SB 033 1212 FT MSC

Service Bulletin
FT4240 S/N Range 410104-412287

SB 033 1212 FT MSC December 21, 2012

SUBJECT: FT4240. Main Frame Crack Repair.

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 certified
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.
! CAUTION
Wear a face shield while grinding and
welding to prevent injury.

page 1 of 4
SB 033 1212 FT MSC December 21, 2012

4. Position reinforcement plates (p/n 317436)

Adding Reinforcement Plates to Main
Frame Underneath Vertical Leg Support
Use drawing 317442 (included with this
bulletin) to complete.
(one on each side of the frame) against the
back side of the existing flange. The bevel
will be on the outside. Weld as shown on
drawing 317442.

Back side of flange

5. Position a top reinforcement plate (p/n

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.
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 flange.

3. Repair cracks by grinding a bevel and

rewelding. Grind weld so that it is flush
with the surface of the frame side and the
reinforcement plates can fit tight against
back side of the flange.

page 2 of 4
SB 033 1212 FT MSC December 21, 2012

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

each side of the frame).

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.
KPI-JCI estimates that this procedure will
2. Arc gouge any existing cracks open to a take 12 hours. Parts and labor will be
bevel. Repair crack by rewelding and covered under KPI-JCI’s warranty policy.
grinding smooth.
If you have any questions, call the KPI Service
3. Weld cover plate to main frame as shown Department at 1-800-532-9311. They can
on drawing 340622. also be reached by e-mail at Service@
kolbergpioneer.com.
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.
page 3 of 4
SB 033 1212 FT MSC December 21, 2012

Check the boxes below and return to KPI-JCI.

Order one kit per unit.

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

FT4240 Lower Frame Repair Kit (P/N 340622)

Procedure should take 12 hours to complete.

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

Please send to:

Name:

Address:

City: State: Zip:

Attn:

FT4240 Serial Number:

KPI-JCI
700 W 21st. St.
Yankton, SD 57078
1-800-532-9311
Fax: 1-800-514-6115
Email: mail@kpijci.com
page 4 of 4
 ITEM PART NO. QTY DESCRIPTION
1 1 317436 4 PL .50 X 12.27 X 12.27
2 317440 2 PL .38 X 6.50 X 14.80
1 3

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.

2 TAPER WELD 2:1 ON ENDS (TYP)

TYP
5/16

TYP
(5/16)

1 TYP 1
5/16

THIS PRINT IS THE PROPERTY OF KOLBERG-PIONEER INC. AND IS SUBJECT TO RECALL AT ANY TIME, WEIGHT MATERIAL BETWEEN FINISHED SURFACES ± 0.010"
NOTICE: AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THEIR INTEREST.
TOLERANCES - UNLESS NOTED: DETAIL DIMENSIONS: ± 0.06

KPI-JCI
DRAWN DATE TITLE
REPAIR; FRAME #264384, FT4240
BHF 7/7/2011
MODELED DATE
ALSO FITS FRAME 319860
ASTEC COMPANIES
1 #1, 317436 (4) WAS (2); DELETE #3, 317441 (2); ADD WELD SYMBOL 10-24-12 SPM 26737 BHF 7/6/2011
SCALE DRAWING NUMBER SHEET
APPROVED DATE
1
317442
NO REVISION DATE BY ECN

REVISIONS AND PATTERN CHANGES 700 WEST 21st STREET P.O. BOX 20 YANKTON, SOUTH DAKOTA 57078 .125=1 1