0433811 JOHNSON CARB. ASSY., 88/90 models.

This Program must be administered as soon as possible. When reporting the repair, use "PI3364" as the Part number and "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 "PI3364" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
June 30, 2000Termination Date
January 31, 2001Problem
The top rail section of the engine end frame may crack and needs to be repaired on certain 992G Wheel Loaders. A crack may develop in a weld joint on the top rail section on the left or right side of the engine end frame. All machines will need to have the weld joint removed and replaced to prevent failure.
Affected Product
Model & Identification Number
992G (7HR1-44, 7HR46-287), (05A11188)
Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
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
Repair Procedure 1:
Repairing the Rear Frame Top Plate - No Visible Crack:
Protect all hoses, tubes, and wiring from damage during removal.
1. Locate weld section using template 1 and Illustration 3. Mark this location on the frame. This weld section begins 148.0mm (5.83in.) forward of the firewall mount.2. Remove the entire width and depth of the original weld in the top frame plate, including the back up strip. Make sure all weld material is removed and all slag, porosity, and inclusions are removed.3. Grind the exposed area smooth for re-welding.4. Install a new back up strip and tack into position.5. Fabricate 50.8mm (2 in.) runout tabs. Tack weld the tabs on both sides of the frame. Start and stop all welds on the tabs. Reference Illustration 1 below.
Illustration 1 - top view of rear frame - partially welded6. Use E7018 welding rod or equivalent low hydrogen welding process to make repair.7. When the bevel is completely full, cut off the runout tabs and grind the sides and top of weld smooth. Repaint as necessary. Repair Procedure II:
Repairing the Rear Frame Top Plate - If Crack has Propagated Longer than 76.2mm (3 in.) Down the Sides of the Box Section:
1. Locate weld section using template 1. Mark this location on the frame. The weld section begins 148.0mm (5.83 in.) forward of the firewall mount. Protect all hoses, tubes, and wiring from damage during removal.
2. Remove the entire width and depth of the original weld in the top frame plate, including the back up strip. Make sure all weld material is removed and all slag, porosity, and inclusions are removed.3. Grind the exposed area smooth for re-welding.4. Locate the entire length of the crack. Remove a window section to provide access to repair the crack internally. If crack has propagated on the outside of the frame, make a window large enough to remove the entire length of the crack. If crack has propagated on the inside of the frame, (near the pump drive), make window large enough to provide adequate room to make weld repairs internally. See Illustration 2, below for example.
Illustrustration 2.5. To repair cracks on the inside wall (engine side) of the box section first gouge out the crack from the inside. Form a V-groove for welding.6. Install a backup strip on the outside of the area to be welded.7. Re-weld the crack using E7018 rod or equivalent. 8. Remove the backup strip from the outside of the frame and grind the weld smooth.9. Replace cut out window with 12mm (0.47 in.) thick plate steel. Bevel edges of new plate and use backup strips behind the plate to reinstall.10. Install a new back up strip and tack into position.11. Fabricate 50.8mm (2 in.) runout tabs. Tack weld the tabs on both sides of the frame. Start and stop all welds on the tabs. 12. Use E7018 welding rod or equivalent low hydrogen welding process to make repair.13. When the bevel is completely full, cut off the runout tabs and grind the sides and top of weld smooth. Repaint as necessary. If cracking exceed 152.4mm (6 in.) down both sides of the box section, refer to Special Instruction REHS0703, "Replacement Procedure for the Top Rail on the Rear Frame of the 992G" for an alternate repair. This repair can be claimed on this PIP, 40 hours per side is then allowed.
Template - shown in actual size
Illustration 3.