Kalmar Ottawa t2, Maintenance Manual

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9.12 Chassis – 9 Frame, Body, Cab and Accessories 123
Maintenance Manual Ottawa T2 4x2
Repair (Frame Damage Analysis)
This section is not intended to cover the causes of all possible
frame problems; however, it should be of valuable assistance
in preparing complete, concise reports. The purpose of this in-
formation is to emphasize the fact that frame damage doesn’t
just happen, there is always a cause or reason. An example of
this would be a vehicle involved in a collision. The reason for
damage in this case is apparent; however, other damages can
be encountered where the reasons are not so apparent.
Three types of frame damage can be classified as follows:
1. Collision
2. Excessive bending moment
3. Localized stress concentration
Damage caused by collision should be repaired using proper
methods and reinforcement. Excessive bending moment dam-
age is caused by overloading, improper weight distribution or
misapplication of the vehicle. Excessive bending moment dam-
age will occur at different areas on various types of vehicles.
The effects of excessive bending moment will vary by type of
vehicle.
page –
Repair (Making Reinforcements, General
Information)
In general, when making reinforcements of any type, observe
the following practices.
1. Contact the Kalmar Engineering Department for design ap-
proval.
2. Taper reinforcement plates to avoid abrupt changes in sec-
tion modulus. Angles at the edge of a reinforcement plate
should be less than 45 degrees.
3. When reinforcement plates are shaped by use of a cutting
torch, all cracks, nicks and burrs must be removed from the
edges by grinding. Burrs must also be removed from the
edges of holes.
C A U T I O N
When welding on a Kalmar truck:
1. Always disconnect the wiring at the battery termi-
nals and ECUs.
2. The ground for the welder should always be at-
tached as close as possible to the work area.
3. Failure to adhere to these cautions can result in
permanent damage to the electrical system.