This document discusses wheel safety, maintenance, and inspection. It outlines objectives to reduce wheel failures, injuries, equipment costs, and tire wear. Wheel failures have increased due to lack of standards, training, and larger equipment. Proper inspection and tracking of wheels is important to identify issues and ensure safety. A wheel recertification program includes gauging, magnetic testing, and refinishing to prolong wheel life, increase safety, and reduce downtime and costs. The program has been validated by a university study to effectively identify fatigue and safety issues.

1. Wheel Safety,
Maintenance and Inspection
Keeping our Customers rolling Safely…….

2. Objective
Reduce:
 Wheel failures in service;
 Injuries and fatalities of service personnel;
 Operating cost of equipment;
 Tire wear.

3. Background On Wheel Failures
Over the years, heavy equipment has been
scrapped or sold as surplus:
 Wheels from the 60’s and 70’s remained in inventory as
they were considered “useable”
 Failures began appearing in the 90’s
Failures can also be attributed to:
 Lack of standards in the wheel industry
 Absence of training and awareness
 Wheels deemed to be “maintenance free”
 Bucket and engine(HP) size increase

4. Equipment Evolution

5. Equipment Evolution
2017 Cat 966M
315 HP
9.68 CYB

6. Equipment Evolution

7. Equipment Evolution
2017 Cat 980M
417 HP
16.0 CYB

8. Reducing Failures
 Train maintenance personnel what to look for when
inspecting wheels;
 Visually inspect all wheels before returning them to service;
 Identify all wheels and rims by manufacturer;
 Track all wheels;
 Begin Nondestructive Evaluation (NDE) testing and
maintenance program;

9. Why Track and Maintain Wheels?
26.5 x 25 Tire at 90 psi has
373,650 ft/lbs of Stored Energy

10. Why Track and Maintain Wheels?
If a 3200 pound car is traveling at 90 km/h
and hits a brick wall; it would produce over
300,000 lbs. of force
It only takes 9 lbs. of force to fracture a
human bone
It only takes 300 lbs. of force to fracture a
human skull

11. Tire Size 2700 x 49
 One person killed;
 The tire was not deflated before removing.

12.  Lock ring was not seated properly and it let go;
 Tire pressure was 50 psi and it resulted in a ripped out axle.
Tire Size 17.50 x 25

13. Inflating Tires

14. Tire Size 10.00 x 15
 The tire flew 50 feet from the machine;
 In the world of wheels… There is no such thing as a
SMALL ACCIDENT!

15. Welding/Torching on Wheels

16. Deceased Rim
tire
6.1m
Welding/Torching on Wheels

18. Maintenance Responsibilities
Visually inspect wheels and components once
properly trained
Wheels without serial numbers should be sent for
inspection and entered in to a tracking database
Verify in database if a serialized wheel requires an
annual inspection
Preliminary Inspection:
 Visual inspection of all dismounted bases prior to
the annual Nondestructive Evaluation (NDE).

19. Visual Rim Inspection Criteria
 Gutter section
 Back section
 Mounting surfaces
 Stud holes
 Bolting plate weld
 Rim base welds
 General condition
 Components (lock
ring, flange and bead
seat)

20. Back Section Wear Gauge

21. Lock Ring Groove Problems
 Washed out lock ring
grooves
 Stress fatigue
fractures
 Causes:
 Friction welding
(Fretting, Galling)
 Aggregate
 Corrosion
Non Pressure
Zone –
Extreme Danger
Pressure
Zone
These are CRITICAL reasons for doing a
Safety inspection of the rim!

22. Gutter Inspection

23. Worn Lock Ring Groove
Lock Ring Groove
Inconsistency

24. Tire Size 21.00 x 25
 Cause: Crack in lock ring groove above pressure zone
 Result: One person killed and another seriously injured

25. Wheel Hardware
Hardware includes:
 bead seat bands
 rim flanges
 lock rings
Inspect hardware using gauges before
reusing
Discard defective or distorted hardware

26. A worn flange and other hardware can impact tire and
wheel performance
Flange / Side Ring
Worn Side Ring Good Side Ring

27. Impact damage
Fretting
Improper fitment
Improper Fitment

28. Lock Rings
Sprung / Stretched Good
Inspect for:
1. Wear 2. Corrosion 3. Flat Spots
4. Ovality 5. Warping Misalignment (Sprung)

29. Improper Fitment
Right Wrong

30.  Elongated or worn stud holes cause improper torque leading to
wheel loss which results in accidents
 Inexpensively repaired by re-facing or replacing the center plate
Stud Holes
Elongated

31.  Visually inspect rims and components
 Track wheels in database by serial number
 Train Maintenance shop personnel
 Issue an Inspection Report for each rim
 Recertify wheels
 Repair or replace rims and components
as required
Responsibilities OTR Wheel

32. Wheel I.D. Location

33. Rim Tracking
All inspected wheels are stamped, recorded
and tracked

34. Rim Tracking
The software tracks:
 Number of wheel assemblies
 Repairs performed
 Locations

35. Rim Tracking
Each wheel has a specific tracking number
A report with repair details and costs can be provided

36. OTR Wheel Recertification
Program
 OTR Wheel Recertification Program:
 While working with one of the largest mines in
North America, OTR Wheel has developed a
unique recertification program as dictated in our
“Incoming Wheel Inspection Criteria” (Proc.9.9)
 It is recommended by the Ministry Of Labour
 It is unique to OTR Wheel

37. OTR Wheel Recertification Program
A recent study commissioned by WSIB and
Work Place Safety North(formally MASHA)
conducted by the University of Windsor
concluded :
“results suggest the dimensions determined by the North
Shore(OTR) Wheel GO/NO-GO gauges are effectively designed
to identify wheels which exhibit a reduced fatigue life condition
and should be considered for maintenance. The use of the gauges
or similar methodologies to facilitate the inspection of rim
components is highly recommended to ensure the safety of the rim
components”

38. Recertification Criteria
Recertify on an annual basis
Hours of operation
Prior to major repairs
Visual damage

39. Stage 1: Preliminary Inspection
 Incoming Wheels for Recertification

40. Stage 2: Shot Blast
Remove Paint and Rust

41. Stage 3: Gauge Testing
Gauge Testing of Wheel

42. Stage 4: Magnetic Particle
Inspection
Test for Fatigue and Cracks

43. Stage 5: Refinishing
Painted to Customer Specifications

44. Stage 6: Ready to Ship

45. Summary
Wheel Recertification process can:
 Reduce Down Time
 Increase Safety
 Prolong Wheel Life
 Reduce Tire Wear
Wheel Recertification program:
 Has been validated by an Independent University study
 Is based on in-depth knowledge and vast experience
 Eliminates guess work while determining defects
 Is cost effective

46. Keeping our Customers Rolling Safely…….
Thank You
Your Partners in Wheel Safety, Sales
and Service