Repairing the Nonmetallic Fenders, Machine Hoods, and Tank Covers {1273, 7251, 7252} Caterpillar


Repairing the Nonmetallic Fenders, Machine Hoods, and Tank Covers {1273, 7251, 7252}

Usage:

426C 1CR
Articulated Truck
725 (S/N: B1L1-UP; AFX1-UP)
725C (S/N: LFB1-UP; TFB1-UP)
730 (S/N: AGF1-UP; B1M1-UP)
730 EJECTOR (S/N: B1W1-UP)
730C (S/N: LFF1-UP; TFF1-UP)
730C EJECTOR (S/N: LFH1-UP; TFH1-UP)
735 (S/N: B1N1-UP; AWR1-UP)
735B (S/N: L4D1-UP; T4P1-UP)
740 (S/N: AXM1-UP; B1P1-UP)
740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)
740B (S/N: L4E1-UP; T4R1-UP)
740B EJECTOR (S/N: L4F1-UP; T4S1-UP)
Backhoe Loader
416C (S/N: 4ZN1-UP; 5YN1-UP; 1WR1-UP; 1XR1-UP)
416D (S/N: BGJ1-UP; BFP1-UP)
420D (S/N: BKC1-UP; BMC1-UP; BLN1-UP)
424D (S/N: BGP1-UP; BKR1-UP)
426C (S/N: 6XN1-UP; 7WN1-UP; 1CR1-UP; 1ER1-UP; 1MR1-UP; 1NR1-UP; 1YR1-UP; 1ZR1-UP)
428C (S/N: 8RN1-UP; 1HR1-UP; 2CR1-UP)
428D (S/N: BNB1-UP; BLL1-UP; BNS1-UP; BMT1-UP)
430D (S/N: BNK1-UP; BML1-UP)
432D (S/N: BLD1-UP)
436C (S/N: 8TN1-UP; 9JN1-UP; 1FR1-UP; 1PR1-UP; 1RR1-UP; 2AR1-UP; 2BR1-UP)
438C (S/N: 9KN1-UP; 1JR1-UP; 1TR1-UP; 2DR1-UP)
438D (S/N: BPE1-UP; BPN1-UP)
442D (S/N: BRG1-UP; BRY1-UP)
Compact Wheel Loader
902 (S/N: 7ES1-UP)
904B (S/N: B4L1-UP)
906 (S/N: MER1-UP; 6ZS1-UP)
908 (S/N: TAR1-UP; 8BS1-UP)
914G (S/N: 7ZM1-UP; 9WM1-UP)
Integrated Toolcarrier
IT14G (S/N: 8ZM1-UP; 1WN1-UP)
IT28G (S/N: WAC1-UP; EWF1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)
Mini Hydraulic Excavator
301.5 (S/N: 3YW1-UP)
301.6 (S/N: BDH1-UP)
301.8 (S/N: BFA1-UP)
302.5 (S/N: 4AZ1-UP)
303.5 (S/N: AFW1-UP)
304.5 (S/N: ANR1-UP)
Wheel Loader
924G (S/N: 9SW1-UP; 3PZ1-UP)
924GZ (S/N: 6YW1-UP; 3DZ1-UP)
924HZ (S/N: JZZ1-UP)
924K (S/N: KW41-UP; ENC1-UP; HJF1-UP; PWR1-UP)
926M (S/N: LTE1-UP)
928G (S/N: 6XR1-UP; 7SR1-UP)
928HZ (S/N: CXK1-UP)
930G (S/N: TWR1-UP; TFW1-UP)
930H (S/N: DHC1-UP)
930K (S/N: DYB1-UP; EYE1-UP; P3K1-UP; RHN1-UP)
930M (S/N: KTG1-UP; HEY1-UP)
938K (S/N: W8K1-UP; SWL1-UP; REP1-UP; HFW1-UP)
938M (S/N: J3R1-UP)

Introduction

This Special Instruction outlines the basic procedure to repair damage to nonmetallic fenders, nonmetallic hoods, and tank covers.

The fenders, hoods, and the tank covers are made from a material specified as polydicyclopentadiene (PDCPD). The thermoset material has high impact resistance, good durability, fewer maintenance requirements, and excellent flexibility at low ambient temperatures. Components may be made of Sheet Molded Composites (SMC) instead.

Repairs to a PDCPD surface can achieve the original strength of the part at the repaired location.

Before you attempt to repair the damaged part, inspect the part. If the part has extensive damage, the part should be replaced. The following conditions must be considered: location and extent of the crack, requirements for strength, repair versus replacement costs, availability of repair facilities and machine requirements.

Note: Once a roof has become permanently deformed by heat, the roof can no longer be repaired.

This Special Instruction provides only a general guideline for the repair of PDCPD and SMC. No specific brand of repair material is covered for PDCPD in this publication. Many products are available for the repair of plastics. New repair materials are being developed constantly. A list of suppliers for repair materials is provided as a reference.

Do not perform any procedure in this publication until you have read the information in this special instruction.

Note: Use for the D-series Backhoe Loaders machines hoods only.

Note: If you are unable or uncomfortable performing the below repair procedures, contacting a local business familiar with repairing fiberglass body panels is recommended.

Identifying the Material and Preparation of the Material

Clean the damaged part with a solution of soap and water.


NOTICE

Do not use petroleum-based solvent cleaners as those cleaners may cause a deterioration of the material.


You can identify the hoods, fenders, and tank covers which are made of the material by looking on the underside of the part. If the part is made of PDCPD, the letters will be molded into the surface of the part. PDCPD material has a smooth underside or the material has a slight roughness on the underside. No fiberglass material is in the base material.

SMC materials are hard to identify in the field. If you have questions about the material which is on your machine, contact your Caterpillar dealer. Provide the dealer with the following information:

  • The machine model number

  • The machine serial number

  • Part Number

  • Description of the part

The recycle code marked on the back of the part can also be used to identify the material. The code shows "UP" or "UP - XXXX" where the "XXXX" represents fillers like glass that are in the polyester resin matrix.

Repair Procedures for PDCPD

Two types of basic repairs are possible:

  • Repairs for damage to the surface of a part

  • Repairs for crack and holes which penetrate the part

Determine the type of repair which will be necessary, and select an appropriate repair material. Refer to the section "List of Suppliers" for repair material.

The repair materials are composed of a resin. The repair materials also contain a catalyst or an activator. These components must be mixed in the proper ratio. Once the two components are mixed, a chemical reaction occurs and the material starts to harden. The material will harden differently depending on temperature and the condition of the part.

Instructions are packaged with the repair materials for performing the following procedures: preparation, mixing, application, and finishing.

Curing times for the repair materials will vary because of the following conditions: thickness of the material, ambient temperature, and relative humidity. Longer curing times will occur when the ambient temperature is below approximately 21 °C (70 °F). Apply heat to the part and repair material when the temperature is lower than 21 °C (70 °F).

With the temperature above 21 °C (70 °F), the repair material will cure in approximately 10 minutes to 30 minutes. Once the repair material is cured, rough sanding can begin. Do not alter the mix composition of the repair material. Curing times must not be altered unless you are directed by the manufacturer.

Cracks will demand longer curing times. The repairs will not reach full strength for several hours.

Read the instructions which are packaged with the repair materials. Do not start to repair a part until you understand the instructions. The following information is intended to be a supplement to those instructions.

Repairing the Damage to the Surface of a Hood, Fender, or Tank Covers

------ WARNING! ------

Dust generated when grinding or cutting nonmetallic materials may be very fine, abrasive, flammable, and/or explosive. Material being removed may contain crystalline silica, quartz, glass fibers, and other fine materials. Prolonged breathing of the dust may cause cancer and irreversible lung damage. Wear goggles, gloves, and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and by the Mine Safety and Health Administration (MSHA).

In the event of contact with the skin, flush the skin with plenty of water. If dust material gets into the eyes, flush the eyes with an approved flushing system and seek medical attention. Before smoking or eating, clean hands thoroughly. Keep the work site clean and dispose of all dust and particles in containers approved for flammable materials.

Refer to the dust handling instructions in this publication for correct disposal of the dust.




Illustration 1g00532853
Remove the damaged material by sanding or grinding. Form a tapered depression (A).

  1. Grind away any damaged material. Use a 50 grit abrasive paper to remove the damaged material. A grinder can also be used. Be careful to grind only as deep as the damage. Taper the depression which was made by the grinding. Refer to Illustration 1.

    The taper should extend at least 25 mm (1.0 inch) beyond the damaged area. The tapered areas should not extend beyond 50 mm (2.0 inch). This process will permit feathering out the repair into the base material for a smooth finish.

  2. Clean the dust from the tapered area with soap and water. Permit the area to dry.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  3. Mix the components of the repair material together. Follow all the directions for mixing the components.

    Note: Use a static mixer nozzle to mix the components. Failure to use a static mixer nozzle to mix material from dual dispensing cartridges may result in a weak repair.



    Illustration 2g00599445
    Leave the repair material (B) higher in the center of the area which is being repaired.

  4. Put the mixture into the tapered depression. Leave the repair material higher in the center of the depression. Refer to Illustration 2.

  5. Allow the repair material to cure before sanding. Curing times will vary with the thickness of the material, ambient temperature, and relative humidity.

    Most repair material will cure in 10 minutes to 30 minutes when the temperature is above 21 °C (70 °F).

  6. Sand the repair material so the material is smooth and even with the surrounding surface. Use an 80 grit to100 grit abrasive paper for rough sanding. Then use a 120 grit to 180 grit paper for smoother finishing.

    Note: Dry abrasive paper or wet abrasive paper can be used to sand the repair material to a smooth finish. Dust will be reduced by using a wet abrasive paper with water.

  7. Inspect the repaired area. If the surface has small imperfections, apply a thin layer of the repair material. Repeat Steps 4 through 7.

  8. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Repairing Cracks and Holes

------ WARNING! ------

Dust generated when grinding or cutting nonmetallic materials may be very fine, abrasive, flammable, and/or explosive. Material being removed may contain crystalline silica, quartz, glass fibers, and other fine materials. Prolonged breathing of the dust may cause cancer and irreversible lung damage. Wear goggles, gloves, and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and by the Mine Safety and Health Administration (MSHA).

In the event of contact with the skin, flush the skin with plenty of water. If dust material gets into the eyes, flush the eyes with an approved flushing system and seek medical attention. Before smoking or eating, clean hands thoroughly. Keep the work site clean and dispose of all dust and particles in containers approved for flammable materials.

Refer to the dust handling instructions in this publication for correct disposal of the dust.




    Illustration 3g00534046
    Remove the damaged material by sanding or grinding. Form two tapered depressions (C).

  1. Remove any damaged material by grinding or cutting. Use a 50 grit abrasive paper. A grinder can also be used with a nonmetallic disc. Grind out the damage to the depth of the damage.

    Form two tapered depressions. The taper should extend at least 25 mm (1.0 inch) beyond the damaged area. The tapered areas should not extend beyond 50 mm (2.0 inch). This process will permit feathering out the repair into the base material for a smooth finish. Refer to Illustration 3.

  2. Clean the tapered areas of dust and other loose particles. Permit the area to dry.


    Illustration 4g00599589
    (B) Repair material
    (D) Backup material (fiberglass)
    (E) Paper (nonstick)
    (F) Cardboard

  3. On the underside of the part, add the backup material (D). The backup material must be made of fiberglass.

    The material is available in the following forms:

    • Woven Fiberglass

    • Screened Fiberglass

    • Chopped Fiberglass

    Cut the backup material to cover the hole. The material must be cut so that the material extends at least 25 mm (1.0 inch) beyond the edge of the hole. Refer to Illustration 4.

    Note: For repairs to the top surface, cut a second piece of the backup material to repair parts which are thicker than 9 mm (0.35 inch). The second piece of fabric must be placed below the surrounding surface.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  4. Mix the components to create the repair material. Follow all the directions for mixing the components.

    Note: Use a static mixer nozzle to mix the components. Failure to use a static mixer nozzle to mix material from dual dispensing cartridges may result in a weak repair.

  5. Position the backup material into the depression on the underside of the part. Push the repair material (B) through the backup material (D). Refer to Illustration 4.

  6. Place a piece of paper (nonstick) (E) between the cardboard (F) and the repair material (B). The paper will prevent the repair material from sticking to the cardboard. The cardboard is taped to the underside of the part to support the repair material while the material cures.

  7. Allow the repair material to cure before sanding. Curing times will vary with the thickness of the material, ambient temperature, and relative humidity.

    Most repair material will cure in 10 minutes to 30 minutes when the temperature is above 21 °C (70 °F).



    Illustration 5g00600274
    (B) Repair Material
    (D) Backup material (fiberglass)
    (G) Hole

  8. From the top, put a portion of the repair material inside the hole (G). Refer to Illustration 5.

  9. Cut a piece of the backup material (D) to cover the hole (G). None of the material must show outside the tapered area. Refer to Illustration 5.

  10. Put the backup material into the top tapered area. Refer to Illustration 5.

    Note: A second piece of backup material can be added. The backup material must also be cut small enough to be covered by the repair material.

  11. Apply the repair material to the top of the part. Push the repair material through the backup material.

    Leave the repair material higher in the center of the depression. Refer to Illustration 5.

  12. Allow the repair material to cure before sanding. Curing times will vary with the thickness of the material, ambient temperature, and relative humidity.

    Most repair material will cure in 10 minutes to 30 minutes when the temperature is above 21 °C (70 °F).

  13. Sand the repair material so the material is smooth and even with the surrounding surface. Use an 80 grit to 100 grit abrasive paper for rough sanding. Then use a 120 grit to 180 grit paper for smoother finishing.

  14. Inspect the repaired area. If the surface has small imperfections, apply a thin layer of the repair material. Allow the layer to dry. Sand the area again. Inspect the repaired area.

    Note: Dry abrasive paper or wet abrasive paper can be used to sand repair material to a smooth finish. Dust will be reduced by using a wet abrasive paper with water.

  15. Remove the cardboard and paper (nonstick) from the repair to the underside of the part.

  16. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Repair Procedures for SMC

------ WARNING! ------

Dust generated when grinding or cutting nonmetallic materials may be very fine, abrasive, flammable, and/or explosive. Material being removed may contain crystalline silica, quartz, glass fibers, and other fine materials. Prolonged breathing of the dust may cause cancer and irreversible lung damage. Wear goggles, gloves, and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and by the Mine Safety and Health Administration (MSHA).

In the event of contact with the skin, flush the skin with plenty of water. If dust material gets into the eyes, flush the eyes with an approved flushing system and seek medical attention. Before smoking or eating, clean hands thoroughly. Keep the work site clean and dispose of all dust and particles in containers approved for flammable materials.

Refer to the dust handling instructions in this publication for correct disposal of the dust.


Crack Repair

The following procedure is for making acceptable cosmetic crack repairs on the surface of SMC material when parts are at room temperature.

Note: A flexible mixing surface is ideal for polyester fillers. The excess hardened filler is easily removed thereby affording reuse of the mixing surface.

Note: The flexible putty spreader used for filling the void should be at least as large as the repair area.

Note: Orbital sander is best for contouring the repaired area.

  1. Identify and mark the damaged area with masking tape.

  2. If present, remove primer from around damaged area using 320 grit sandpaper for proper bonding of the filler.

  3. Route a hole all the way through the part where the crack ends. Doing so will stop the crack from running further into the part.

    Rough up crack and area around the crack, at least 6 mm (0.25 in) on each side with router.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  4. Mix two part filler and cream hardener together following container directions.

    Note: The preferred fillers for cracks are everglass or fibral. Specifically use fibral if crack is completely through the part.

  5. Fill the area to be repaired with the filler using a firm but flexible putty spreader.

    When applying the repair material, use an up and down motion and then left to right to reduce trapped air.

  6. Using the putty spreader, remove any excess filler around the repair area. Let filled repair cool to room temperature.

  7. Sand the repaired area until all excess repair material is removed.

    Note: If pinholes are present after repair is complete, the area must be filled again.

  8. Use a safety nozzle to blow all dust off the part and spot prime repaired area. After spot prime dries, scuff all spot primed areas.

  9. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Porosity Repair

The following procedure is for making acceptable porosity repairs on the laminate of SMC material when parts are at room temperatures.

Note: A flexible mixing surface is ideal for polyester fillers. The excess hardened filler is easily removed thereby affording reuse of the mixing surface.

Note: The flexible putty spreader used for filling the void should be at least as large as the repair area.

Note: Orbital sander is best for contouring the repaired area.

  1. Identify and mark the damaged area with masking tape.

  2. If present, remove primer from around damaged area using 320 grit sandpaper for proper bonding of the filler.

  3. Blow off damaged area using safety nozzle to remove any dust.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  4. Mix two part filler and cream hardener together following container directions.

    Note: The preferred filler for porosities is spot-lite.

  5. Fill area to be repaired with filler using a firm but flexible putty spreader slightly larger than the defective area.

    When applying the repair material, use an up and down motion and then left to right to reduce trapped air.

  6. Using the putty spreader, remove any excess filler around the repair area. Let filled repair cool to room temperature.

  7. Sand the repaired area until all excess repair material is removed.

    Note: If pinholes are still present after repair is complete, the area must be filled again.

  8. Use a safety nozzle to blow all dust off the part and spot prime repaired area. After spot prime dries, scuff all spot primed areas.

  9. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Gouge Repair

The following procedure is for making acceptable gouge repairs on the laminate of SMC material when parts are at room temperature.

Note: A flexible mixing surface is ideal for polyester fillers. The excess hardened filler is easily removed thereby affording reuse of the mixing surface.

Note: The flexible putty spreader used for filling the void should be at least as large as the repair area.

Note: Orbital sander is best for contouring the repaired area.

  1. Identify and mark the damaged area with masking tape.

  2. If present, remove primer from around damaged area using 320 grit sandpaper for proper bonding of the filler.

  3. Remove any loose fibers with a pencil router. If the gouge is on an edge, use a router to rough up the area around the gouge.

  4. Blow off any dust around the damaged area using safety nozzle.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  5. Mix two part filler and cream hardener together following container directions.

    Note: The preferred filler for gouge is everglass or spot-lite. Specifically use everglass if gouge is on the edge.

  6. Fill the area to be repaired with the filler using a firm but flexible putty spreader slightly larger than the defect.

    When applying the repair material, use an up and down motion and then left to right to reduce trapped air.

  7. Using the putty spreader, remove any excess filler around the repair area. Let filled repair cool to room temperature.

  8. Sand the repaired area until all excess repair material is removed.

    Note: If pinholes are still present after repair is complete, the area must be filled again.

  9. Use a safety nozzle to blow all dust off the part and spot prime repaired area. After spot prime dries, scuff all spot primed areas.

  10. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Edge Chip Repair

The following procedure is for making acceptable edge chip repairs on the laminate of SMC material when parts are at room temperature.

Note: A flexible mixing surface is ideal for polyester fillers. The excess hardened filler is easily removed thereby affording reuse of the mixing surface.

Note: The flexible putty spreader used for filling the void should be at least as large as the repair area.

Note: Orbital sander is best for contouring the repaired area.

  1. Identify and mark the damaged area with masking tape.

  2. If present, remove primer from around damaged area using 320 grit sandpaper for proper bonding of the filler.

  3. Remove any loose fibers with a pencil router or 60 grit sandpaper. Since this defect is an edge chip, the area around the chip must also be roughed up with a pencil router or 60 grit sandpaper.

  4. Blow off damaged area using safety nozzle to remove any dust.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  5. Mix two part filler and cream hardener together following container directions.

    Note: The preferred filler for edge chip is everglass.

  6. Fill the area to be repaired with the filler using a firm but flexible putty spreader.

  7. Using the putty spreader, remove any excess filler around the repair area. Let filled repair cool to room temperature.

  8. Sand the repaired area until all excess repair material is removed.

    Note: If pinholes are still present after repair is complete, the area must be filled again.

  9. Use a safety nozzle to blow all dust off the part and spot prime repaired area. After spot prime dries, scuff all spot primed areas.

  10. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Blister Repair

The following procedure is for making acceptable blister repairs on the laminate of SMC material when parts are at room temperature.

Note: A small, pointed router bit is used to remove the raise surface to expose the void.

Note: A flexible mixing surface is ideal for polyester fillers. The excess hardened filler is easily removed thereby affording reuse of the mixing surface.

Note: The flexible putty spreader used for filling the void should be at least as large as the repair area.

Note: Orbital sander is best for contouring the repaired area.

  1. Identify and mark the damaged area while the part is hot with a marking pen.

    Note: Some blisters will go down while cooling, so marking these areas is important.

    Allow the part to reach room temperature before proceeding with the repair procedure.

  2. If present, remove primer from around damaged area using 320 grit sandpaper for proper bonding of the filler.

  3. With a small router bit, rout the blister out of the surface of the part. When opening the blister up, there will be separation of the material. Rout the area until solid material is found.

  4. After blister is routed out of the part, blow off the damaged area using dry safety nozzle.

    ------ WARNING! ------

    Resins, activators, and/or catalysts used in the repair of plastics, including fiberglass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of the vapor or spray mist. Do not take internally. Keep out of reach of children.

    Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush the skin with plenty of water. For eyes, get medical attention.

    Read, understand, and follow both the instructions for use and the warnings which are packaged with, or printed on, the repair material containers for the specific repair product you are using.


  5. Mix two part filler and cream hardener together following container directions to make the filler.

    Note: The preferred filler for blister is fibral.

  6. Fill void with the filler using a firm but flexible putty spreader slightly larger than the defect.

    When applying the repair material, use an up and down motion then left to right to reduce trapped air.

  7. Cover the repaired area with a piece of masking tape and using the palm of your hand, run back and forth over the repair to force out any trapped air.

  8. Remove excess material from the part that was forced out around the tape. Let filled repair cool to room temperature.

  9. Sand the repaired area until the excess repair material is removed.

    Note: If pinholes are still present after repair is complete, the area must be filled again.

  10. Use a safety nozzle to blow all dust off the part and spot prime repaired area. After spot prime dries, scuff all spot primed areas.

  11. Paint the repaired area. Refer to section "Painting the Repair" in this publication.

Painting the Repair

  1. A rough surface may be applied to the repair material. A rough surface will allow paint to stick to the repair material. Allow the material to remain unpainted for at least 4 hours. The materials will oxidize for better adhesion by the paint.

    ------ WARNING! ------

    Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing the vapors in enclosed areas without adequate ventilation and do not smoke.

    Isopropyl alcohol is flammable. Do not use near open flame, welding operations, or around heated surfaces exceeding 482°C (900°F).



    NOTICE

    Do not use petroleum-based solvents to clean the material. Petroleum-based solvents will cause deterioration of the material.


  2. Clean the entire area of the repair. Also clean the surrounding area around the repair.

    Use soap and water to clean the areas. You can also use isopropyl alcohol to clean the surfaces.

  3. Allow the cleaned areas to dry.

  4. Cover any area which will not be painted.

  5. Before you paint the repaired area, wipe the area with a new tack cloth. The cloth will remove any foreign material which may be present on the surfaces.

    ------ WARNING! ------

    Paint and products used in painting may be flammable and hazardous. Read, understand, and follow instructions for use on the container. Wear NIOSH/MSHA certified respiratory protection.


  6. Prime the repaired areas with a suitable epoxy primer that is compatible with urethane paints.

    Note: Primer is not used when touch-up paint is applied to flexible surfaces which are nonmetallic.

  7. Paint the repaired areas in a color that conforms to the rest of the repaired component. Use paint that is designed for urethane finishes.

    Note: Paint used for the repair must be compatible with the original finish which is on the machine. Primer is not used when touch-up paint is applied to flexible surfaces which are nonmetallic. Refer to Section 23 of the Caterpillar Tools and Shop Products Guide.

  8. After the paint is dry, remove any protective covers.

List of Suppliers

Repair materials consist of adhesives and fillers. For joining two pieces together, use an adhesive. For repairing a surface, use a filler. Some repair materials may combine the qualities of an adhesive and a filler.

To repair PDCPD plastic, the repair material must have some flexibility.

Repair materials have a limited effective life. Caterpillar recommends obtaining the correct repair materials at the time of the repair.

Repair materials are also available from the following distributors: automotive, marine, and industrial. If there is not a local supplier in your area, contact one of the following suppliers:

Bond-Tite Products
U.S. Chemical and Plastics Inc.
600 Nova Dr., S.E.
Massillon, OH 44646
330-830-6000
800-530-5322
www.uschem.com
techinfo@uschem.com

The company offers adhesives and fillers.

Ciba Specialty Chemicals
4917 Dawn Ave.
East Lansing, MI 48823-5691
517-351-5900

Ciba Specialty Chemicals (Europe)
Duxford, Cambridge
United Kingdom CB2 4QA
44-1223-832-121

The company offers adhesives.

Bondo/Mar-Hyde Corp.
3700 Atlanta Industrial Parkway, N.W.
Atlanta, GA 30331-1098
888-442-6636

The company offers adhesives and fillers.

Fibre Glass-Evercoat Co., Inc.
6600 Cornell Rd.
Cincinnati, OH 45242-2000
513-489-7600

The company offers adhesives, fillers, and fiberglass fabrics.

ITW Devcon
30 Endicott St.
Danvers, MA 01923
800-933-8266
Devcon UK -- 441-933-675-299
ITW Devcon Industrial, Germany -- 494-317-18830

The company offers adhesives and fillers.

SEM Products, Inc.
651 Michael Wylie Dr.
Charlotte, NC 28217-1546
704-522-1006
800-831-1122

The company offers adhesives and fillers.

INP (SEM Products, Inc.)
Holland
311-874-826-03

The company offers adhesives and fillers.

3M
Automotive Trades Division
Building 223-6NW, 3M Center
St. Paul, MN 55144-1000
651-733-5547

This company offers fiberglass fillers.

U-POL US, Inc.
108 Commerce Way
Stockertown, PA 18083
610–746–7081
610–743–8654
sales-us@u-pol.com

The company offers adhesives and fillers.

3M (Europe)
www.MMM.com

Refer to the web site for phone numbers in your country.

Handling and Disposal of Dust

Repair of the fenders, hoods, and tank covers will create dust and particles. Refer to the following information which outlines the procedures to handle the dust and dispose of the dust.



Illustration 6g00601034


Illustration 7g00601037

Caterpillar Information System:

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