CELITE TYRE MANAGEMENT

Standard Operating
Procedure for
Management of OTR
tyres

Standard operating and safety procedure to be followed by Supervisors and technicians in

carrying out the various Tyre Management Functions.
 General Safety Instructions
.
.
DEMOUNTING
PRECAUTION
Before removing any rim or wheel component
(i.e., nuts or rim clamps):
• Exhaust all air from a single tire.
• Exhaust all air from both tires of a
dual assembly.
Remove valve core completely. This will
assure all air is exhausted from tire.
• Remove both cores from dual assembly.
• Run a piece of wire through stem
to be sure it’s not plugged
Always stand clear during deflation.
Use approved eye protection.
Use mechanical aids when removing
heavy rim components.
Demounting tools apply high pressure to
rim flanges when unseating tire beads.
INSPECTION
Clean rims with wire brush. Repaint at regular
intervals. This will stop
corrosion. It will also make it easier to
mount and check components
Clean dirt and rust from lock ring and
gutter.
Remove moisture from the air inflation
equipment as far as possible.
Check rim components for cracks
Replace all components which are:
• Cracked
• Badly worn
• Damaged
• Severely rusted
Never, under any circumstances, attempt
to rework, weld, heat, or braze
any rim components that are cracked,
broken or damaged.
Replace with parts that are not cracked,
broken or damaged. Always use parts of
the same size and type.
Don’t reinflate a tire that has been run
REASON FOR PRECAUTION
A broken rim part under pressure can blow
apart and cause fatal injury. If you remove
lugs while tire is under pressure, the
assembly
may fly apart
Foreign material may clog the valve stem
during deflation
If the assembly bursts, the operator should
be far away from the explosive force.
Use approved eye protection. Protect eyes
from dust and dirt when exhausting
air from tires.
This will help protect you from injury.
A dropped flange can crush a hand or foot.
If tool slips, it can fly with enough force to
cause severe injury or death. Keep fingers
clear. Always stand to one side when you
apply pressure
Parts must be clean for proper fit. This is
especially true of the gutter section which
holds lock ring in position.
This is important to seat the lock ring
properly.
Drain the compressor tank daily. Online filters
in teh air line can remove the moisture.
Parts that are cracked, damaged or
excessively
rusted are weakened. Bent or
repaired parts may not engage properly.
Heating may weaken a part. It may then be
unable to withstand forces of inflation or
operation. This can lead to an incident
resulting
in serious injury or death.
Components can be damaged or dislocated
flat until you inspect:
• Tire
• Tube
• Flap
• Rim and wheel assembly
Stand clear of the tire while inflating.
MOUNTING AND INFLATION
Don’t hammer bead seat rings or other
components while tire is inflated. You
may tap the lock ring when inflation begins
with a rubber or shot hammer to insure
it is properly seated
Double check to be sure all components
are properly seated before inflating.
Inflate in a safety cage. Use safety chains
or equivalent restraining devices during
inflation.
Don’t inflate tire before all components
are properly in place.
Place in safety cage or use chain sling
and inflate to approximately 5 PSI (.5
Bar). Recheck components for proper
assembly.
If assembly is not proper at approximately
5 PSI (.5Bar) completely deflate
tire (both tube-type and tubeless) and
start over.
Inflation to recommended operating
pressure should be done on the vehicle.
Never hammer on a fully or partially inflated
tire/rim assembly.
Never sit or stand in front of a tire and
rim assembly that is being inflated.
Use a clip-on chuck. Use inflation hose
long enough to stand to side of tire.
Do not stand in front or back of tire
assembly.
Stand clear when using a steel cable or
chain sling.
Never weld on a tire/rim assembly.
OPERATION
Don’t overload or overinflate tire/rim
assemblies.
Never run a vehicle on one tire of a dual
assembly.
Never use a tube in a tubeless tire where
the rim assembly is suspected of leaking.
when a tire is run flat or seriously
underinflated.
This can lead to an incident resulting
in death or serious injury.
If parts are improperly installed they may
fly apart with explosive force.
If parts are improperly installed they may
fly apart with explosive force.
Parts can fly apart with explosive force during
Inflation
Properly matched and assembled
components
will seat without tapping. If a part is
tapped, it or the tool can fly out with explosive
force.
Parts can fly apart with explosive force.
The cable or chain may break. If it does it
can lash out and cause serious injury.
Heat from welding will cause a sudden rise
in pressure. This may result in a powerful
explosion.
Deflated tires also can catch fire inside the
chamber. Pressure will build up. An explosion
may occur
Excessive overload due to undersized rims
can cause damage to the tire and rim
assembly.
This will exceed the carrying capacity of
the single tire and rim. Operating a vehicle
in this manner can result in damage to
rim and tire.
Loss of air pressure warns you of a potential
rim failure due to fatigue cracks or other
fractures. This indicator is lost when tubes

Always inspect rims and wheels for damage
during tire checks.
Never modify a rim without approval
from the manufacturer.
Never heat, weld or braze a rim.
Always remove the tire from the rim before
service.
Don’t let the brakes become overheated.
Avoid abuses that can overheat brakes.
These include:
• Dragging of brakes
• Speeding
• Poor brake adjustment
• Overloading
SERVICING TIRE AND RIM ON MACHINE
Block tire and wheel on opposite side of
machine before placing jack in position
Put hardwood blocks under jack.
Use blocks regardless of how hard or
firm ground appears to be.
Always crib up a vehicle with blocks or
a jack stand
Do not, under any circumstances, use
any type of heat source on an inflated
tire.
are used with leaking rims. Continued use
may cause the rim to burst with explosive
force.
Early detection of rim damage or wear may
prevent an accident.
Modification or heating of the rim or one
of its parts can weaken it. It may not
withstand
inflation or operation forces.
An explosion can occur when a tire is
exposed
to extreme temperatures from external
sources. This can cause death, serious
personal injury or property damage.
Machine may shift and slip off jack. This
can cause death or serious injury.
Machine may shift and slip off jack. This
can cause death or serious injury.
Welding or other heating of an inflated
tire/rim assembly can cause an explosion.
This can cause death, serious injury or
property damage.
Welding or brazing a rim with a deflated tire
can cause damage to the tire. When
reinflated,
the damaged tire could also explode.
Welding or brazing a rim with no tire is
contrary to recommendations of rim
manufacturers.
It can cause a structural weakness
in the rim. This can also lead to failure
under inflation or service conditions
 LIST OF PPES TO BE USED
Item Usage
Used for protection of the head.Should be
used at all times while working indoors or
outdoors.

Hard Hat
For usage at all times while working
indoors or outdoors.

Safety Shoes
For usage at all times.

Flourescent Jacket
For usage while working in high noise
environment.

Ear Protection
For usage while releasing air from the tyre
or while working at buffing tyre for repair.

Eye Protection
For usage while handling tools for tyre
dismantling or repair jobs.

Gloves
Name of Procedure: Procedure for Tyre Visual Inspection

 Remove any trapped stones in the tread region

 Check all tyres have valve caps
 Check all lug nuts
 Check for cracked wheels and rim damage
 All duals to have rock ejectors
 NSD (non skid depth mm) to be checked and recorded at least once in 30 days
Name of Procedure: Inflation pressure checking

Recommended inflation pressures are always based on a cold reading.

A cold tire is one:
1) That has been idle at least 24 hours.
2) Has reached ambient temperatures.

Recommended Cold Inflation pressure for 24.00-35/24.00R35 tyres – 95 psi

Pressure Gauge to be used:

ND 6297 Large Bore Pressure Gauge (Make: Schrader)

Note : depending on operating condition, wear pattern, loading etc it may be necessary to
reduce or increase the pressure suitably

1) Cold inflation checks and adjustments should be made once a week. Hot checks should be
made daily.
2) Never bleed air from a hot tire to correct pressure. Normal equipment operation causes
inflation pressure to increase. A hot pressure increase up to 20% is acceptable.If excessive
pressure is present, find and fix the cause. Bleeding air will result in serious underinflation
and tire damage.
3) Record inflation pressure every time it is checked. Records provide information that can be
used to detect problems and schedule preventive maintenance.
4) Accurate pressure gauges must be used.
Service gauges should be calibrated with a master gauge once a month.
5) Before placing pressure gauge on valve:
• Clean any dust, dirt, grease or other matter from tip of valve stem.
• Press the valve core briefly and release a small quantity of air.
This cleaning procedure will help assure an accurate reading and prevent damage to the
gauge.
6) Use a valve cap on every valve. It acts as the primary air seal. It also helps to prevent dirt,
dust and water damage to the core.
7) Check spuds, stems and extensions. Be sure all joints are tight and secure to avoid leaks in
service.
8) Use valve extensions or hosing for easy access for inflation checks.
9) Compressors:
• Must have a minimum, capacity of 150 PSI (10.0 Bar).
• Compressors must have water trap assemblies to prevent moisture inside tires.
10) Use a new, correctly sized O-ring each time a tire is changed. Use a new grommet on
tubeless spuds.
11) Thoroughly clean rims and rim parts before mounting tires. Wire brush:
• bead seat areas.
• flanges.
• O-ring and lock-ring grooves.
• lock ring.
Bare metal must be painted or coated with rust inhibitor
Name of Procedure : Tyre Demounting & Mounting
Removal from machine

TYRE REMOVAL PROCEDURE

 Park the dumper over flat surface .
 Use stopper in both side of tyre .
 Place the hydraulic jack .
 Loosen the bolts.
 Remove the tyre from vehicle using the tyre handler.
 Remove the Valve core to deflate the tyre completely before starting
the dismantling procedure.

Fitment on machine

FITMENT PROCEDURE
 Keep dumper over flat surface .
 Position the tyre assembly by using tyre handler.
 Place & tighten all the nuts.
 Tighten to recommended torque 1900 NM using torque wrench .
 Ensure all nuts are torque – put a chalk mark on tyre sidewall to ensure
all nuts are torqued correctly
  Remove hydraulic jack &stopper .

Demounting tyre from rim

 Release all air

Prior to demounting tyre from rim, release all air by removing the valve core
housing with the valve tool.

First, remove the valve core and release all air from the tyre.

Be aware of the trajectory of the valve core as it may shoot out during its
removal.

There is any foreign matter inside the valve, the air will not be released. Insert
wire, etc. into the valve to clear away foreign matter.

When removing tyre and rim from a vehicle, prior to removing the parts
(clamps, nuts, etc.), secure the rim

 Remove lock ring

Use a tyre lever to force the bead seat band free from the
locking ring.
Use the tyre lever to leave out one end of the locking ring
from the locking groove.
With a second tyre lever, continue to dislodge the locking
ring around the circumference of the rim until the locking
ring is free from the assembly

 Remove O-ring

Use the tyre lever to push down on the bead seat band so

that the O-ring is freed.

Remove O-ring.

 Remove bead seat band

Mount bead breaker on Bead seat bend base.

As in Step 3, operate the bead breaker, push down the side Flange, and unset
the tyre bead from the bead seat band.
Alternatively, using levers, the bead seat band may be removed.

 Remove rim base

Mount bead breaker on rim base.

As in Step 3, operate the bead breaker, push down the

side ring, and unset the tyre bead from the bead seat band.

Use the lifting equipment to remove the rim base.

 Remove side ring

Use the lifting equipment to remove the side Flange.

Tyre Mounting on rim
Clean rim components and check condition

Clean rim components with a wire brush so that examination, maintenance,

and mounting can be done correctly.

Check that there is no deformation, bent, cracking, wear, corrosion, or damage

on the rim components.

Set up rim base and install side ring

Place rim base on rim base stand with gutter side up.

Install the side ring

Mount tyre on rim base

Apply a vegetable oil-based lubricant to both tyre bead seats.

Place tyre on rim base, and assemble.

Fit side Flange

Fit the side Flange.

Install bead seat band

Insert bead seat band into side ring and rim base.
Use the tyre lever to push in the bead seat band so that its edge fits with the
tyre bead.

Use in conjunction with auxiliary equipment (tyrehandler,crane, press

machine, etc.), when necessary

Fit O-ring

Apply lubricant to new O-ring and install it in the O-ring groove.

Fit lock ring

Place the ends of the lock ring into the lock ring groove in the rim base. Use
the tyre lever to successfully install the lock ring around the entire
circumference.

Starting opposite the locking ring gap, lightly tap the locking ring with a soft
metal or hard plastic hammer in both directions back to the locking ring gap to
ensure the locking ring is clamped into the locking ring groove.
Inflating the tyre and rim

Wherever possible, place the tyre and rim inside a tyre inflation safety cage,
then inflate tyre. During inflation, keep away from the tyre. When tyre has been
inflated to a pressure of approximately 7 to 10 psi check assembly of tyre and
rim components.
If assembled correctly, continue inflating up to the rated value.
Tyre Repair

 First detect the damaged area

 Clean thoroughly the affected area from outside as well as inside.
 Follow the bellow listed procedure
.

1. Tyre to be mounted on the repair stand

2. Skive affected area .
3. Buff out side affected areas .
4. Mark affected areas where patch will be fixed.
5. Buff inside area.
6. Clean inside & outside buffing zone.
7. Apply solution & allow to dry completely.
8. Attach the repair patch from inside so as to completely cover the
damage .
9. Fill cushion gum rubber from outside .
10. Attach the air bags and heater pads of the Monaflex machine and attach
to power supply.
11. Set curing hours as recommended.
12. Once curing is completed, allow complete cooling for 4 or 5 hours or
over night before removal from the machine.
Handling and Storage of Tires, Tubes and Rims
Unmounted tires should be shipped and stored vertically. Horizontal storage may compress
the beads. This may make initial inflation difficult.

Do not lift tires by the beads. Sharp hooks or forks cut and tear beads. In service, beads may
leak at these lifting points. For handling tyres, preferably use a Tyre handler. If a fork lift has to
be used, please ensure that the sharp blades do not damage the tyre beads and sidewalls.

Foreign material and moisture must be removed from the inside of the tire before mounting.

Store O-ring seals in a cool, dry place.

Lay flat. Do not stack other materials on O-rings.
Store valves in a clean, cool, dry place.

Rims
Tubeless rims are an important part of the air seal in a mounted tire. Do not distort or mutilate
rim arts.

Never lift rims by valve holes.

Never drop, tumble or roll rim parts.

Use babbit or lead hammers sparingly during assembly. Sledge hammers can damage rim
parts.

Tire and Tube Storage

Tires and tubes deteriorate rapidly if improperly stored.

Improper storage conditions include:

• Direct sunlight.
• Heat.
• Air in motion.
• Ozone.
• Gasoline and oil.
• Dust and dirt.
• Water or moisture inside tires
 DAILY TYRE PRESSURE AND WEAR REPORT.
CENTRAL COALFIELDS
CUSTOMER LIMITED SITE NAME DATE
Inflation Pressure (psi)

MACHINE
MODEL MACHINE SL NO FL FR RLO RLI RRI RRO REMARKS

HD 465-7E0

DAILY CHECK LIST

1) ALL NUTS IN FRONT & REAR
2) RIM CONDITION CHECK
3) TYRE TREAD AND SIDEWALL CONDITION CHECKED
4) TRAPPED STONES REMOVED
5) CHECK VALVE CONDITION/ VALVE CAP

6) REMARKS

CELITE L&T CUSTOMER

SIGNATURE SIGNATURE SIGNATURE

copy Distribution :- 1st (whith) L&T,2nd (Blue) Celite, 3rd (green) Customer
CELITE TYRE MANAGEMENT

CHECK LIST FOR TYRE FITMENT

DATE :
CUSTOMER NAME
SITE
SUPERVISOR/TEAM LEADER
VEHICLE SERIAL NO
POSITION ON MACHINE

CHECK LIST

SL NO CHECKED POSITION STATUS

1 STUD-BOLT
2 TORQUE
3 INFLATION PRESSURE
4 VALVE CORE
5 DUST CAPS

SIGNATURE OF SUPERVISOR/TEAM LEADER