ASTEC KPI-JCI FT4240 Service Bulletin

Brand: ASTEC

Model: KPI-JCI FT4240

Type: Service Bulletin

SUBJECT: FT4240. Main Frame Crack Repair.

page 1 of 4

Cracking has occurred in the rear portion of

the main frame underneath the front vertical

feeder leg support. Cracks have also been

found at the bottom of the main frame near

the tracks at the side plates to horizontal plate

connection. Refer to the picture below for

locations.

NOTICE

Welding must be completed by a certiﬁ ed

welder.

Tools

• Welder

• Weld wire (0.45” L56 or equivalent)

• Torch

• Grinder

• Face Shield

• Primer (Gray SW# E61AS28)

• Paint (KPI Beige SW# F88HC700)

• 1/8” Drill Bit and Drill

Use the following procedure to weld

reinforcement plates to the FT4240 main

frame.

1. Lockout/tagout all power to the FT4240.

2. Before welding anywhere on the FT4240,

disconnect all electronic devices on the

control panel. Failure to disconnect

will result in electronic component failure.

Reference weld disconnect decal on unit

and O & M manual for disconnect locations.

3. Turn the battery disconnect to the “OFF”

position. Use the provided hasp to lock it

out.

Wear a face shield while grinding and

welding to prevent injury.

CAUTION

SB 033 1212 FT MSC

Service Bulletin

FT4240 S/N Range 410104-412287

December 21, 2012SB 033 1212 FT MSC

page 2 of 4

Adding Reinforcement Plates to Main

Frame Underneath Vertical Leg Support

Use drawing 317442 (included with this

bulletin) to complete.

4. Position reinforcement plates (p/n 317436)

(one on each side of the frame) against the

back side of the existing ﬂ ange. The bevel

will be on the outside. Weld as shown on

drawing 317442.

5. Position a top reinforcement plate (p/n

317440) on the top side of the frame. Weld

into place as shown on drawing 317442.

NOTE: Welds must have 2:1 taper on the

ends as to not cause stress risers across the

tension ﬂ ange.

Back side of ﬂ ange

1. Use 1/8” drill bit to drill a hole at the end of

any existing cracks to prevent the crack

from spreading.

2. Arc gouge the cracks.

3. Repair cracks by grinding a bevel and

rewelding. Grind weld so that it is ﬂ ush

with the surface of the frame side and the

reinforcement plates can ﬁ t tight against

back side of the ﬂ ange.

December 21, 2012

SB 033 1212 FT MSC

December 21, 2012

SB 033 1212 FT MSC

Frame Reinforcement Complete

Installing Reinforcement Plate on Lower

Main Frame Near the Tracks

Use drawing 340622 (included with this

bulletin) to complete.

A reinforcement plate will also need to be

added to the main frame near the back end of

the tracks.

Use the following procedure to install this

reinforcement plate.

1. Remove 2-3 track pads near the area to be

welded. To remove, unbolt four bolts from

each track pad.

2. Arc gouge any existing cracks open to a

bevel. Repair crack by rewelding and

grinding smooth.

3. Weld cover plate to main frame as shown

on drawing 340622.

4. Extend welds on the ends. Grind to a

smooth taper.

5. Grind off extended side plate corner at 45

degrees. Refer to the drawing for more

information.

KPI-JCI estimates that this procedure will

take 12 hours. Parts and labor will be

covered under KPI-JCI’s warranty policy.

If you have any questions, call the KPI Service

Department at 1-800-532-9311. They can

also be reached by e-mail at Service@

kolbergpioneer.com.

page 3 of 4

6. Repeat for both sides of frame (2 plates for

each side of the frame).

Please send to:

Name:

Address:

City: State: Zip:

Attn:

FT4240 Serial Number:

page 4 of 4

Check the boxes below and return to KPI-JCI.

Order one kit per unit.

Send ______ FT4240 Frame Repair Kit (P/N 317442)

Procedure should take 12 hours to complete.

Parts and labor will be covered under KPI-JCI warranty.

KPI-JCI

700 W 21st. St.

Yankton, SD 57078

1-800-532-9311

Fax: 1-800-514-6115

Email: [email protected]

FT4240 Lower Frame Repair Kit (P/N 340622)

December 21, 2012

SB 033 1212 FT MSC

DESCRIPTIONQTYPART NO.ITEM

PL .50 X 12.27 X 12.2743174361

PL .38 X 6.50 X 14.8023174402

SHEETDRAWING NUMBER

700 WEST 21st STREET P.O. BOX 20 YANKTON, SOUTH DAKOTA 57078

TITLEDATE

DATE

DRAWN

MODELED

APPROVED

SCALE

ECNDATEREVISION

REVISIONS AND PATTERN CHANGES

NO BY

THIS PRINT IS THE PROPERTY OF KOLBERG-PIONEER INC. AND IS SUBJECT TO RECALL AT ANY TIME,

AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THEIR INTEREST.

BETWEEN FINISHED SURFACES ± 0.010"

DETAIL DIMENSIONS: ± 0.06

TOLERANCES - UNLESS NOTED:NOTICE:

MATERIAL

WEIGHT

317442

REPAIR; FRAME #264384, FT4240

7/6/2011

BHF

.125=1

BHF

7/7/2011

ALSO FITS FRAME 319860

KPI -JCI

ASTEC COMPANI ES

(5/16)

TYP

5/16

TYP

TAPER WELD 2:1 ON ENDS (TYP)

GENERAL REPAIR PROCEDURE BY A CERTIFIED WELDER:

1. IF EXISTING, REMOVE PREVIOUS REPAIR PLATE (SIMILAR TO ITEM #1).

RECOMMEND GRINDING OFF AS TO NOT DAMAGE MAIN FRAME STRUCTURE.

2. IT IS VERY IMPORTANT TO ARC GOUGE THE CRACKS, THEN WELD AND

GRIND FLUSH. ALSO REMOVE THE WELD ON THE BACK SIDE OF THE FLANGE,

IN THE LOCATION OF THE NEW PLATE (ITEMS 1 & 3) THEN GRIND A BEVEL AND

REWELD. NEW WELD IS TO BE FLUSH WITH THE SURFACE OF THE FRAME SIDE

SO THAT PLATES (ITEMS 1 & 3) CAN SIT TIGHT AGAINST BACK SIDE OF FLANGE.

3. POSITION ITEMS 1 AND 3 AGAINST THE BACK SIDE OF THE EXISTING

FLANGE. THE BEVEL WILL BE ON THE OUTSIDE. WELD AS SHOWN.

4. POSITION ITEM 3 AND WELD AS SHOWN. PLEASE NOTE THAT THE WELD

MUST HAVE A 2:1 TAPER ON THE ENDS AS TO NOTE CAUSE STRESS

RISERS ACROSS THE TENSION FLANGE.

5. REPEAT PROCESS ON OTHER SIDE.

#1, 317436 (4) WAS (2); DELETE #3, 317441 (2); ADD WELD SYMBOL

10-24-12

SPM

26737

5/16

TYP

ASTEC KPI-JCI FT4240 Service Bulletin

Brand: ASTEC

Model: KPI-JCI FT4240

Type: Service Bulletin

Download PDF

report

ASTEC KPI-JCI FT4240 Service Bulletin

ASTEC KPI-JCI FT4240 Service Bulletin

Other documents