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REMOVAL - TM-5-4210-229-14P_371
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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REPAIR - TM-5-4210-229-14P_373
TM5-4210-229-14&P 5-18. CAB PANELS REPAIR. This task covers: a.  Removal b.  Installation INITIAL SET-UP Tools Materials/Parts General Mechanics Tool Kit Sandpaper (Appendix D, Item 46) Heat Gun Filler (Appendix D, Item 17) Rubber Mallet Putty (Appendix D, Item 44) File Paint (Appendix D, Item 40) Grinder General Safety Instructions Engine OFF. Transmission in (N) neutral Parking brake set. Batteries disconnected. Battery selector switch OFF. REPAIR a. Repair holes using metal insert. (1) Using  the  appropriate  tools,  cut  the  rusted  or damaged material from the panel. (2) Using   a   rubber   mallet,   form   a   step   in   the original  panel  so  that  the  new  sheet  metal  or aluminum insert will set flush with the original panel. Welding   and   brazing   operations   produce   heat, toxic   fumes,   radiation,   metal   slag,   and   carbon particles.  Welding and brazing goggles with the proper tinted lenses, with gloves, apron or jacket, and welders boots are required. (3) Cut  a  new  sheet  metal  or  aluminum  insert  to fit   within   the   step   area   of   the   panel   being repaired. (4) Attach the insert to the original panel by spot or tack welding it in place. (5) Using a grinder, cut down the welds flush with the exterior surface of the repair area. (6) To complete the repair, use the procedure for Surface filling and finishing. b. Repairing dents. (1) Clean metal to the bare surface. (2) Drill or punch 1/2 inch holes in the dent to assure a good anchor for the filler. (3) To complete the repair, use the procedure for Surface filling and finishing. c. Surface filling and finishing. After repairing the damaged areas, apply filler (Appendix D, Item 17) and finish the surface as follows: (1) Following the manufacturer's instructions, mix enough body filler to re-establish the surface. Mix    filler    on    formica,    teflon    or    other    hard surface.  Do not work on a porous surface such as cardboard. (2) Work the filler (Appendix D, Item 17) into the repaired  surface  making  sure  to  fill  all  voids and remove larger air bubbles. NOTE Allow filler to extend above the original surface to allow for shrinkage. 5-41

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