GKN Wheel & Rim, Safety Manual

Page 1: ...Wheel Rim Safety Manual...

Page 2: ...Components Proper Maintenance of Rim Wheel Components GKN Wheels Overview 2 The Basics Safety Warnings Terminology Equipment 3 Safety Warnings General Guidelines 3 Warning about Removal of Air before...

Page 3: ...add further value to the supply chain and contribute to innovative product ranges Working in partnerships with universities industry wide bodies and customers GKN Wheels ensures its new product introd...

Page 4: ...ch or if you cannot find size markings on the components do not mount and inflate the tire Safe Servicing Operating Procedures Learn and follow safe procedures every time Comply with the proper recomm...

Page 5: ...amp nut READ AND FOLLOW THE SAFETY INSTRUCTIONS FAILURE TO DO SO COULD RESULT IN SERIOUS OR FATAL INJURY For safety s sake always remove the valve core and exhaust all air from a single tire and from...

Page 6: ...onents that will restrain all rim wheel components during an explosive separation of a multi piece rim wheel or during the sudden release of the contained air of a single piece rim wheel Rim Manual A...

Page 7: ...e Height 6 Flange Width 7 Bead Seat Area Multi Piece Rims Three Piece Style Single Piece Rims Reference SAE Standard J751 1 Nominal Rim Width 2 Nominal Rim Diameter Bead Seat Diameter 3 Rim Inside Dia...

Page 8: ...im Diameter 3 Rim Inside Diameter Id 4 Valve Hole 5 Flange Height 6 Flange Width 7 Flange Removable Flange 2 Required 8 Lock Ring 9 O Ring 10 28 Degree Mounting Angle 11 Lock Ring Groove 12 O Ring Gro...

Page 9: ...hen the mounting face is outboard of the rim centerline This is also known as positive inset Back Set The distance between the mounting face and inboard face of the bead seat Negative Offset Negative...

Page 10: ...d Seat Ba nd Driver P ocket Heavy Duty Loose Key Style Multi Piece Rims Rim Driver Locks Lug Style with Notched Gutter Heavy Duty Loose Key Style Demountable Rim Driver Driver Lug Notch in the Bead Se...

Page 11: ...duty driver application 2 1 Align driver pockets in bead seat band and base as shown 2 Insert driving key into driver pocket on base 3 Make certain that all parts are properly aligned as shown above b...

Page 12: ...clip on air chuck with an in line valve and gauge with sufficient length of hose to stand clear from the trajectory A clip on air chuck allows you to keep your hands arms and body clear of the traject...

Page 13: ...e Removal Tools D Wire Brush E Chain or Cable Slings of Adequate Length F Bead Lubricant Non Petroleum Base G Sledge Hammer H Rubber Mallet or Equivalent e g Babbitt Hammer I Inflation Hose with Clip...

Page 14: ...ange when removing tires from 5 125 mm tapered rims 7 Mounting Stand A mounting stand is used when replacing tires on rims that have been removed from a vehicle or machine 8 11 2 ton Capacity Coffin H...

Page 15: ...Servicing 2 Proper Matching of Components before Assembly 3 Ensure All Components are in Good Condition 4 Preparation of Parts before Assembly 5 Safety Precautions during Inflation 6 Safety Precautio...

Page 16: ...not clogged the valve If working on a dual assembly separately perform each step for each tire Never deflate the tire near sparks or open flames Run a wire through the valve stem to ensure tire is com...

Page 17: ...RNING Stay out of the trajectory as indicated by shaded area Always use a safety cage or other restaining device in compliance with OSHA regulations Note Under some circumstances the trajectory may de...

Page 18: ...uld be destroyed and discarded Rim components must not be interchanged except as provided for in the OSHA Multi Piece Rim Matching Chart For information on how to get free copies of this chart see OSH...

Page 19: ...is possible to pass a 16 diameter tire over the lip or flange of a 16 1 or 16 5 size diameter rim it cannot be inflated enough to position itself against the rim flange If an attempt is made to seat...

Page 20: ...gs or in gutter areas The illustrations below show some of these conditions WARNING Use of damaged parts is very dangerous and is prohibited by the OSHA Standard for Servicing Multi Piece and Single P...

Page 21: ...the tire rubber or cause rust buildup or tire to rim slippage For tubeless rims inspect the valve stem to ensure that it is in good condition is not cracked or bent and is capable of handling proper...

Page 22: ...nd back Keep yourself and others away from and out of the trajectory of the inflating assembly Do not lean or put any part of your body in or on the safety cage The movement of the safety cage or air...

Page 23: ...icles or machines with more than 80 of the recommended air pressure can be re inflated on the vehicle without disassembly as long as there is no reason to suspect the tire or rim has been damaged For...

Page 24: ...An incorrectly assembled or damaged multi piece rim could have components that are not firmly locked in place Proper Assembly for Two Piece Rims Correct Incorrect The components in a correctly assembl...

Page 25: ...fully deflated and remount Remember Tire rim assemblies operated in a run flat or seriously underinflated condition 80 or less of recommended pressure can explode if you try to reinflate the tire Def...

Page 26: ...d rim it may be necessary to be within the trajectory If you are in the trajectory you should use extreme care Always deflate completely before starting to loosen the nuts to remove a rim wheel from a...

Page 27: ...ot of the tire or axle WARNING Rims and wheels produced by GKN are designed and tested to meet the requirements of specific tires vehicles and or machines Some high load capacity high inflation tires...

Page 28: ...of spacer band on dual demountable rim assemblies Correct nut tightening sequence Correct torque of the nuts tightening expressed in foot pounds or Newton meters See the section on Recommended Nut Bo...

Page 29: ...ehicle or machine Inspect wheels and rims for damage during tire checks and at periodic maintenance intervals Early detection of potential rim failures may prevent unexpected hazards Remove replace an...

Page 30: ...Bar Ledge Mounting Tires on Earthmover Rims Oversized Tires on the Vehicle Mounting Instuctions Demounting Rims with Pry Bar Pockets Demounting Rims with or without Pry Bar Pockets Handling Tubes Fla...

Page 31: ...ubricant such as a thin solution of neutral vegetable oil soap Silicone or petroleum based lubricants must not be used 2 2 Place tire over rim base Place side flange over rim base and push straight do...

Page 32: ...he side of the tire during inflation using an air hose having a clip on chuck and an in line gauge and control valve Inflate to about 5 psi 35 kPa and again check for proper engagement of all componen...

Page 33: ...he steps below Tools Required 2 Goose necked beads unseating tools rubber lubricant and babbitt hammer 1 1 Drive the goose necked ends of the unseating tools between the tire and flange about 5 127 mm...

Page 34: ...ide flange Turn tire and rim over and unseat second bead by inserting both tools between tire bead and rim flange as in Step 2 Repeat Steps 1 2 until the tire is completely unseated from the rim on th...

Page 35: ...ng ram as shown 2 2 Remove the O ring by depressing the bead seat band and inserting a pry bar or screwdriver under the O ring and pulling it from the groove Cut the O ring with a knife and dispose of...

Page 36: ...l about of the way around the rim then apply pressure until the tire bead is unseated CAUTION Do not use tool in the vicinity of the flange butt weld Remove bead seat band using hoist or pry bars Remo...

Page 37: ...e and lay the assembly gutter side up on ground or floor 2 2 Depress tire and flange Stand inside rim and remove lock ring using two pry bars Start at the split and work the tools around the ring 3 3...

Page 38: ...with one hand This allows control should the tool not seat properly and fly off If necessary release the pressure and readjust the ram adjusting screw 6a 6b 6 While the flange is depressed place a nu...

Page 39: ...around the rim then apply pressure until the tool is completely unseated Avoid using the tool within 12 0 3 m of the flange butt weld 8 8 Lift out the bead seat band using a hoist or pry bars Then re...

Page 40: ...res Standards for Servicing Off Highway Rim Wheels Rim Wheel Components Inspection Guidelines 1 1 Place base on blocks 4 6 100 150 mm high on floor gutter side up Place loose flange on rim base Flange...

Page 41: ...he bead seat band on the rim base Due to limited clearance between bead seat and rim base bead seat band will bind if cocked slightly Be sure driver pockets in bead seat band and base are in line If n...

Page 42: ...circumference Insert drive key as required Place rim and tire in a safety cage or use another restraining device during tire inflation Stand to the side of the tire during inflation Use clip on chuck...

Page 43: ...nspect all rim components especially the lock ring groove and O ring groove areas Coat the rim with paint or a rust inhibitor Also check the tire cavity for water or foreign matter and remove any fore...

Page 44: ...d NOTE Lock rings should be fully seated in lock ring groove around the circumference Insert drive key as required Use a restraining device during tire inflation Stand to the side of the tire during i...

Page 45: ...wire through the stem to make sure it is not plugged Stand to the side of the rim Remove driver key 3 3 Place the hook of the hydraulic demounting tool into one of the pry bar pockets Adjust the ram...

Page 46: ...Depress bead seat band to insert tip of a pry bar under the O ring and pull it from the groove It is good practice to cut the O ring with a knife to ensure that a new O ring is used Use a pry bar unde...

Page 47: ...ut of the way 8 8 To UNSEAT the back tire bead use either the bead unseatting tool as used on the front bead or a shorty ram between the frame of the vehicle and the flange as shown 9 9 Remove the tir...

Page 48: ...outer rim flange by slipping the clamping jaws over the outer edge of the flange 2 2 Securely tighten adjusting screws at bottom of jaws Set hand screw against lock ring and adjust until jaw assembly...

Page 49: ...from flange 6 Move to spot approximately 90 from first application either direction and repeat entire procedure Repeat procedure until tire bead is free Four or five applications usually accomplishes...

Page 50: ...inspect the tire casing carefully inside and out for breaks bruises nails etc Remove all dirt and foreign matter from inside the tire casing 2 Replace the tube in the tire casing starting at the botto...

Page 51: ...ies mounting CAUTION Always completely deflate tire by removing valve core before removing the tire from vehicle or before attempting any other demounting operation Check the valve stem by carefully r...

Page 52: ...xtend wiper arms to draw the tire s bottom bead into the rim s drop center rim well 5 B C A 5 Extend push block to get bottom bead firmly into the rim s drop center rim well Extend wiper arms to compl...

Page 53: ...to raise top bead opposite push block above the rim flange C B A C B A 8a 8b 8 Retract wiper arms to approximately 120 partially retract push block to permit tire to walk across rim Repeat above proce...

Page 54: ...on upper shoulder and work top bead into rim drop center rim well Extend wiper arms to 180 apart To ease the mounting of the top bead extend push block up and down until the bead is firmly placed in t...

Page 55: ...rms from center post bracket 13 Inflate tire to its recommended cold operating pressure This automatically seats the beads 14 Prepare tire and rim assembly for removal When tire and rim are supported...

Page 56: ...ost bracket D D 2 2 Lower tire and rim assembly onto centering blocks Expand blocks to secure rim D A C 3 3 Position push block on bottom shoulder Work the push block upward to break the bottom bead a...

Page 57: ...air pressure when seating beads ALWAYS use a safety cage or other restraining device and a clip on extension hose ONLY specially trained persons should mount tires Tire failure due to misapplication i...

Page 58: ...valve hole and place the tube in the tire starting at the bottom Place the valve in the valve hole and screw the rim nut in place Be sure that the tube is well inside the rim before proceeding to the...

Page 59: ...e with the tire iron in the other hand 7 With the valve stem at the bottom lower the jack until the tire is centered on the rim Centering the tire and rim assembly is extremely important to prevent br...

Page 60: ...nd push the valve through the valve hole 2 2 After the tire is completely deflated place a hydraulic bead unseating tool between the tire bead and rim flange and force the bead off the bead seat Be ca...

Page 61: ...at the bottom If only the tube requires repair or replacement it can be removed repaired and replaced in the tire without removing the tire completely from the wheel Before reinstalling the tube thor...

Page 62: ...rim Attach a valve retrieval tool to the valve and thread the tool through the valve hole Placing a block under the tire may make it easier to insert the tube and attach the tool 4 4 Starting opposite...

Page 63: ...tire is tube type completely deflate it to allow repositioning of the tube by removing the valve core housing For tubeless tires mounting depends on how well the tire s shape has been maintained If th...

Page 64: ...flange being careful not to damage the tire bead area After the bead has been released completely around the tire turn the tire and rim over and repeat the bead unseating procedure with the narrow led...

Page 65: ...inside of the casing for damage or other foreign material Remove any remaining fluid from inside the tire 6 6 To completely remove the tire from the rim turn the assembly over so the narrow ledge is...

Page 66: ...sical injury or even death The rims in question are 15 3 in diameter and 9 wide However rims manufactured in 1981 and earlier are marked as 15 diameter only those manufactured in 1982 and 1983 are mar...

Page 67: ...66 Wheel Rim Safety Manual Rim Wheel Components Inspection guidelines Identification of Damaged Components Proper Maintenance of Rim Wheel Components...

Page 68: ...roper clamp wedge length and or use of improper components Circumferential cracks in middle of rim caused by overload over inflation Cracks in rim gutter caused by overinflation hammer damage improper...

Page 69: ...le caused by damaged and or worn out at chamfers Chamfer enlarged or walled out by nut caused by loose cap nuts or insufficient nut torque due to damaged threads improper torquing and or worn out nut...

Page 70: ...ring mishapen caused by improper installation and or improper removal Split Side Ring Problems Split Ring caused by overload over inflation improper installation and or improper removal Excessive cor...

Page 71: ...st and other materials that could obstruct proper seating of rings 2 2 Rings should be cleaned thoroughly with wire brushes Pay particular attention to the seating surfaces and bead seat areas Proper...

Page 72: ...om the first nut Install the remaining nuts Snug up the nuts to 30 of the recommended torque value Use a criss cross tightening pattern sequence Do not tighten the nuts fully until all of the nuts hav...

Page 73: ...aining nuts making them finger tight as well Snug up the wheel bolts to 30 of the recommended torque value Use a criss cross tightening pattern sequence Following these steps will allow for the unifor...

Page 74: ...73 Wheel Rim Safety Manual GKN OffHighway Wheels Products...

Page 75: ...d Steer Loader Road Roller Telehandler Motor Grader Heavy Construction Wheels Wheel Loader Articulated Dump Truck Mobile Crane Rigid Dump Truck Underground Mining Loader Material Handling Wheels Count...

Page 76: ...ndices OSHA STANDARD 29 CFR Part 1910 177 Servicing Multi Single Piece Rim Wheels Mine Safety Health Administration Regulations EUWA Safety Service Recommendations for Wheels Other Sources of Rim Whee...

Page 77: ...tled Demounting and Mounting Procedures Truck Bus Tires and Multi piece Rim Matching Chart or any other poster which contains at least the same instructions safety precautions and other information co...

Page 78: ...he employer shall assure that no employee services any rim wheel unless the employee has been trained and instructed in correct procedures of servicing the type of wheel being serviced and in the safe...

Page 79: ...ng devices and barriers shall be visually inspected prior to each day s use and after any separation of the rim wheel components or sudden release of contained air Any restraining device or barrier ex...

Page 80: ...oyer shall establish a safe operating procedure for servicing multi piece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at least th...

Page 81: ...emounting 2 Mounting and demounting of the tire shall be done only from the narrow ledge side of the wheel Care shall be taken to avoid damaging the tire beads while mounting tires on wheels Tires sha...

Page 82: ...oken bent or otherwise damaged wheels shall not be reworked welded brazed or otherwise heated Trajectory warning 1910 177 App A brazed or otherwise heated 89 Stay out of the Trajectory as indicated by...

Page 83: ...and Health Administration OSHA Area and Regional Offices The address and telephone number of the nearest OSHA office can be obtained by looking in the local telephone directory under U S Government U...

Page 84: ...cted by the equipment operator before being placed in operation on that shift b Defects on any equipment machine and tools that affect safety shall be corrected in a timely manner to prevent the creat...

Page 85: ...ed position until the equipment has been blocked or mechanically secured to prevent it from rolling or falling accidentally b Persons shall not work on top of under or work from a raised component of...

Page 86: ...motion where a hazard exists unless equipped with extended fittings or cups 30 C F R 77 405 Performing work from a raised position safeguards a Men shall not work on or from a piece of mobile equipmen...

Page 87: ...ed by qualified experts of the EUWA members we intend to prevent possible problems in service to an improper use unsafe mounting demounting or other dangerous operations 1 Safety is important The whee...

Page 88: ...igin of the components must be the same Mismatched or wrong rings mounted on a multi piece rim can cause serious mounting or service accidents or at the least the wheel failure without any prior warni...

Page 89: ...rt must be replaced The replacement has to be carried out with new pieces having completely identical characteristics In the event that the correct removable rings are not available a new complete rim...

Page 90: ...l bead seat side of the rim push the lower bead over the rim flange and then progressively into the rim well Using the first lever to keep in place the upper tire bead work by short steps with the sec...

Page 91: ...disc wheels have to be fastened in accordance with the vehicle manufacturer s instructions either using a torque spanner or by means of a tool designed to reach the torque value specified by the vehic...

Page 92: ...ion instructions recommendations and any other additional information 2 7 Maintenance of wire spoke wheel Particular attention must be devoted to the wheels with wire spoke for passenger cars and moto...

Page 93: ...sently the mounting demounting operations of the tire are no longer carried out manually but on special machines In any event carefully clean and check all matching surfaces Inspect with attention the...

Page 94: ...one to be avoided when handling multi piece rim wheels Examples of nut tightening sequence related to commercial vehicle disc wheels having 6 8 10 bolt fixing and to the TRILEX wheel system 6 bolt fix...

Page 95: ...t press the adjacent bead over the rim flange into the rim well Then press progressively the whole bead over the flange In event of difficulties use a suitable bent lever Mounting second tire bead Pre...

Page 96: ...m on each side of the valve Keeping in position one lever use the other in small steps in order to ease the bead completely over the rim flange Demounting the second bead Turn the assembly over the fl...

Page 97: ...ed Seen from above valve rests against left side of valve slot Rim base to rest all along against tyre bead Retreated tires having generally a large bead width may have to be compressed until play bet...

Page 98: ...nd Rim Safety Awareness Program MSHA IG 60 revised 1996 is available on line in PDF format on MSHA s web site www msha gov at www msha gov S HINFO IG60 PDF The MSHA s Accident Prevention Program Safet...