RE-CERTIFICATION PROGRAMInspection Guidelines for Wheels and Rims

Field Inspection Handbook

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FOr mOre PrOdUC T & ser VICe InFO VIs IT WWW.RIMEX.

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I ntroduc tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Nomenclature of a R im . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4sTeP 1: Understanding the sections of the base parts . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lock R ing Prof i le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

RIMEX Field I nspec tion K it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Site Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7sTeP 2: Conduct an assessment of the product and site . . . . . . . . . . . . . . . . . . . . . . . . 7

sTeP 3: location description of defect/identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

sTeP 4: Critical areas for visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gutter section–Check the wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gutter section–lip–indication/fractures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Gutter section–galling on the mounting taper . . . . . . . . . . . . . . . . . . . . . . . . . . .11

back section–tire bead wear to the taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

back section lip–compression/cracks/galling . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Tsr back–galling/out of round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

disc section (T-section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Valve/deFuzer Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Parts: side ring/bead band/lock ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

side ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

bead seat band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

lock ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

RIMEX Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Ta b l e O F CO n T e n T s

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I n T r O d U C T I O n

with over 35 years of experience as a world leader in design and manufacturing of earthmoving wheels and rims, rimex realizes the necessity of proper field assessment and evaluation of wheels, rims and components. safety is the top concern and this information will give the qualified tire service technician the ability to do qualified field evaluations.

Once in service, earthmoving wheels and rims must be maintained and inspected for maximum safety and service life. If the qualified tire service technician can do a simple wire brush cleaning of the base sections and parts, a basic evaluation can be achieved.

The implementation of the australian standards as 4457-2007.1 earthmoving wheels rims and components have been given a set of guidelines for inspection and repair that will assist the qualified tire service technician in reviewing wheels, rims and components presently in service.

This initial inspection allows for informed decision to either scrap a product at the mine site or to send it into rimex’s repair facility for further ndT inspection and repair. This advanced knowledge results in savings of time, money and unnecessary freight costs for all stake holders.

n O m e n C l aT U r e O F a w H e e l r I m a s s e m b ly

STEP 1: Understanding the sec tions of the base par tsa basic 5 piece rim/wheel assembly consists of a rim/wheel base, two side rings, a bead band and a lock ring. In rimex’s simple terminology, a rim mounts to the truck by the 28° gutter section taper and independent clamps (e.g. 830e), while a wheel uses a welded in disc (e.g. Cat 789)

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r I m e x F I e l d I n s P e C T I O n k I T

sIde rInG wear GaUGe(part # 782-000-0026)

sIde rInG wear GaUGe (part # 782-000-0027)

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¾ - 14 nPT TaP

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½ - 1/4 nPT / ¾” - 14 nPT

rImex InsPeCTIOn rePOrT—refer page 20 for example

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r I m e x F I e l d I n s P e C T I O n k I T

STEP 2: Conduc t an assessment of the pro duc t and site

For a wheel/rim base, cleaning of the three critical areas (gutter, back and disc section) are required to make a basic assessment. The application of a wire brush to remove dirt, material and light grease to these sections is essential in obtaining a minimal assessment. even if paint is still present, this will be sufficient enough to conduct a basic field examination.

Concerning parts, again a wire brush must be applied to all metal to metal contact points between the base and the parts. a basic visual inspection and use of a wear gauge can then be applied for examination of critical areas.

The following is Rimex’s Best Practise and is critical for both the end user and Tire service Provider to understand;

“If the wheel/rim base requires more than one section to be replaced and has had five years or more continual service life, then the wheel/rim should be retired.”

The cost of the repairs usually out weights that of purchasing a new product.

Recommended I nsp ec tion I nter vals

Haul Trucks

RIMEX MES RIMEX TSR

rims (eg: 830e) 15,000 hrs rims (eg: 830e) 20,000 hrs

wheels (eg: 793F) 15,000 hrs wheels (eg: 793F) 30,000 hrs

5,000 hour intervals there after 5,000 hour intervals there after

Wheel Loaders

RIMEX MES RIMEX TSR

wheels, Front: 10,000 hrs wheels, Front: 15,000 hrs

wheels, rear: 15,000 hrs wheels, rear: 30,000 hrs

5,000 hour intervals there after 5,000 hour intervals there after

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STEP 3: Lo c ation description of defec t/ identif ic ation rImex uses an Id Tag (below) to identify all of our earthmoving wheel/rim bases. This tag is stamped with a wide variety of information that helps us guarantee the integrity and traceability of our products. Typically other manufacturers stamp their identification on the gutter section or back section. Technicians are required to locate the date and manufacturing stamps in order to properly Id the product.

when reviewing a rim or wheel, the locality of the area of defect needs to be understood. In order to describe what section is damaged and how to document its specific location the rim needs to be viewed like a clock with noon position (12 o’clock) being the ½” valve hole.

start by positioning the rim on its side (center band). standing in front of the rim, the gutter section must be in the most forward position, making it the first part to be viewed. Finally, the rim must be turned and stopped where the valve holes are at its highest circumference. From this position, the rim is now viewed as a clock, with the valve holes at twelve o’clock. Each area of the rim can be described by its section and with a designation between one and twelve o’clock. This is done to describe both the outside (Od) and the inside (Id) of a rim.

E x a m p l e : G u t t e r F a c e — M e c h a n i c a l d a m a g e a t 6 : 0 0

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size

serial number

part number

month and year of manufacture

RIMEX Best Practices

each wheel/rim to have a unique brand number for tracking

service life

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STEP 4: Crit ic al areas for visual insp ec tion

G utter S ec tion– check the wear

( R i m ) G u t t e r — H D T

The gutter section both locks the tire into place and seals the tire wheel assembly. The gutter section has the highest degree of failure.

It is the first place to review for wear, indication of fractures (fretting) and mechanical damage.

The area between the lock ring groove and the o-ring groove should have minimal wear. review the diagram above and pictures on the following page using the wear gauge. If the wear exceeds 1.5 - 2mm, the gutter section is not fit for service and should be replaced.

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10G utter S ec tion–lip —indic ation/frac turessecond point of review in the gutter section is the lip. Chips and or fractures in the lip will develop over time. Chipping of the lip is fairly obvious to spot. refer pictures below.

On a fairly clean surface, indications/fractures can also be clearly observed. In the photo below, the wheel was returned to replace the back section. Visible fractures of the gutter lip were observed. a magnetic Particle Inspection was done to clearly photograph the fractures, to verify for the customer, the wheel was scrap.

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G utter S ec tion– gall ing on the mounting tap er The mounting taper of the gutter is where the rim is secured to the hub. If improper torquing takes place, the rim will spin and damage to the id of the gutter will occur. severe galling of the taper and with the removal of the valve protector is the usual scenario. If the damage exceeds 1mm wear to the taper surface, the gutter section requires replacement.

all in all, if the gutter has these types of wear and or fractures, a replacement of the section will be required.

B ack S ec tion–tire b ead wear to the tap erThe back taper is the area where the tire bead contacts the rim. If the tire bead slips on the rim, a 360 wear mark will develop on this section of the back. The tire bead with time will erode the metal and a cause a change in the contact surface. This will eventually decrease the performance of the tire and rim. If a 360° groove around the back taper has been observed, the maximum allowance of the change to the surface of the back taper is 2 mm. any measurement taken beyond the 2 mm, at any point within the erosion area, should result in a failed back section.

B a c k S e c t i o n – M E S

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B ack S ec tion Lip – compression/cracks/gall ingThe mes/standard design has the flange and back lip securing at approximately a ninety degree angle. This design applies a significant amount of force to the lip and flange. Overtime, the back lip will compress and fold downward. In addition, under inflation or material within the back lip and flange can create extreme galling (metal to metal wear). This wear will affect the performance of the rim to secure the tire. when visually inspecting the rim, one needs to assess the amount of wear and compression to the back lip. It is critical to understand that cracks unseen to visual inspection, may be present. If the compression or galling within the lip itself is greater than 2 mm, the back section should be replaced

Pictured below, is an example of a failed back lip section from cracking, only visible by mPI inspection.

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TSR B ack– gall ing/out of roundwith its design and increased material over the mes, the Tsr provides a superior rim system. Overall, the tire is better secured within the rim and the stresses placed on the parts are evenly spread out. as a result, the wear presented is minimized over many years of service. a properly maintained Tsr back may show no signs of wear after many years of service life.

when visually inspecting a Tsr back, the taper wear needs to be examined. If galling or mechanical damaged to the taper exceeds 2mm, the section is subject to failure. If the wear to the taper is 360 around, with 1.5 mm or greater depth, the section has failed and needs to be replaced. In addition, the flange should never touch the lip of a Tsr back. Therefore, any mechanical wear close to the lip need to be carefully examined. Finally, after 5 or more years of service (57”/63”), the roundness of the back section may be in question. The inspector should take a cross measurement of the back section id. If the measurements show a difference of +/- .075mm, the back section should be replaced.

B a c k S e c t i o n – T S R

D isc S ec tion ( T-S ec tion)Failure to properly torque the disc to the hub is the most common reason for disc repair. Tools should be calibrated every six months to insure proper torque. damage can result in the irregular shaping of the Od of the stud holes. most of the time, only certain sections of the disc will be affected. In more severe cases, threads from the studs may be embedded into the stud holes. replacement of the disc section/T-section is required.

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Valve/DeFuzer HoleThe standard nPT hole sizes are a ½“ for the air valve system and a ¾” for the deFuzer valve. This critical area must be properly maintained. To conduct a proper inspection, all valve hardware should be removed. after a thorough cleaning with a wire brush attached to a drill, a nPT gauge is used to assess the valves. If the valve holes fail the gauge test, the correct size tap is used to re-thread the valve hole by hand. now is the time to assess the deFuzer. If the cap is still on and the valve is in good shape, clean out any material blockages. If the deFuzer is older than three years, product should be replaced.

PA R T S : Side R ing/B ead B and/Lo ck R ingComponents parts should be visually inspection and contact areas cleaned during each tire change. Periodically, bead band and side rings, which have passed visual inspection, should be returned to the manufacture for a complete inspection. we consider the lock ring to be a consumable item and should be replaced after 5,000 hours. Please note that parts can take excessive amount of time and energy to conduct magnetic particle inspections. The ability to conduct a proper visual inspection with a side ring Od gauge and caliper can reveal failure points early in the process.

Side R ing (f lange) S i d e R i n g — M E S

S i d e R i n g — T S R

C l e a n i n g o f t h e ¾ N P T v a l v eN P T g a u g e t e s t — p a s s

R e - t a p v a l v e h o l e b y h a n d i f g a u g e e x a m i n a t i o n f a i l s .

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each rim/wheel assembly consists of two side rings. The purpose of the side ring is to hold the tire bead in place. Once inflation occurs, the side wall of the tire will force outward against the side rings, thus sealing and securing the tire.

when inspecting an mes side ring (diagram ), the most important areas to evaluate is the level of wear from the metal to metal contact between the side ring and the bead band/back lip. Once the depth of the material in the inner lip has eroded to a level of 2 mm, the side ring must be removed from service. On the mes design, this inner lip will be the critical area to inspect; a digital caliper can be used to measure the change in wear.

with the Tsr design (diagram ), metal to metal wear is spread across the tapers and thus will not show in the same presentation as the mes. First, the inspector needs to examine for any mechanical wear or galling present into the taper. any damage to the taper which exceeds 2 mm needs to be replaced. In addition to the visual inspection, a cross measurement will need to be taken of the inner lip from the outer diameter side of the taper. an allowance of only +/- .075 mm is allowed before the side ring must be replaced.

next is the level of wear to the outer diameter of the side ring where contact is made with the tire. The outer diameter of the side ring contacts the tire and holds its bead while inflated. with use, the tire will wear a 360 mark along the outer diameter of the side ring (pictures and ). with time, the metal will erode and loose its ability to secure the tire. The maximum allotment for erosion to the outer diameter of the side ring is 2 mm.

Furthermore, any mechanical damage to a side ring which places the integrity or roundness in questions should be replaced.

Side R ing (recommended for 49” to 63”)

If the side ring passed the visual inspection, no cracks are found, and the service hours are within rImex’s recommended service life, the side ring should be painted and returned to service.

4 - 5 m m , F a i l e d — D i s t o r t e d F l a n g e

2 - 3 m m We a r, F a i l e d — N o r m a l We a r

M i n i m a l O D We a r — P a s s I n s p e c t i o n

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B ead S eat B and

For the basic rim design, the tire bead sits on the outer diameter of the bead band and the back section taper. basically, the bead band acts as a removable back section. when inflated the tire will force the side ring into the lip of the bead band and secure it against the lock ring. For visual inspection, the three areas which are critical for review are: the bead band taper, where the tire bead rests; the bead band lip, where the flange makes contact with the bead band; the location of the o-ring. any excessive wear (2 mm), cracks, mechanical damage or corrosion to the bead seat band would result in a failure. any cracking found would result in an immediate failure. a bead band which has passed inspection can be painted and returned to service.

B e a d B a n d — M E S

B e a d B a n d — T S R

RIMEX Best Practices

If in doubt, remove the component from service. send

the component to rImex for an in depth analysis, as

required, or scrap on site.

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O u t o f R o u n d

E x c e s s T i r e B e a d We a r

E x c e s s i v e C o r r o s i o n

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Lo ck R ing

L o c k R i n g H D T

The lock ring is the final part added to secure the rim/wheel assembly, holding the assembly together. To secure all the components and minimize the friction between parts of the tire assembly, the lock ring must be elastic to expand then contract into place within the lock ring groove of the gutter section. a new lock ring in will have an overlap of three to four inches (57” & 63”) (picture )between its tips before mounting. with time, the lock ring will lose its ability to hold its original form. when inspecting a lock ring, the distance between the ends of it and the overall condition of the taper area must be reviewed. when the lock ring is not installed, the ends of the tips should overlap (picture ). Once a lock ring loses its ability to bounce back to its origin form, distance between the tips will widen and the lock ring will no longer be usable (picture ).

C o r r e c t l o c k r i n g o v e r l a p S p r u n g H D T l o c k r i n g

M e c h a n i c a l D a m C r a c k e d l o c k r i n g

RIMEX Best Practices

lock rings are a wear component. some styles of lock rings, such as eV and em, should

be considered throw away after a couple of uses. They are subject to circumferential cracking in some

extreme applications.

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r I m e x r e Pa I r P r O C e d U r e s

STEP 5: Fai led pro duc t to b e either scrapp ed on site or returned to RIMEX for insp ec tion and repair

RIMEX Best Practices

If any component is in doubt, remove from service

and send to rImex for further ndT inspection including

a magnetic Particle Inspection, if required.

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CO n C lU s I O n

The purpose of the following Inspection report is to ensure the mine site and on site inspectors have a better understanding of the field visual and the wear requirements concerning the evaluation of ndT rim/wheel assemblies. safety is the primary concern and this information should make the evaluation process easier.

Rimex Supply Ltd.9726 - 186th StreetSurrey, British ColumbiaCANADA V4N 3N7Phone: (604) 888-0025Fax: (604) 888-0020

1. MPI areas include: All welds / Valve hole / Lock ring and O’ring groove / Back lip / Mounting disc weld & disc surface.2. All wheels/rims s/blasted to Class 2.5 and viewed with the Gutterband facing the inspector with the Valve hole at the 12 o’clock position.

RIMEX INSPECTION REPORTVisual, Magnetic Particle & Circumferential Roundness inspection

(Conforms to AS 4457.1-2006)

Rim / Wheel Size Serial No.Contact Tire Size HoursClient PO No. Manufacturer Inspector TimRRD No. Manufacture date DateModel No. Machine Signature Tim Beardall

SECTION AREA VISL MPI G CRITERIAArea Should Have NONE of the Following

GUTTER

Face X Cracked Or Mech. DamageLock Ring Groove X X X CRACKED, 1.5mm WEAR, MECH. DAMAGE

O Ring Groove X X X CRACKED, 1.5mm WEAR, MECH. DAMAGEMounting Taper X X Taper Damage, Cracked

GutterCircumferential Weld X X Cracked, Corrosion

Valve Protector X X Cracked, Bended Or Removed

CENTER BAND

Surface X Cracked, Excessive CorrosionCenter Band

Circumferential Weld1 X X Cracked, Corrosion

Center Band Circumferential Weld2 X X Cracked, Corrosion

Valve Hole / Defuzer Hole X X Broken Brass, Bad Threads, Cracked

DISCId Welds X X Cracked

Stud Holes X X Cracked, Oval Stud Holes

BACK

Back Circumferential Weld X X Cracked, Corrosion

Back Taper X 1.5mm OF MATERIAL WEAR PRESENTBack Lip X X Cracked, Compression

Face X Cracked, Mech. Damage

PARTSSide Ring X 49-63 X CRACKED, WEAR 2mm, OORBead Band X 49-63 X CRACKED, WEAR 2mm, OORLock Ring X Mechanical Damage, Cracked,

Ends Do Not Touch

ROUNDM if in question OR 6yrs old

Gutter X X Tolerances +/-.075mmDisc X X Tolerances +/-.075mmBack X X Tolerances +/-.075mm

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n OT e s

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n OT e s

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Canadian BranchesRIMEX Supply (Alberta) Ltd15 Capital Circlesaskatoon, sk s7r 0H4

RIMEX Supply (Alberta) Ltdlot 209, 26229 Township rd 531aParkland County, ab T7x 5a4

RIMEX Supply (Alberta) Ltd12-7408 40 street seCalgary, ab T2C 2l6

Austral ian BranchesRIMEX Wheel Pty Ltd27 Crichtons, PO box 5059Paget, mackay, Qld 4740

RIMEX Wheel Pty Ltdlot 651 strathmore roadmuswellbrook, nsw 2333

RIMEX Wheel Pty Ltdshed b, 283 Treasure roadwelshpool, wa 6986

RIMEX Wheel Pty Ltd9 Oborn streetwhyalla, sa 5608

USA BranchesRIMEX Inc5801 w. Van buren streetPhoenix, aZ 85043

RIMEX Inc15503 lee Highwaybristol, Va 24201

RIMEX Inc5608 s. winland driveGillete, wy 82718

I nternational BranchesChileRIMEX Ltdno 21, Office 601nunoa, santiago

Brazi lRIMEX Supply Ltd. do Brasilrua morganita 23, Venda nova, Candelaria, belo Horizonte, mG 31510-180

S outh Afric aSA Heavy EquipmentPO box 14319leraatsfontien, witbank 1038

I ndonesiaPT RIMEX InternationalJI mulawarman mo 128 rT 23kelurahan sepinggan, balikpapaneast kalimantan 76115

Head O fficeRIMEX Supply Ltd9726 - 186 street

surrey, bC V4n 3n7

604.888.0025fax: 604.888.7642www.rimex.com