
the Engine Information plate, "Full Load Static Fuel" Refer
to Illustration 2. Set the Fuel Setting as closely as
possible to the specified setting. DO NOT set Fuel Settings
"to the high side" of tolerance. If Fuel Setting is
adjusted, install lockwire and a dealer seal.
ANNEX B
PAGE 2 OF 2
3. Set the fuel timing to a specification of 64.16 mm. Also,
check and adjust the valve clearance. The tightening
specification for the injector rocker arm adjusting nuts is
39 +/- 7 N.m (29 +/- 5 lb. ft). Half of the injectors and
half of the valves can be adjusted at each top-dead-center
(TDC) position of the crankshaft. Refer to the Service
Manual procedure for "Fuel Timing".
4. Stamp the new fuel timing specification of 64.16 mm on the
new 4W5140 Information Plate. The plate is 'scored'
lengthwise (to be easily broken lengthwise) so that only the
part of the plate with new information can be applied over
the original Engine Information Plate allowing the other
information to remain showing (refer to Illustration 2).
This plate has a self-stick adhesive on the back, which is
exposed by removing the protective covering. The original
engine information plate may be located on top of the valve
cover, on the side of the engine between the governor and
the fuel filter, or on the side of the engine on the rear
side-cover. The part of the new 4W5140 Plate with the new
Fuel Timing specification must be applied over the previous
plate so that only the new Fuel Timing specification is
visible. The other engine specifications did not change, and
must remain visible.
5. Install the valve cover using the new 1051542 Gasket. Use
the 5H2471 or 8T9021 Gasket Cement to hold the new gasket in
place on the valve cover during installation. Follow the
tightening sequence shown in Illustration 3 and tighten the
valve cover bolts to a torque of 12 +/-3 N.m (9 +/- 2 lb.
ft).
6. The units should have a Low Idle of 950 rpm. This can be
checked either before or after the other update items are
completed. Allow the engine to warm up for several minutes.
Use the instrument panel tachometer to determine Low Idle
rpm. The Low Idle should be 950 rpm, +/- 30 rpm.
NOTE: The engine low idle may be lowered at a minimum of
825 rpm. Refer to TIB dated May 6, 1993 for
conditions in which low idle can be lowered.
NOTE: Steps 1 and 6 above (Fuel Setting and Low Idle
Adjustment) are also included in Rework 1 as part
of a governor update for certain earlier 950F
units. For eligible machines, both programs should
be completed at the same time. If so, Steps 1 and
6 should be performed AFTER the governor has been
updated and installed.
ANNEX C
PAGE 1 OF 5
INSTALL NEW ENGINE OIL PAN AND OIL LEVEL GAUGE
1. Remove the oil level gauge and replace it with the correct
new gauge. Be sure to check the part number of the former
oil level gauge (dipstick) and the new one to be sure the
correct one is being installed (refer to Illustrations 4
and 5).
NOTE: For the earlier 950F units with an oil level gauge
and tube which enters the cylinder block near the
flywheel housing, as shown in Illustration 4, BOTH
the tube and the oil level gauge must be removed
BEFORE changing the oil pan. This is necessary so
the oil pan does not damage the tube during pan
removal and installation. The tube and new oil
level gauge may be installed after the new oil pan
has been installed. Oil level gauge tubes as shown
in Illustration 5 do not have to be removed during
oil pan replacement.
2. Remove the transmission and engine crankcase guards, if so
equipped, to gain access to the engine oil pan 8 nuts for
the rear axle trunnion bolts.
3. Drain and collect the used engine oil for proper disposal.
4. Refer to Illustration 6. Remove 4 bolts and flanged 6C5497
Tube from the oil cooler, and allow approximately 4 Liters
(1 U.S. Gallon) of torque converter oil to drain. Collect
this oil for reuse or proper disposal. Loosen the hose
clamps to remove and discard the 6C5497 Tube for the torque
converter oil cooler (save the hose clamps). This tube must
be removed to provide clearance for the new larger engine
oil pan. It will be replaced by a short flanged 106-6584
Tube and 60 cm of 5P1506 Hose. Collect the torque converter
oil that will drain from the tube when it is disconnected.
There will be approximately 4 Liters (1 U.S. Gallon) of oil.
This torque converter oil must be returned to the
transmission before operating the unit.
5. Remove the existing engine oil filter, and install a new
1R0739 Oil Filter.
6. Loosen and remove the eight nuts from the rear axle
trunnions. This will allow the rear frame of the unit to be
lifted or jacked up off the rear axle trunnions to allow
access to the engine oil pan.
ANNEX C
PAGE 2 OF 5
7. Put the bucket control levers in the "float" position. Then,
lift or jack the rear of the unit slowly until there is
about a 6.0 cm (2.5 inch) clearance between the machine
frame and the trunnions, measured at the rear trunnion bolts
on both sides as the rear of the unit is lifted up slowly
from the axle trunnions. This is when the rear trunnion bolt
threads begin to be visible on both sides. Take care to see
that axle trunnions do not become caught on one side and
axle lifted up with the rear of the unit. Use a suitable pry
bar as needed.
NOTE: Do not lift the unit too high, or the trunnion
bolts will become disengaged from the trunnions,
and make re-assembly more difficult. Lift only far
enough to create the clearance described above.
This will disengage the trunnion dowels on both
sides, but should not be a problem as long as the
trunnion bolts remain engaged in their holes. This
requires approximately 15.3 cm (6.0 inches) of
lift, measured vertically from the floor to the
bottom of the rear bumper under the clevis pin.
8. More clearance for installation of the new oil pan can be
obtained, if necessary, by removing the round trunnion
cover. Refer to the Service Manual, Power Train, Disassembly
& Assembly section for proper lifting and blocking
procedures.
9. Remove the existing oil pan. Remove the oil drain valve and
install it in the new oil pan. Before installing the new oil
pan and gasket, clean the block mounting surface with 6V1541
Primer, and apply 1U8846 Sealant at each of four (4) corners
of the block where the cast iron joins the aluminum front
housing and rear seal carrier joins the cylinder block. This
will help to prevent gasket leaks at these locations.
10. Install the new 1051556 Oil Pan, along with the new 7W8860
Gasket. Use 5H2471 or 8T9021 Gasket Cement to hold the
gasket in place on the oil pan during installation. With pan
in position, install the bolts and tighten evenly to a
torque of 28 +/- 7 N.m (20 +/- 5 lb. ft).
Note: The front and rear oil pan bolts should be
installed and tightened by hand. Do not use an air
wrench, as these bolts can be easily
cross-threaded and/or stripped in the aluminum
front housing and rear seal carrier.
11. Install the short, 4-bolt flanged tube at the oil cooler.
Install 60 cm of 5P1506 Hose. Install one end of the hose at
the oil cooler end first, and clamp it securely. Install the
other end of the hose to the tube from the converter. Twist
the hose slightly so that it does not touch the engine oil
pan, and has at least 12 mm (.5 inch) clearance from the oil
pan. Clamp securely.
ANNEX C
PAGE 3 OF 5
12. Replace oil in the transmission/converter to make up for oil
lost when cooler tube was removed - approximately 4 Liters
(1 U.S. Gallon).
13. After the new oil pan, oil filter, and oil level gauge have
been installed, fill the engine with 31 Liters (8.25 U.S.
Gallons) of API Specification CF-4 oil.
14. Lower the rear of the unit slowly and carefully down onto
the axle trunnions. Make sure the dowels on each side are
engaged in the mating holes properly. Apply 5P3931 Anti-
Seize Compound to the threads of the bolts. Install and
tighten the eight trunnion nuts.
15. On units with over 500 SMU, loosen the oil supply tube from
the cylinder head to the governor. Take care not to damage
or loose the small seals. Remove the oil fitting from the
governor, use a 6 mm hex wrench to remove the small 7C4483
oil inlet screen from the governor. Inspect the 7C4483
Screen for build-up of oil sludge or debris and clean or
replace the screen as needed. Remove the 2W9162 Crankcase
Breather. Clean the breather by washing it a clean, non-
flammable solvent. Install breather on engine. The
recommendation is to clean the crankcase breather every
500 hours.
16. Replace the valve cover gasket with a new 105-1542 Gasket
only if the former gasket is leaking oil. Use 5H2471 or
8T9021 Gasket Cement to hold the new gasket in place on the
valve cover during installation. Follow the tightening
sequence shown in Illustration 3 and tighten the valve cover
bolts to a torque of 12 +/- 3 N.m (9 +/- 2 lb. ft). (See
also item 5 of ANNEX B).
17. Before starting the engine after the rework is completed,
check the oil level. The oil level should be slightly above
the FULL mark because the filter is empty until the engine
pumps it full of oil.
18. Start the engine and check for proper operation and leaks.
Stop the engine.
19. Install transmission and engine crankcase guard, if so
equipped.
20. Check the engine oil level again. It should now be at the
FULL mark, or within +/- 6 mm (.25 inch) when the unit is
parked on a level surface. Also check the transmission oil
level again.
ANNEX C
PAGE 4 OF 5
21. Locate the Operation and Maintenance Management Guide inside
the cab, in the literature compartment. Turn to the page
showing the "Lubricant Viscosities and Refill Capacities".
Refer to 'Refill Capacity' for the Engine Crankcase. Install
the new SEES6492 Refill Capacities Chart over the top of the
original chart. If SEES6492 Chart is not available, put a
mark through the former Engine Crankcase capacity of
20 Liters, 5.2 U.S. Gal, 4.4 Imperial Gal, and WRITE IN the
new engine oil refill capacity of 31 Liters, 8.2 U.S.
Gallons, 7 Imperial Gal.

The SOS Infrared Analysis limit for Allowable Soot is 100% and
should be used for all oils. If AVSpare-brand DEO CF-4 oil is
used, then a maximum limit of 130% soot can be used for the 950F.
This 130% allowable soot limit does NOT apply to other brands of
CF-4 oil because the level of soot dispersant additives in other
brands of oil is unknown and varies considerably. Of course,
other oil conditions such as wear metal content, "dirt",
oxidation, fuel dilution, etc. should also be monitored.

Advise Customers and maintenance personnel of the following
information:
These engine updates are intended to reduce 950F engine oil
sooting/sludging during the recommended 250 hour engine
oil/filter change interval.
1. After this update, the oil refill is 31 Liters (8.25 U.S.
Gallons, or 7.0 Imperial Gallons) due to the new larger
engine oil pan and new oil level gauge (dipstick) which
raises the liquid level slightly. The former engine oil
refill capacity was 20 Liters (5.2 U.S. Gallons, 4.4
Imperial Gallons). Failure to install the new larger
quantity of oil may result in oil starvation and engine
damage. Customers should inform their maintenance personnel
of the new larger Engine Crankcase capacity.
2. The recommended engine oil/filter change interval is 250
hours, and should NOT be exceeded, even with the new larger
oil capacity. The recommended oil is API Specifications
CF-4, which has more dispersant additives than either CE or
CD oils. If AVSpare-brand oil is used, be sure to use
DEO CF-4 instead of DEO CD.
3. If an oil other than API Specification CF-4 is used, such as
CD, or CCMC-D4 in Europe, then the engine oil/filter change
interval should be shortened. Monitor oil condition with
Scheduled Oil Sampling (S.O.S.) including infrared analysis
to determine soot level, and establish an acceptable
oil/filter change interval.
ANNEX C
PAGE 5 OF 5
4. Applications at altitudes over 1525 M (5000 feet) may need
to use somewhat shorter engine oil/filter intervals.
AVSpare recommends the use of S.O.S., including infrared
analysis, to monitor engine oil condition, including soot.
The recommendations concerning shorter engine oil and filter
change intervals when using of high-sulphur fuel have not
changed.
5. For units which have been experiencing excessive sooting or
sludging of the engine oil, AVSpare recommends that
customers temporarily shorten the engine oil and filter
change interval to approximately 100 hours for the next 300
hours of operation to allow the fresh engine oil to loosen
and dissolve any existing soot deposits that may still be
inside the engine. Then, return to the recommended oil and
filter change interval of 250 hours (also see items 3 and 4
above).
ANNEX D
PAGE 1 OF 1
REPLACEMENT OF CERTAIN TURBOCHARGER COMPRESSOR HOUSING
1. Check the turbocharger part number. Only 100-5865
Turbocharger Groups with date code 0493 (April 93) or
earlier are eligible for the rework, provided the machine
Serial Number is listed within the Rework 4 list (page 9).
Do not remove the turbocharger from the engine.
NOTE: 100-5865 Turbocharger Groups with package labels
with date code of 0493 or earlier should not be
used if the letters "DG" are not written next to
the label.
NOTE: Turbochargers Groups that have been reworked in
the Parts Department are identified with an orange
mark on the outside of the compressor outlet.
NOTE: Units that have been factory reworked show a
letter "T" stamped on the Turbocharger
identification plate.
2. Remove the air inlet hose and the compressor outlet hose
from the turbocharger compressor. Inspect the blades of the
compressor wheel. If the blades are damaged, replace the
complete turbocharger with a new 100-5865 Turbocharger
Group. If the blades are not damaged, proceed to step 3.
NOTE: If it is necessary to install a complete new
100-5865 Turbocharger Group, also install a new
7C7431 Gasket (turbo mounting), 1S7057 Gasket
(turbo oil supply), and 7W2398 Gasket (turbo oil
drain).
3. Remove the bolts holding the aluminum compressor housing to
the turbocharger center housing.
4. Mark the position of the outlet of the compressor housing.
The new housing must be installed in the same position.
5. Remove the compressor housing carefully. Do not damage the
blades of the compressor wheel.
6. Install the new 100-5879 Housing. Be careful not to damage
the blades of the compressor wheel. Be sure to align the
compressor outlet in the same position as noted in Step 4.
7. Tighten housing bolts to 7.3 +/- .5 Nm (65 +/- 5 lb-in).
8. After the new 100-5879 Housing is installed, install the air
hoses and clamps. Be sure the hoses and clamps are installed
securely to prevent dirt entry.
ILLUSTRATIONS
PAGE 1 OF 6
LOAVSION OF TURBOCHARGER NAME PLATE
AIR INLET 4P4677  EXHAUST
OUTLET
Illustration 1
ILLUSTRATIONS
PAGE 2 OF 6
Stamp new Fuel Setting information on
4W5140 Plate and install here.
Illustration 2
Tighten valve cover bolts in sequence to a torque of
12 +/- 3 Nm ( 9 +/- 2 lb-ft)
VALVE COVER TIGHTENING SEQUENCE
Illustration 3
ILLUSTRATIONS
PAGE 3 OF 6
Location of the 105-9776 Oil Level Gauge
that replaces the 7E4501 Oil Level Gauge
Engine left side view  Engine rear view
NOTE: 950F's with the engine S/N 4TF1-5321 with this
type of oil level gage must have the gage and the
gage tube removed from the engine before removing
the existing oil pan and while installing the new
oil pan to avoid interference. After the new pan
is installed, the gage tube and new oil level gage
should be installed.
Illustration 4
ILLUSTRATIONS
PAGE 4 OF 6
Location of the 105-8919 Oil Level Gauge
that replaces the 6I1958 Oil Level Gauge
Engine left side view  Engine rear view
NOTE: 950F's with the engine S/N 4TF5322-up with this
type of oil level gage DO NOT have to have the
gage tube removed from the engine before removing
the existing oil pan.
Illustration 5
ILLUSTRATIONS
PAGE 5 OF 6
For units with S/N prefixes of 6YG, 5PJ
Remove the 4-bolt flanged
tube during pan
replacement and install
new 106-6584 Tube before
5P1506 Hose is installed
Replace the existing
6C5497 Tube with a new
106-6584 Tube and 60 cm
of 5P1506 Hose
Frame
Illustration 6
ILLUSTRATIONS
PAGE 6 OF 6
Installation of 8C3091 Seal-O-Ring (to prevent seal damage at
installation)
DO NOT INSTALL THE SEAL IN THE GROOVE
NOT OK   OK
8C3091 Seal-O-Ring
2W6546 Cover
7C0706 Housing Flywheel
8C3091 Seal-O-Ring
2W6546 Cover
Illustration 7