rim instruction manual(pdf:2mb)

VERSION 1 (2008.08)
Multi-piece Rims for Industrial and Construction Vehicles
RIM INSTRUCTION MANUAL
Warning
In order to handle rims safely, correctly, and reliably, work
supervisors and workers involved in handling rims must
comply with the following:
■ Only begin work after carefully reading and understanding
this Rim Instruction Manual. Failure to follow these
instructions and safety precautions can be extremely
hazardous and result in SERIOUS INJURY or DEATH to the
tire changer or bystanders.
■ Keep this manual in a designated place where it is easily
accessible. Maintain this manual for future use and review
it whenever necessary.
■ If there are any questions or clarifications required
concerning the contents of this manual, please contact
your distributor.
■ When transferring rims to someone else, be sure to give
them this manual.
TOPY INDUSTRIES, LIMITED
Introduction
NThis Rim Instruction Manual concerns TOPY multi-piece rims for industrial
and construction vehicles. It contains detailed information regarding their
construction, specifications and handling to ensure the safe use of these
products. Failure to follow these instructions and safety precautions can be
extremely hazardous and result in SERIOUS INJURY or DEATH to the tyre
changer or bystanders.
N Servicing of tyres and rims is very dangerous. This manual sets out
important safety points and gives step-by-step explanations of the tasks
involved in handling TOPY multi-piece rims.
NRead Safety Points in this manual and be sure that you fully understand
them before starting tyre and rim servicing.
NWhen servicing tyres and rims, please refer to the following documents in
addition to this manual:
OSHA (U.S. Occupational Safety and Health Administration), Code of Federal
Regulations 29 CFR Part 1910.177, “Servicing multi-piece and single-piece rim
wheels”.
MSHA (Mine Safety and Health Adiminstration) Introduction guide series IG60
SAE (Society of Automotive Engineers) J1337 Off-Road Rim Maintenance
Procedures and Service Precautions.
RMA (U.S. Rubber Manufacturers Association) “CARE AND SERVICE OF OFFTHE-HIGHWAY TYRES”
RMA (U.S. Rubber Manufacturers Association) “TYRE INFORMATION SERVICE
BULLETIN”
“Tyre and Rim Handling Manual”, published by tyre manufacturer.
“Work Manual”, published by vehicle manufacturer.
NIn this manual, the word “rim” is used as a general term which includes
wheels with discs.
NCopying this manual for purposes other than ownership transfer is strictly
forbidden.
(2008.08)
1
Contents
1. Safety precautions ..................................................................................... 3
2. General safety rules for rim handling........................................................ 3
3. Important warnings ................................................................................... 4
3.1 Precautions for prevention of "explosive separation of rim components" ...............
4
3.2 Precautions for reduction or prevention of injury, death or damage from explosive
separation ....................................................................................................................
5
3.3 General precautions .....................................................................................................
6
4. Definitions of rim components .................................................................. 7
4.1 Names and size specifications of rim components ....................................................
7
4.2 Designations of each rim component .........................................................................
8
5. Markings .................................................................................................... 9
5.1 Location of markings ...................................................................................................
9
5.2 Composition of markings .......................................................................................... 10
5.3 Rim component specifications .................................................................................. 11
6. Matching charts ....................................................................................... 14
7. Examples of potentially hazardous matches .......................................... 18
8. Procedures for servicing tyres and TOPY rims ...................................... 24
8.1 How to demount tyre from TOPY 3-piece rim ........................................................... 25
8.2 How to mount tyre onto TOPY 3-piece rim ............................................................... 30
8.3 How to demount tyre from TOPY 5-piece rim ........................................................... 36
8.4 How to mount tyre onto TOPY 5-piece rim ............................................................... 43
8.5 Check point of servicing tyres and rims when rim remains installed on vehicle .... 52
9. Maintenance............................................................................................. 54
9.1 Regular inspection check points ............................................................................... 55
9.2 Inspections when servicing tyres and rims............................................................... 56
9.3 Action as a result of inspection ................................................................................. 61
2
(2008.08)
1. Safety precautions
1. Definition for safety precautions
In this manual, safety precautions utilize signal words that are classified according to the level
of risk and displayed as shown below. To ensure safety, understand the meanings of these
signal words and follow all precautions.
Warning
Indicates a potential danger. If procedures and instructions are not
followed, a serious accident causing death or severe injury could
occur.
Caution
If procedures and instructions are not followed, minor or moderate
injury could occur.
Notice
If the precaution indicated here is not followed, property damage or
malfunction/shortened lifespan of the product, etc. could occur.
2. General safety rules for rim handling
2. General safety rules for rim handling
Warning
/ Safety shall be given the highest priority in all aspects of work <Safety First>.
/ Before any work involving rim handling is carried out, use this manual to confirm the correct method of
work as well as the precautions. Be aware of “what must be done” and “what must not be done” during
the work.
/ If there are any doubts about procedure or work safety while performing mounting, demounting,
supplementing, removing, or fitting, suspend the work in progress immediately and seek the expert
advice of a competent rim personnel.
(2008.08)
3
3. Important warnings
3. Important warnings
Improper servicing of tyres and rims entails a serious risk of an “explosive separation of the
rim”, which can lead to serious, even fatal, accidents for the worker as well as to others in the
vicinity. Workers and persons responsible for supervising the work must comply strictly with
the following warnings.
3.1 Precautions for prevention of "explosive separation of rim
components"
Warning
/ When servicing tyres and rims, always start by completely deflating the tyre. Completely deflate the tyre,
before removing it from the rim.
/ Before removing tyre and rim from a vehicle, completely deflate the tyre before removing the clamp
components and other parts installed in the rim base.
/ Before servicing a tyre, remove the valve core to ensure that all of the air can escape.
/Identify the appropriate combination of rim components using the matching charts and product markings.
/If air pressure has fallen 80% below the pressure at the time of inflation, or the tyre has been punctured,
dismantle the rim and determine the cause. After you determine the cause, replace any deformed or
damaged rim components that may have caused air leaks.
/ Until the above-mentioned checks have been performed, DO NOT inflate.
/ DO NOT combine rim components from different manufacturers.
There may be differences in terms of shape and other features between components from other
companies and components manufactured by TOPY Industries (lock rings, rim bases, bead seat bands,
side rings). Always make sure that components are not mixed by checking the manufacturer’s markings
prior to assembly.
/ DO NOT use lock rings with open ends (ends that do not touch). There is a danger that the lock ring will
not set correctly.
/DO NOT remove or install components or otherwise modify a rim in such a way that the product
specifications are changed.
DO NOT make modifications involving welding, heating, soldering, etc. Such modifications could lead
to the deformation as well as the deterioration of the strength and structural integrity of the rim
components.
/ When the tyre is being mounted, it is strictly forbidden to perform tasks that may generate heat, flames,
or sparks such as welding, soldering or grinding. There is possibility to lead a explosion or a fire by
excessive tyre pressure.
/Prior to inflation, it may be necessary to tap the rim components into position to set them. If it is, DO
NOT use a steel mallet. Instead use a soft metal or hard plastic mallet. Use of a steel mallet could cause
deformation or cracking of components.
/While inflating the tyre, when the air pressure reaches 35kPa (5psi), check whether the rim components
are set correctly. If they are not set correctly, immediately stop the work in progress, deflate completely
and disassemble the components. Inspect the component's mating surfaces and discard any components
or materials that interfere with complete assembly. When the problem is resolved, resume assembly.
/ DO NOT exceed the tyre pressure recommended by the tyre manufacturer.
/ Tyre and rim assemblies should be stored so as to prevent unintended movement.
/ Store inflated tyres in a manner in which they will not fall and cause accidents. Falling tyres can cause
major accidents involving workers, and the impact from a significant fall could lead to the "explosive
separation of rim components".
/ Comply with the air pressure recommended by your tyre manufacturer. Do not exceed the standard air
pressure without checking first with your TOPY rim dealer.
4
(2008.08)
3. Important warnings
3.2 Precautions for reduction or prevention of injury, death or
damage from explosive separation
Warning
/ When inflating tyres, or when deflating tyres for tyre and rim servicing, workers must always be outside
the range of the “hazardous trajectory” shown in the diagram below. Exercise extreme caution as the
trajectory may widen.
/ During inflation and deflation work, DO NOT allow other workers or third parties to approach the area
surrounding the hazardous trajectory.
Hazardous
trajectory
Hazardous
trajectory
/Wherever possible, when inflating the tyre following rim assembly, ensure that the work is carried out
with the tyre inside a “tyre inflation safety cage”.
Tyre inflation safety cage
/Ensure that protective equipment is worn when servicing tyres and rims.
(Wear gloves, safety shoes, safety glasses, ear protection, hard hat)
(2008.08)
5
3. Important warnings
3.3 General precautions
Warning
/ Handling of tyres and rims should be carried out only by workers who have received training and
accreditation based on instruction from a qualified work supervisor.
/ Check the “Tyre and Rim Handling Manual” published by the tyre manufacturer for information on work
and inspections, etc. involving tyre handling.
/ When lifting heavy components or equipment, make sure that you use suitable lifting equipment and that
you follow the instructions in the manual for the equipment to be used.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure others in the
vicinity.
/ There are several types of tools for work involving tyre and rim handling. Be sure you have a proper
understanding of how the tools are used and carry out the work in accordance with the proper
procedures.
/ Be sure to perform a visual examination of tyres and rims when conducting regular inspections of
vehicles and tyres, or tyre rotations.
/ Rim components that are deformed, bent, cracked, worn, corroded, or damaged should be clearly labeled
to indicate their condition, and discarded.
/Use tyres and rims suited to the vehicle, as specified by the vehicle manufacturer and tyre manufacturer.
/ In the case of dual assemblies, DO NOT operate the vehicle on a single tyre as the load capacity of the
tyre and rim will be drastically reduced and may result in damage.
6
(2008.08)
4. Definitions of rim components
4. Definitions of rim components
4.1 Names and size specifications of rim components
Rims are classified according to the number of components. There are 3-piece and 5-piece
rims.
Names and specifications of 3-piece rim components
Side ring
Rim width
Bead seat width
Rim
diameter
Rim
diameter
Flange
height
Flange
height
Bead seat width
Rim base
Lock ring
Names and specifications of 5-piece rim components
Side ring
Side ring
Rim width
Bead seat width
Bead seat width
Flange
height
Rim
diameter
Rim
diameter
Flange
height
Bead seat band
(bead seat ring)
Rim base
(2008.08)
Lock ring
7
4. Definitions of rim components
4.2 Names of rim components
SIDE RING
BEAD SEAT BAND
LOCK RING
OUT BOARD DRIVER KEY
RIM BASE
KNURLING
OUT BOARD
DRIVER POCKET
BEAD SEAT AREA
RIM CIRCUM-WELD
BACK FLANGE
DISC WELD
VALVE HOLE
(TUBE TYPE)
BOLT HOLE
GUTTER
VALVE ACCESS NOTCH
DISC
Names of rim component involving an out board driver
PRY BAR SLOT
LOCK RING DRIVER
LOCK RING GROOVE
"O" RING
The O-ring is not
a rim component
"O" RING GROOVE
VALVE HOLE
(TUBE-LESS TYPE)
RIM DRIVER
Names of gutter section involving a lock ring driver
8
(2008.08)
5. Markings
5. Markings
Markings clarify the specifications of the rim components.
Workers servicing tyres and rims must fully understand “5.1 Location of markings”, “5.2
Composition of markings”, as well as “5.3 Rim component specifications”, and must confirm
that the combination of rim components is correct.
Correct combinations (matching) of rim components are provided in “6. Matching charts”.
Workers servicing tyres and rims should check the markings on the combined rim components
and confirm that the combination is correct using the matching chart.
Warning
/ Check the markings on the rim components and confirm that they are TOPY products.
/ DO NOT combine TOPY products with products from other companies. Doing so could cause “explosive
separation of the rim” and result in serious injury or death.
/ An incorrect combination of rim components can cause explosive separation of the rim and serious injury
or death.
5.1 Location of markings
Rim components manufactured by TOPY have markings in the areas shown below. The
markings are positioned so they can be visually confirmed even after tyre assembly.
Rim base (side or inner surface)
Lock ring
Markings
Markings
Markings
Side ring
Bead seat band
For 3-piece rim
Markings
(2008.08)
For 5-piece rim
Markings
Markings
9
5. Markings
5.2 Composition of markings
Markings on TOPY rim components consist of
[month & year of manufacture], [rim component specification],
[TOPY (manufacturer)].
For details regarding the aforementioned [rim component specification], refer to “5.3 Rim
component specifications”.
Example of markings:
Composition of markings
12-06
RM2957EU
TOPY
[Month & year of
manufacture]
[Rim component
specification]
[Manufactured
by TOPY]
e.g. manufactured in
Dec. 2006
e.g. rim base component,
rim width 29 inches,
rim diameter 57 inches
EU type
Marking information
[Month & year of
manufacture]
Indicates the month and year in which component was
manufactured.
[Rim component
specification]
Indicates the rim component specification (component category,
size, type).
Vital information for confirming combination (matching) of rim
components.
[TOPY (manufacturer)]
All TOPY rim components are marked with “TOPY”.
Note: The order of month and year of manufacture, rim component specification, and TOPY in the
markings may vary.
10
(2008.08)
5. Markings
5.3 Rim component specifications
When servicing tyres and rims, workers must use the matching charts below and the rim
component specification to confirm that the combination of rim components is correct.
/ If there are any doubts concerning the interpretation of rim component specifications,
please contact your TOPY rim dealer.
Markings on [rim component specification] consist of
[rim component category], [size], and [type].
Please refer to “5.3.1 Rim component categories” and “5.3.2 Size and type of rim components”
for details.
Example of rim component
specification markings :
RM
2525
EM
[Rim component category]
[Size]
[Type]
5.3.1 Rim component categories
The first 2 letters in the [rim component specification] markings indicate the “rim component”
classification, as shown in the table below.
Marking
Special comments
RM
Rim base
·RM may be omitted
·D or S might be used instead
LR
Lock ring
·Component of 3-piece and 5-piece rim
SR
Side ring
·Component of 3-piece and 5-piece rim
BB
(2008.08)
Rim component
Bead seat band
(bead seat ring)
·Component of 5-piece rim
11
5. Markings
5.3.2 [Size] and [type] of rim components
Details regarding [size] and [type], which are important specifications for rim components, are
described below for each rim component (rim base, lock ring, side ring, bead seat band).
(1) Rim base
Example of markings:
RM
2957
EU
[Component classification]
[Size]
[Type]
N[Size]
For both of the marking examples in the table below, the rim width and rim diameter are
indicated in inches.
Example of [Size]
markings
[Size]
Special comments
Rim width
Rim diameter
1949
First 2 digits (19)
e.g. 19.5 inches
Next 2 digits (49)
e.g. 49 inches
In the rim width markings
shown below, digits
following the decimal point
are omitted.
11.25 inches : 11
19.50 inches : 19
29.0057
Numbers preceding
“” (29.00)
e.g. 29 inches
Numbers following
“” (57)
e.g. 57 inches
The order of rim width and
rim diameter may vary.
N[Type]
Indicates the type of rim base and identifies the matching lock ring, bead seat band, and side
ring.
See “6. Matching charts” for rim component combinations.
(2) Lock ring
Example of markings:
LR
57
EU
[Component classification]
[Size]
[Type]
N[Size]
Indicates the rim diameter of the matching rim base in inches.
N[Type]
Indicates the type and identifies the matching rim base and bead seat band.
See “6. Matching charts” for rim component combinations.
12
(2008.08)
5. Markings
(3) Bead seat band
Example of markings:
BB
7557
HS
[Component classification]
[Size]
[Type]
N[Size]
Indicates bead seat width and rim diameter of matching rim base in inches.
Example of [Size]
markings
7557
[Size]
Bead seat width
Rim diameter
First 2 digits (75)
e.g. 7.5 inches
Next 2 digits (57)
e.g. 57 inches
Special comments
Decimal places are omitted
from bead seat width
N[Type]
Indicates the type and identifies the matching rim base, lock ring, and side ring.
See “6. Matching charts” for rim component combinations.
(4) Side ring
Example of markings:
SR
5063
[Component classification]
[Size]
N[Size]
Indicates flange height of side ring and rim diameter of matching rim base in inches.
Example of [Size]
markings
5063
[Size]
Flange height
Rim diameter
First 2 digits (50)
e.g. 5.0 inches
Next 2 digits (63)
e.g. 63 inches
Special comments
Decimal places are omitted
from flange height
*Special side ring – W type side ring
W type side rings are exclusively for EUW type rim bases and bead seat bands.
The size is followed by a W or SW mark.
See “6. Matching charts” for rim component combinations.
Example of markings
for W type side ring :
(2008.08)
SR
5063
W or SW
13
6. Matching charts
6. Matching charts
Correctly combining rim components is called “matching”, and the tables of rim component
combinations are called “matching charts”.
In this manual, matching lock rings, bead seat bands, and side rings for each rim base type are
shown in the matching charts.
Correctly combine (match) rim components according to the “matching charts” shown starting
on the next page.
Warning
/ Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts.
The wrong combination could cause “explosive separation of the rim” resulting in serious injury or death
to workers and possibly bystanders.
/ Confirm tyre and rim combinations with your tyre dealer or confirm using the specifications for tyres and
rims.
/ If there are any doubts concerning combinations or the matching charts, immediately suspend the work
in progress and contact your TOPY rim dealer.
14
(2008.08)
6. Matching charts
EUW TYPE RIM (Rim diameter 63 inches)
Rim component size and type
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim base
Lock ring
Bead seat
band
53/80R63
6336.00/5.0
DM3663EUW
LR63EUS
BB7563HSW
SR5063W
53/80R63
6336.00/5.0
DM3663EUW
LR63EUS
BB7563HSW
SR5063SW
58/80R63
6344.00/5.0
DM4463EUW
LR63EUS
BB7563HSW
SR5063W
58/80R63
6344.00/5.0
DM4463EUW
LR63EUS
BB7563HSW
SR5063SW
Side ring
EU TYPE (Rim diameter 63 inches)
Rim component size and type
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim base
Lock ring
Bead seat
band
Side ring
55/80R63
6341.00/5.0
D4163EU
LR63EU
BB7563HS
SR5063
58/80R63
6344.00/5.0
D4463EU
LR63EU
BB7563HS
SR5063
EU TYPE (Rim diameter 57, 51 inches)
Rim component size and type
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim base
Lock ring
Bead seat
band
Side ring
30.00R51
5122.00/4.5
RM2251EU
LR51EU
BB7551HS
SR4551
33.00R51
5124.00/5.0
RM2451EU
LR51EU
BB7551HS
SR5051
36.00R51
5126.00/5.0
RM2651EU
LR51EU
BB7551HS
SR5051
37.00R57
5727.00/6.0
RM2757EU
LR57EU
BB7557HS
SR6057
40.00R57, 46/90R57
5729.00/6.0
RM2957EU
LR57EU
BB7557HS
SR6057
46/90R57
5732.00/6.0
RM3257EU
LR57EU
BB7557HS
SR6057
48/95R57
5732.00/6.5
RM3257EU
LR57EU
BB7557HS
SR6557
49.5/80-57, 50/80-57
5736.00/6.0
RM3657EU
LR57EU
BB7557HS
SR6057
55/80R57
5744.00/5.0
RM4457EU
LR57EU
BB7557HS
SR5057
55.5/80-57
5744.00/6.0
RM4457EU
LR57EU
BB7557HS
SR6057
EJ TYPE (Rim diameter 51 inches)
Rim component size and type
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim base
Lock ring
Bead seat
band
Side ring
30.00-51
33.00-51
36.00-51
50/65-51
5122.00/4.5
5124.00/5.0
5126.00/5.0
5140.00/4.5
RM2251EJ
RM2451EJ
RM2651EJ
RM4051EJ
LR51EJ
LR51EJ
LR51EJ
LR51EJ
BB7551HS
BB7551HS
BB7551HS
BB7551HS
SR4551
SR5051
SR5051
SR4551
(2008.08)
15
6. Matching charts
EV TYPE (Rim diameter 49, 35, 33 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
18.00-33
35/65-33
21.00-35
24.00-35
24.00R49
27.00R49
3313.00/2.5
3328.00/3.5
3515.00/3.0
3517.00/3.5
4917.00/3.5
4919.50/4.0
Rim component size and type
Rim base
RM1333EV
RM2833EV
RM1535EV
RM1735EV
RM1749EV
RM1949EV
Lock ring
LR33EV
LR33EV
LR35EV
LR35EV
LR49EV
LR49EV
Bead seat band
BB5533EV
BB5533EV
BB5535EV
BB5535EV
BB5549EV
BB5549EV
Side ring
SR2533
SR3533
SR3035
SR3535
SR3549
SR4049
ES TYPE (Rim diameter 57, 45, 39 inches)
Standard
tyre
Rim component size and type
Rim size
(Diawidth/Flange height)
Rim base
Lock ring
Bead seat band
Side ring
41.25/70-39
3932.00/4.5
RM3239ES
LR39ES
BB5539ES
SR4539
45/65-45
4536.00/4.5
RM3645ES
LR45ES
BB5545ES
SR4545
65/65-57
5752.00/6.0
D5257EU
LR1057ES
BB1057ES
SR6057
* For rim size 57X52.00/6.0, although the EU type rim base is used, combine with ES type lock ring
and ES type bead seat band.
EMR TYPE (Rim diameter 45, 39 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
33.5-39
40/65-39
45/65-45
3928.00/4.0
3932.00/4.5
4536.00/4.5
Rim component size and type
Rim base
RM2839EMR
RM3239EMR
RM3645EMR
Lock ring
LR39EM
LR39EM
LR45EM
Bead seat band
BB5539EV
BB5539EV
BB5545EV
Side ring
SR4039
SR4539
SR4545
EMH TYPE (Rim diameter 33, 29 inches)
16
Standard
tyre
Rim size
(Diawidth/Flange height)
29.5-29
18.00-33
24.00-33
35/65-33
33.5-33
2925.00/3.5
3313.00/2.5
3317.00/3.5
3328.00/3.5
3328.00/4.0
Rim component size and type
Rim base
RM2529EMH
RM1333EMH
RM1733EMH
RM2833EMH
RM2833EMH
Lock ring
LR29EM
LR33EM
LR33EM
LR33EM
LR33EM
Bead seat band
BB5529EM
BB4033EM
BB5533EM
BB5533EM
BB5533EM
Side ring
SR3529
SR2533
SR3533
SR3533
SR4033
(2008.08)
6. Matching charts
EM TYPE (Rim diameter 25 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
14.00-25
16.00-25
18.00-25
17.5-25
21.00-25
24.00-25
20.5-25
23.5-25
26.5-25
29.5-25
30/65R25
18.00-33
2510.00/1.5
2511.25/2.0
2513.00/2.5
2514.00/2.0
2515.00/3.0
2517.00/3.5
2517.00/2.0
2519.50/2.5
2522.00/3.0
2525.00/3.5
2524.00/3.0
3313.00/2.5
Rim component size and type
Rim base
RM1025EM(D)
RM1125EM(D)
RM1325EM(D)
RM1425EM(D)
RM1525EM(D)
RM17255EM(D)
RM17254EM(D)
RM1925EM(D)
RM2225EM
RM2525EM
RM2425EM
RM1333EM
Lock ring
LR25EM(D)
LR25EM(D)
LR25EM(D)
LR25EM(D)
LR25EM(D)
LR25EM(D)
LR25EM(D)
LR25EM(D)
LR25EM
LR25EM
LR25EM
LR33EM
Bead seat band
BB4025EM(D)
BB4025EM(D)
BB4025EM(D)
BB4025EM(D)
BB4025EM(D)
BB5525EM(D)
BB4025EM(D)
BB4025EM(D)
BB5525EM
BB5525EM
BB5525EM
BB4033EM
Side ring
SR1525
SR2025
SR2525
SR2025
SR3025
SR3525
SR2025
SR2525
SR3025
SR3525
SR3025
SR2533
*(D) indicates Lock Ring Driver type rims.
WI TYPE (Rim diameter 24, 20 inches)
Standard tyre
Rim size
(Diawidth/Flange
height)
14.00-20
12.00-24
14.00-24
2010.00WI
248.50V-W
2410.00WI
Rim component size and type
Rim base
Lock ring
Side ring
RM1020WI
RM8524VW
RM1024WI
LR20WIA
LR24WIA
LR24WIA
SR20WI
SRWV24
SR24WI
WI TYPE (for tubeless tyre, rim diameter 24, 20 inches)
Standard tyre
14.00-20
12.00-24
14.00-24
Rim size
(Diawidth/Flange
height)
2010.00WI-T
248.50V-W-T
2410.00WI-T
Rim component size and type
Rim base
Lock ring
Side ring
RM1020WI-T
RM8524VW-T
RM1024WI-T
LR20WIA-T
LR24WIA-T
LR24WIA-T
SR20WI-T
SRWV24-T
SR24WI-T
TG Rim and Others (Rim diameter 24, 25 inches)
Standard tyre
13.5-20
12.00-24, 13.00-24
14.00-24, 16.00-24
15.5-25
15.5-25
17.5-25
14.00-25
20.5-25
(2008.08)
Rim size
(Diawidth/Flange
height)
2011.00TG
248.00TG
2410.00VA
2512.00
2512.00/1.3(A)
2514.00/1.5
2510.00/1.5
2517.00/1.7
Rim component size and type
Rim base
Lock ring
Side ring
RM1120TG
RM8024TG
RM1024
RM1225
RM1225A
RM1425
RM1025
RM1725-1.7
LR20TG
LR8024
LR1024
LR1225
LR25GR
LR25GR
LR25GR
LR25GR
SR20TG
SR8024
SR8024
SR1225
SR1225A
SR1425
SR1025
SR1725-1.7
17
7. Examples of potentially hazardous matches
7. Examples of potentially hazardous matches
Warning
/If you are assembling these combinations, be especially careful. Incorrect assembly can result in serious
injury or death.
/ If you have any questions about safe combinations, stop working and contact your TOPY rim dealer.
(1) EUW, EU type rim with rim diameter 63 inches
The contact shapes of rim components (rim bases, lock rings, bead seat bands, side rings) for EUW
type and EU type rims vary. Always make sure you assemble them correctly.
N Diagrams showing the correct assembly of EUW type rim components and EU type rim components
EUW type rim
(reinforced type)
W type side ring
W type side ring
Tapered shape
Tapered shape
35 degrees
HSW type bead seat band
EUW type rim base
EUS type lock ring
EU type rim
(standard type)
Standard type side ring
Standard type side ring
Not tapered
Not tapered
45 degrees
HS type bead seat band
EU type rim base
EU type lock ring
N Characteristics of EUS, EU type lock rings of 63-inch rim diameter
Verify the grooves and markings to distinguish between EUS type and EU type lock rings of 63-inch rim diameter.
Type of lock ring
LR63EUS
LR63EU
Type of matching rim
EUW type
EU type
Lock ring angle
35 degrees
45 degrees
Grooves for identification
45o
Cross-sectional shape
35°
Identification
Marking: EUS
Shape: Has grooves for identification
Marking: EU
Shape: No grooves for identification
Warning
/ Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts.
/ Incorrect assembly could lead to a fatal accident. Always verify the compatibility of components before
assembling.
18
(2008.08)
7. Examples of potentially hazardous matches
(2) Rim base and lock ring combination
For rim diameters 63, 57, 51 inches
On gutters of EU type and EJ type rim bases, or on gutters of other manufacturers rim base, the
shape of the lock ring groove differs. Ensure that they are combined with the correct lock ring.
(manufactured by
another company
Here to refer to
PHASE2 the note below)
Lock ring
Gutter band
EU type
EJ type
CORRECT
WRONG
WRONG
WRONG
CORRECT
WRONG
WRONG
WRONG
CORRECT
EU type
EJ type
PHASE2
(manufactured by
another company
Here to refer to
the note below)
CORRECT
: Correct combination
WRONG
: Wrong combination
* PHASE: PHASE is manufactured by another company. As far as TOPY Industries is aware of,
this is the current name by which this lock ring is referred to in the industry. Please note that the
name and/or shape may change in the future.
Warning
/Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts.
/ NEVER mix TOPY rim components with PHASE type rim components manufactured by another company.
Incorrect assembly could lead to a serious injury or death. Always verify the compatibility of components
before assembling.
(2008.08)
19
7. Examples of potentially hazardous matches
(2) Rim base and lock ring combination (cont'd)
For rim diameter 49, 35, 33 inches
On gutter of EV type and EM type rim bases, the shape of the lock ring groove differs. Make sure
that they are combined with the correct lock ring.
Lock ring
Gutter
EV type
EM type
CORRECT
WRONG
WRONG
CORRECT
EV type
EM type
CORRECT
: Correct combination
WRONG
: Wrong combination
Warning
/ Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts.
/Incorrect assembly could result in serious injury or death. Always verify the compatibility of components
before assembling.
20
(2008.08)
7. Examples of potentially hazardous matches
(3) Lock ring and bead seat band combination
For rim diameter 57 inches
On ES type and EU type lock rings, the contact angle with the bead seat band differs. Make sure
that they are combined with the correct bead seat band.
Lock ring
Bead
seat band
45o
35o
ES type
EU type
CORRECT
WRONG
WRONG
CORRECT
35o
ES type
45o
HS type
CORRECT
: Correct combination
WRONG
: Wrong combination
N Characteristics of ES, EU type lock rings for nominal diameter 57 inches
Type of lock ring
LR1057ES
LR57EU
Matching bead seat
band type
ES type
HS type
Lock ring angle
35 degrees
45 degrees
Grooves for identification
45o
Cross-sectional shape
35°
Identification
Marking: ES
Shape: Has grooves for
identification
Marking: EU
Shape: No grooves for
identification
Warning
/ Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts.
/Incorrect assembly could result in serious injury or death. Always verify the compatibility of components
before assembling.
(2008.08)
21
7. Examples of potentially hazardous matches
(3) Lock ring and bead seat band combination (cont'd)
For rim diameters 45, 39 inches
On ES type and EM type lock rings, the contact angle with the bead seat band differs. Make sure
that they are combined with the correct bead seat band.
Lock ring
45°
35°
Bead
seat band
ES type
EM type
CORRECT
WRONG
WRONG
CORRECT
35°
ES type
45°
EV type
CORRECT
: Correct combination
WRONG
: Wrong combination
N Characteristics of ES, EM type lock rings for rim diameters 45, 39 inches
Type of lock ring
LR45ES, LR39ES
LR45EM, LR39EM
Matching bead seat
band type
ES type
EV type
Lock ring angle
35 degrees
45 degrees
Identification
45o
35°
Cross-sectional shape
Marking: ES
Marking: EM
Warning
/ Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts.
/Incorrect assembly could lead result in serious injury or death. Always verify the compatibility of
components before assembling.
22
(2008.08)
7. Examples of potentially hazardous matches
(4) Facing of lock ring
The correct installation of the locking ring can only be achieved if the markings on the locking ring
can be seen before, during, and after installation.
If the locking ring is installed back to front it will not interface properly with the gutter band and
there is a risk of the locking ring dislodging under pressure.
<Typical example> For WI type lock ring
Correct facing
Wrong facing
CORRECT
WRONG
Markings
are visible
Markings
are not visible
Warning
/ Prior to installing the locking ring, confirm that the locking marking is visible so that the installation can
be carried out correctly.
/If the locking ring is installed back to front, the markings are not visible, and continuing assembly could
result in an explosion and serious injury or death.
(2008.08)
23
8. Procedures for servicing tyres and TOPY rims
8. Procedures for servicing tyres and TOPY rims
Warning
/Servicing tyres and rims can be very dangerous. Failing to heed the warnings could result in serious
injury or death.
/Servicing of tyres and rims should be carried out only by workers who have received adequate training
from a qualified supervisor on safe handling of tyres and rims. This training must include reading this
manual completely.
/Tyres should be deflated while standing outside the range of the “hazardous trajectory” shown by the
arrows in the diagram below. Exercise extreme caution as the direction of the trajectory may widen.
/While deflating, DO NOT allow other workers or third parties to approach the area of the trajectory.
/Check the “Tyre and Rim Handling Manual” published by the tyre manufacturer for information on work
and inspections, etc. involving tyre handling.
/There are several types of tools for servicing work. Be sure you have a proper understanding of how the
tools are used and carry out the work in accordance with the proper procedure.
/Ensure that protective equipment is worn when servicing tyres and rims.
(Wear gloves, safety shoes, safety glasses, face protection, earplugs, hard hat, etc.)
/If there are any doubts during demounting, mounting, or inflating tyres and rims, immediately stop the
work in progress and seek instruction from a supervisor.
Hazardous
trajectory
Hazardous
trajectory
24
(2008.08)
8.1 How to demount tyre from TOPY 3-piece rim
[Required tools]
•Valve tool •Wire for valve cleaning •Wire brush
•Tyre lever for tyre mount/demount (confirm specifications of tool type with your tyre dealer)
•Lifting equipment (crane, chains, nylon sling, forklift, tyre handler, etc.)
STEP
1
Release all air
D Prior to demounting tyre from rim, release all air by removing the valve core housing with the valve tool.
Valve core housing
Valve
Valve tool
Warning
/ 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.
/If 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 base accessories (extension valve fixing brackets, etc.) and rim base to the vehicle and release all
air from the tyre.
/ When demounting outer tyres and rims of dual assemblies, make sure you release all air from the inner
tyres as well.
/ Tyres should be deflated outside the range of the “hazardous trajectory” shown by the arrow in the
diagram below. Exercise extreme caution as the range of the trajectory may widen.
/ During deflation work, DO NOT allow other workers or third parties to approach the area of the trajectory.
/ When releasing air, stand in a safe location as foreign matter or frozen particles inside tyre might be
discharged.
/ Do not allow high pressure air to hit skin.
Hazardous
trajectory
Hazardous
trajectory
(2008.08)
25
8.1 How to demount tyre from TOPY 3-piece rim
STEP
2
Set up the tyre and rim
D After fully releasing the air, place the
tyre and rim on the ground with the
gutter side facing up.
Gutter
UP
Warning
/Because this work involves handling heavy items, where necessary, you must use appropriate lifting
equipment.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
STEP
3
Detach tyre bead seat from side ring
D Insert the tyre lever between the tyre bead and the side
ring. Unseat the bead from the side ring by using the lever
to push the tyre down around the entire circumference.
Warning
/ When mounting and demounting tyres, maintain a firm grip on the tyre lever as it may jerk loose and
cause injury.
26
(2008.08)
8.1 How to demount tyre from TOPY 3-piece rim
STEP
4
Remove lock ring
D Use the tyre lever to lift one end of the locking ring from
the locking ring groove.
J 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.
Never Reuse
REUSE
Ends are open
Warning
/ Discard lock rings with open ends (ends aren't touching) as they will not set correctly (see above) and
could result in serious injury or death.
/ When removing the lock ring, DO NOT spread the ends excessively as they will no longer touch and will
have to be discarded.
/ Keep fingers away from lock ring.
/ Be careful when removing the lock ring as it may literally fly off as it is being freed.
/ Maintain a firm grip on the tyre lever as it may be thrown and cause injury.
(2008.08)
27
8.1 How to demount tyre from TOPY 3-piece rim
STEP
5
Remove O-ring
D Use the tyre lever to push down on the side ring so that
the O-ring may be removed. Remove the O-ring.
Warning
/ Keep fingers away from side ring.
/ When mounting and demounting tyres, maintain a firm grip on the tyre lever as it may be jerk loose and
cause injury.
Notice
Once used, O-rings become deformed and can result in air leaks. Used O-rings should be cut and discarded.
STEP
6
Remove side ring
D Use the tyre lever to remove the side ring.
Warning
/ Keep fingers away from side ring.
/ When mounting and demounting tyres, maintain a firm grip on the tyre lever as it may be jerk loose and
cause injury.
/ Be careful not to drop components on your feet.
28
(2008.08)
8.1 How to demount tyre from TOPY 3-piece rim
STEP
7
Turn over tyre and rim
D Use lifting equipment to turn over the tyre and rim, and
place them on the ground.
Warning
/ Because this work involves handling heavy items, where necessary, you must use appropriate lifting
equipment.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
STEP
8
Detach tyre bead from rim base, and remove rim base.
D As in Step 3, insert the tyre lever between the tyre bead
and the rim base.
J Push down the tyre around the entire circumference, and
detach tyre bead from the rim base.
8 Remove the rim base.
Warning
/ Because this work involves handling heavy items, where necessary, you must use appropriate lifting
equipment.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
/ Be careful not to get your fingers caught.
/ When mounting and demounting tyres, maintain a firm grip on the tyre lever as they may jerk loose and
cause injury.
(2008.08)
29
8.2 How to mount tyre onto TOPY 3-piece rim
[Required tools]
•Valve tool •Wire for cleaning valve core •Tyre seating blocks
•Tyre lever for tyre mount/demount (confirm specifications of tool type with your tyre dealer)
•Soft metal or hard plastic hammer (not steel)
•Lifting equipment (crane, chains, nylon sling, forklift, tyre handler, etc.)
•Lubricant for tyre mounting (product recommended by tyre dealer)
•Wire brush •Air gauge •Air chuck
STEP
1
Confirm tyre and rim component combination
D Check tyre size and markings on rim base, and make sure that the combination is correct.
J Check markings on rim components and matching charts, and make sure that the combination is correct.
Warning
/ Confirm tyre and rim combinations with your tyre dealer or confirm using the specifications for tyres and
rims.
/Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts. The wrong combination could cause “explosive separation of the rim” resulting in
severe injury or death to workers and bystanders.
/ DO NOT combine TOPY rim components with rim components manufactured by other companies.
/ If there are any doubts concerning combinations or matching charts, immediately suspend the work in
progress and contact your TOPY rim dealer.
STEP
2
Clean rim components and check condition
D Clean rim components with a wire brush so that examination,
maintenance, and mounting can be done correctly.
J Check that there is no deformation, bent, cracking, wear,
corrosion, or damage on the rim components.
Warning
/ Discard any rim components that are deformed, bent, cracked, weared corroded, or damaged, or are
suspected of being so, and replace them with undamaged components.
/ Discard any lock rings with open ends (ends aren't touching).
/ DO NOT make modifications that change the product specifications.
/DO NOT make modifications involving welding, heating, soldering, etc. Such modifications could lead
to the deformation as well as the deterioration of the strength and structural integrity of the rim
components.
Notice
If there's any foreign matter, etc. adhering to the lock ring grooves on the rim base or to O-ring grooves, proper
assembly will not be possible and air leaks will occur. Make sure all grooves are clean before assembly.
30
(2008.08)
8.2 How to mount tyre onto TOPY 3-piece rim
STEP
3
Recoat
DRecoat any areas where the anti-corrosive oil or paint is peeling.
Caution
/ Anti-corrosive oil and paint may contain toxic ingredients. Follow any safety instructions provided by the
manufacturers of the anti-corrosive oil or paint.
/Depending on the vehicle, some parts have certain areas that may be uncoated in order to prevent
loosening of parts attaching the rim base to the vehicle (clamps, nuts, etc.) and slipping of rim
components, etc. If you're not sure, check with the vehicle manufacturer or your TOPY rim dealer.
STEP
4
Set up rim base and install valve
DPlace rim base on rim base stand with gutter side up.
JInstall valve.
Warning
/ Because this work involves handling heavy items, where necessary, you must use appropriate lifting
equipment.
/ When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
/For valve selection and installation, follow instructions in the manuals provided by your tyre dealer and
valve manufacturer. If in doubt, contact the dealer or manufacturer for guidance.
STEP
5
Confirm absence of tyre defects
DConfirm absence of tyre defects.
Warning
/Check with tyre dealer to confirm that there are no tyre defects. Using defective tyres could result in tyre
failure while you are mounting the tyre and rim or during use, resulting in tyre separation and possible
severe injury or death.
(2008.08)
31
8.2 How to mount tyre onto TOPY 3-piece rim
STEP
6
Mount tyre on rim base
D Apply a vegetable oil-based lubricant to both tyre
bead seats.
J Place tyre on rim base.
Notice
/DO NOT apply tyre lubricant to areas other than where the rim components come in contact with the tyre.
Doing so could cause circumferential slippage between rim components when the vehicle is being driven.
/Consult your tyre dealer when selecting tyre lubricant.
Warning
/Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
STEP
7
Fit side ring
DInsert side ring into rim base and fit edge section to tyre bead.
Caution
/ Keep fingers away from side ring.
32
(2008.08)
8.2 How to mount tyre onto TOPY 3-piece rim
STEP
8
Fit O-ring
DApply lubricant to new O-ring and install it in the O-ring
groove.
Caution
/ Keep fingers away from side ring.
Notice
/Check with your tyre dealer for O-ring specifications or when selecting lubricant.
/Be careful not to twist the O-ring.
(2008.08)
33
8.2 How to mount tyre onto TOPY 3-piece rim
STEP
9
Fit lock ring
DPlace the end 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.
JStarting 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.
Never Use
USE
Ends are open
Warning
/DO NOT use lock rings with open ends (ends aren't touching).
/ Check the facing of the lock ring. The lock ring is installed correctly if its markings are visible after tyre assembly.
/ DO NOT use a steel mallet.
Caution
/ Be careful when handling the lock ring as it may fly off.
/ Be careful not to get your fingers caught.
34
(2008.08)
8.2 How to mount tyre onto TOPY 3-piece rim
STEP
10 Confirm that rim components are assembled correctly
DMake sure the combinations (matching), facings, and positions of rim components are correct.
Warning
/ Recheck the tyre and rim component combinations (matching) and make sure they are correct.
/ Recheck the facing of the lock ring and make sure it is installed correctly and is securely in the lock ring groove.
/DO NOT inflate, hammer, weld or solder to position the rim components. Doing so can lead to the
deformation as well as the deterioration of the strength and structural integrity of the rim components.
STEP
11 Inflating the tyre and rim
DWherever possible, place tyre and rim inside a tyre
inflation safety cage, then inflate tyre. During inflation,
keep away from the tyre.
Tyre inflation safety cage
JWhen tyre has been inflated to a pressure of approximately
35kPa (5psi), check assembly of tyre and rim components.
8If assembled correctly, continue inflating up to the rated
value.
Warning
If assembly has been done incorrectly, inflation could result in an explosive separation of the rim. This
separation could result in serious injury or death to you or bystanders. Workers and persons responsible
for supervising the work must comply strictly with the following warnings.
/ Wherever possible, ensure that the work is carried out with the tyre inside a tyre inflation safety cage.
/ While inflating, workers and bystanders must always be outside the range of the “hazardous trajectory”.
Exercise extreme caution as the trajectory may widen.
/ During inflation, use an air pressure gauge and regulator valve.
/ To ensure that the worker inflating the tyre can remain outside of the "hazardous trajectory", use an air
pressure gauge and a hose of adequate length, and use an air chuck.
/ During inflation, DO NOT allow the air pressure to exceed the pressure recommended by tyre
manufacturer.
/ If you notice a mistake in the assembly, immediately stop inflation, release the air, and reassemble the
tyre and rim components.
/NEVER attempt to position the rim components by inflating the tyre.
/Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/When moving rim components, be careful to avoid accidental drops or falls that could injure you or others in the
vicinity.
/Lay the assembled and inflated tyre rim so it is flat and stable and not subject to impacts.
Notice
In order to prevent corrosion of the rim components, inflate tyres with dry air.
(2008.08)
35
8.3 How to demount tyre from TOPY 5-piece rim
[Required tools]
•Valve tool •Wire for valve cleaning
•Tyre lever for tyre mount/demount (confirm specifications of tool type with your tyre dealer)
•Lifting equipment (crane, chains, nylon sling, forklift, tyre handler, etc.)
•Hydraulic bead breaker
STEP
1
Release all air
D Prior to demounting tyre from rim, release all air by removing the valve core housing with the valve tool.
Valve core housing
Valve
Valve tool
Warning
/ 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.
/If 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
base accessories (extension valve fixing brackets, etc.) and rim base to the vehicle and release all air from the
tyre.
/When demounting outer tyres and rims of dual assemblies, make sure you release all air from the inner
tyres as well.
/Tyres should be deflated outside the range of the “hazardous trajectory” shown by the arrow in the
diagram below. Exercise extreme caution as the range of the trajectory may widen.
/During deflation work, DO NOT allow other workers or third parties to approach the area of the trajectory.
/When releasing air, stand in a safe location as foreign matter or frozen particles inside tyre might be
discharged.
/ Do not allow high pressure air to hit skin.
Hazardous
trajectory
Hazardous
trajectory
36
(2008.08)
8.3 How to demount tyre from TOPY 5-piece rim
STEP
2
Set up tyre and rim
D After fully releasing the air, place the
tyre and rim on the ground with the
gutter side facing up.
Gutter
UP
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
STEP
3
Unseat the tyre bead from the bead seat band
D Mount bead breaker on bead seat band.
J Operate the bead breaker, push down the side ring, and
unseat the tyre bead from the bead seat band.
Caution
/ Be careful not to get your fingers caught.
/ When loading using the bead breaker, stand to one side and carry out the work carefully as the bead
breaker could fly off.
/ DO NOT apply tools to welded areas of the bead seat band, side ring, or rim base. If welds are damaged,
discard the component.
/ When handling the bead breaker, refer to the instructions provided by the manufacturer.
(2008.08)
37
8.3 How to demount tyre from TOPY 5-piece rim
STEP
4
Remove driver key
D For rims fitted with a driver key, remove the driver key.
Caution
/ Be careful not to get your fingers caught.
STEP
5
Remove lock ring
D Use a tyre lever to force the bead seat band free from the
locking ring.
J Use the tyre lever to leave out one end of the locking ring
from the locking groove.
8With 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.
Never Reuse
REUSE
Ends are open
Warning
/ Discard lock rings with open ends (ends aren't touching) as they will not set correctly (see above) and
could result in serious injury or death.
/ When removing the lock ring, DO NOT spread the ends excessively as they will no longer touch and will
have to be discarded.
/ Keep fingers away from lock ring.
/ Be careful when removing the lock ring as it may literally fly off as it is being freed.
/ Maintain a firm grip on the lever tools as they may jerk loose and cause injury.
38
(2008.08)
8.3 How to demount tyre from TOPY 5-piece rim
STEP
6
Remove O-ring
D Use the tyre lever to push down on the bead seat band so
that the O-ring is freed.
J Remove O-ring.
Warning
/ Be careful not to get your fingers caught.
/ When mounting and demounting tyres, maintain a firm grip on the tyre lever as they may jerk loose and
cause injury.
Notice
Once used, O-rings become deformed and can result in air leaks. Used O-rings should be cut and discarded.
STEP
7
Remove bead seat band
D Use lifting equipment to raise and remove the bead seat
band.
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
(2008.08)
39
8.3 How to demount tyre from TOPY 5-piece rim
STEP
8
Remove side ring
D Use lifting equipment to remove the side ring.
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
STEP
9
Turn over tyre and rim
D Use lifting equipment to turn over the tyre and rim, and
place them on the ground.
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
40
(2008.08)
8.3 How to demount tyre from TOPY 5-piece rim
STEP
10 Unseat the tyre bead from the rim base
D Mount bead breaker on rim base.
J As in Step 3, operate the bead breaker, push down the
side ring, and unset the tyre bead from the bead seat
band.
Caution
/ Be careful not to get your fingers caught.
/ When loading using the bead breaker, stand to one side and carry out the work carefully as the bead
breaker could fly off.
/ DO NOT apply tools to welded areas of the bead seat band, side ring, or rim base. If welds are damaged,
discard the component.
/ When handling the bead breaker, refer to the instruction provided by the manufacturer.
STEP
11 Remove rim base
D Use the lifting equipment to remove the rim base.
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
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41
8.3 How to demount tyre from TOPY 5-piece rim
STEP
12 Remove side ring
D Use the lifting equipment to remove the side ring.
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving tyres and rims, be careful to avoid accidental drops or falls that could injure you or others
in the vicinity.
42
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8.4 How to mount tyre onto TOPY 5-piece rim
[Required tools]
•Valve tool •Wire for cleaning valve core •Tyre seating blocks
•Tyre lever for tyre mount/demount (confirm specifications of tool type with your tyre dealer)
•Soft metal or hard plastic hammer (Not steel)
•Lifting equipment (crane, chains, nylon sling, forklift, tyre handler, etc.)
•Lubricant for tyre mounting (product recommended by tyre dealer)
•Wire brush •Air gauge •Air chuck
STEP
1
Confirm tyre and rim component assembly
D Check tyre size and markings on rim base, and make sure that the combination is correct.
J Check markings on rim components and matching charts, and make sure that the combination is correct.
Warning
/ Confirm tyre and rim combinations with your tyre dealer or confirm using the specifications for tyres and
rims.
/Check the rim component markings and confirm that the combination of rim components is correct using
the matching charts. The wrong combination could cause “explosive separation of the rim” resulting in
severe injury or death to workers and bystanders.
/ DO NOT combine TOPY rim components with rim components manufactured by other companies.
/ If there are any doubts concerning combinations or matching charts, immediately suspend the work in
progress and contact your TOPY rim dealer.
STEP
2
Clean rim components and check condition
D Clean rim components with a wire brush so that
examination, maintenance, and mounting can be done
correctly.
J Check that there is no deformation, bent, cracking, wear,
corrosion, or damage on the rim components.
Warning
/ Discard any rim components that are deformed, bent, cracked, corroded, weared or damaged, or are
suspected of being so, and replace them with undamaged components.
/ Discard any lock rings with open ends (ends aren't touching).
/ DO NOT make modifications that change the product specifications.
/DO NOT make modifications involving welding, heating, soldering, etc. Such modifications could lead to the
deformation as well as the deterioration of the strength and structural integrity of the rim components.
Notice
If there's any foreign matter, etc. adhering to the lock ring grooves on the rim base or to O-ring grooves, proper
assembly will not be possible and air leaks will occur. Make sure all grooves are clean before assembly.
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43
8.4 How to mount tyre onto TOPY 5-piece rim
STEP
3
Recoat
DRecoat any areas where the anti-corrosive oil or paint is peeling.
Caution
/ Anti-corrosive oil and paint may contain toxic ingredients. Follow any safety instructions provided by the
manufacturers of the anti-corrosive oil or paint.
/ Depending on the vehicle, some parts have certain areas that may be uncoated in order to prevent
loosening of parts attaching the rim base to the vehicle (clamps, nuts, etc.) and slipping of rim
components, etc. If you're not sure, check with the vehicle manufacturer or your TOPY rim dealer.
STEP
4
Set up rim base and install side ring
DPlace rim base on rim base stand with gutter side up.
JInstall the side ring.
Warning
/ Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/ When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
STEP
5
Install valve
DInstall valve.
Warning
/For valve selection and installation, follow instructions in the manuals provided by your tyre dealer and
valve manufacturer. If in doubt, contact the dealer or manufacturer for guidance.
44
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8.4 How to mount tyre onto TOPY 5-piece rim
STEP
6
Confirm absence of tyre defects
DConfirm absence of tyre defects.
Warning
/Check with tyre dealer to confirm that there are no tyre defects. Using defective tyres could result in tyre
failure while you are mounting the tyre and rim or during use, resulting in tyre separation and possible
severe injury or death.
STEP
7
Mount tyre on rim base
D Apply a vegetable oil-based lubricant to both tyre bead
seats.
J Place tyre on rim base, and assemble.
Notice
/DO NOT apply tyre lubricant to areas other than where the rim components come in contact with the tyre.
Doing so could cause circumferential slippage between rim components when the vehicle is being driven.
/Consult your tyre dealer when selecting tyre lubricant.
Warning
/Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
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45
8.4 How to mount tyre onto TOPY 5-piece rim
STEP
8
Fit side ring
D Fit the side ring.
Warning
/Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
46
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8.4 How to mount tyre onto TOPY 5-piece rim
STEP
9
Install bead seat band
D Insert bead seat band into side ring and rim base.
J 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 (tyre handler,
crane, press machine, etc.), when necessary.
Warning
/Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
/If a mallet is used to aid in pressing down on the bead seat band, make sure you use soft metal or hard
plastic hammer.
/DO NOT use a steel mallet.
/Insert the bead seat band carefully. Failure to keep the bead seat band horizontal during insertion will
damage the inner surface.
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47
8.4 How to mount tyre onto TOPY 5-piece rim
STEP
10 Fit O-ring
D Apply lubricant to new O-ring and install it in the O-ring
groove.
Caution
/ Be careful not to get your fingers caught.
Notice
/ Check with your tyre dealer for O-ring specifications or when selecting lubricant.
/ Be careful not to twist the O-ring.
48
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8.4 How to mount tyre onto TOPY 5-piece rim
STEP
11 Fit lock ring
D 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.
J 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.
Never Use
USE
Ends are open
Warning
/DO NOT use lock rings with open ends (ends aren't touching).
/Check the facing of the lock ring. The lock ring is installed correctly if its markings are visible after tyre
assembly.
/DO NOT use a steel mallet.
Caution
/ Be careful when handling the lock ring as it may fly off.
/ Be careful not to get your fingers caught.
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49
8.4 How to mount tyre onto TOPY 5-piece rim
STEP
12 Install driver key
D For rims set with a driver key, install the driver key.
Caution
/ Be careful not to get your fingers caught.
STEP
13 Confirm that rim components are assembled correctly
D Make sure that the combinations (matching), facings, and positions of rim components are
correct.
Warning
/Recheck the tyre and rim component combinations (matching) and make sure they are correct.
/Recheck the facing of the lock ring and make sure it is installed correctly and is securely in the lock ring
groove.
/DO NOT inflate, hammer, weld or solder to position the rim components. Doing so can lead to the
deformation as well as the deterioration of the strength and structural integrity of the rim components.
50
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8.4 How to mount tyre onto TOPY 5-piece rim
STEP
14 Inflating the tyre and rim
DWherever possible, place the tyre and rim
inside a tyre inflation safety cage, then inflate
tyre. During inflation, keep away from the tyre.
Tyre inflation safety cage
JWhen tyre has been inflated to a pressure of
approximately 35kPa (5psi), check assembly
of tyre and rim components.
8If assembled correctly, continue inflating up
to the rated value.
Warning
If assembly has been done incorrectly, inflation could result in an explosive separation of the rim. This
separation could result in serious injury or death to you or bystanders.
Workers and persons responsible for supervising the work must comply strictly with the following
warnings.
/ Wherever possible, ensure that the work is carried out with the tyre inside a tyre inflation safety cage.
/ While inflating, workers and bystanders must always be outside the range of the “hazardous trajectory”.
Exercise extreme caution as the trajectory may widen.
/ During inflation, use an air pressure gauge and regulator valve.
/ To ensure that the worker inflating the tyre can remain outside of the "hazardous trajectory", use an air
pressure gauge and a hose of adequate length, and use an air chuck.
/ During inflation, DO NOT allow the air pressure to exceed the pressure recommended by your tyre
manufacturer.
/ If you notice a mistake in the assembly, immediately stop inflation, release the air, and reassemble the
tyre and rim components.
/NEVER attempt to position the rim components by inflating the tyre.
/Because this work involves handling heavy items, correctly use lifting equipment when necessary.
/When moving rim components, be careful to avoid accidental drops or falls that could injure you or
others in the vicinity.
/Lay the assembled and inflated tyre rim so it is flat and stable and not subject to impacts.
Notice
In order to prevent corrosion of the rim components, inflate tyres with dry air.
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51
8.5 Checkpoint of servicing tyres and rims when rim remains installed on vehicle
If servicing tyre and rim when the rim remains installed on the vehicle, be sure to comply
strictly with the following points.
POINT
1
Release all air from the tyre
Valve core housing
Valve
Valve tool
Warning
/ Ensure that the power is off and vehicle is blocked so it can't move.
/ When jacking up the vehicle during tyre and rim servicing work, carefully read the vehicle manufacturer's
instruction manual and make sure that all protective measures are in place to prevent the vehicle or jack
from moving.
/ 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.
/If 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.
/ Before removing rim base accessories (extension valve fixing brackets, etc.), remove all air from the tyre.
/ When removing the outer tyre and rim of dual assemblies, also fully release the air from the inner tyre.
/ Tyres should be deflated outside the range of the “hazardous trajectory” shown by the arrow in the
diagram below. Exercise extreme caution as the range of the trajectory may widen.
/ During deflation work, DO NOT allow other workers or third parties to approach the area of the trajectory.
/ When releasing air, stand in a safe location as foreign matter or frozen particles inside type might be
discharged.
/ Do not allow high pressure air stream to hit skin.
Hazardous
trajectory
52
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8.5 Checkpoint of servicing tyres and rims when rim remains installed on vehicle
POINT
2
Mount bead breaker securely
Warning
/ When the bead breaker is to be pressed against part of the vehicle, follow the instructions and manual
published by the vehicle manufacturer for the pressing location, and mount the bead breaker as
instructed. Damage to vehicle components and the bead breaker falling due to coming loose can be
extremely dangerous.
POINT
3
Protection against explosive separation of tyre and rim components
Warning
/ Always work outside the range of the “hazardous trajectory” shown in the diagram below. Exercise
extreme caution as the range of the trajectory may widen.
/ During work, DO NOT allow other workers or third parties to approach the area near the hazardous
trajectory.
/ “Explosive separation of the rim” could cause severe injury, not just to workers but also to bystanders in
the vicinity.
/ When servicing tyres still on the vehicle, take protective measures against the hazardous trajectory, such
as using the crane arm or tyre handler.
Hazardous
trajectory
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53
9. Maintenance
Comply with the warnings and precautions given here, in order to fully utilize the performance
of tyres and rims when used with industrial and construction vehicles, and to prevent
accidents during maintenance, servicing, and operation.
Warning
/ Maintenance work should be carried out only by workers who have received adequate training from a
qualified supervisor on safe handling of tyres and rims.
/ During maintenance work, DO NOT allow other workers or third parties to approach the area near the
hazardous trajectory.
/ Check the “Tyre and Rim Handling Manual” published by the tyre manufacturer for information on work
and inspections, etc. involving tyre handling.
/ Be sure you have a proper understanding of how the tools are used and carry out the work in accordance
with the proper procedure.
/ Ensure that protective equipment is worn during maintenance work. (Wear gloves, safety shoes, safety
glasses, face protection, earplugs, hard hat, etc.)
/ Refer to “8. Procedures for tyre and rim servicing” of this manual for performing servicing and
maintenance work on tyres and rims.
/ When performing maintenance with the tyre and rim installed on a vehicle, ensure that the power is off
and vehicle is blocked so it can't move during maintenance.
/ When jacking up the vehicle during tyre and rim servicing work, etc., carefully read the vehicle
manufacturer's instruction manual and make sure that all protective measures are in place to prevent
the vehicle or jack from moving.
/ Record rim maintenance history because it is a vital reference in safe application.
54
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9.1 Regular inspection checkpoints
The following is an explanation of regular inspections performed with the tyre mounted on the
rim.
Warning
/ During tyre inspections, check that there is no cracking, wear, or deformation etc. on the rim components.
Conduct a thorough inspection of the gutter section and back flange section, indicated by the red circle in
the diagram below. The diagram below also shows check points for "9.2 inspections when servicing tyres
and rims".
/Conduct daily inspections in order to maintain the performance and the safety of tyres and rims.
/ When servicing tyres, make sure that inspections are performed in accordance with “9.2 Inspections
when servicing tyres and rims”.
Notice
Before starting maintenance work, it is recommended that tyre pressure records are updated to ensure early
detection of air leaks which may be caused by cracks in rim components.
Crack
Friction,
Deformation
Deformation
Friction
Friction
Crack
Deformation
Corrosion
Friction,
Deformation
Crack
Crack
Crack
Friction,
Deformation
Deformation
Friction
Corrosion
Crack
Crack
Crack
Deformation
Friction,
Deformation
Crack
Crack
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55
9.2 Inspections when servicing tyres and rims
9.2.1 Ensuring safety when servicing tyres and rims
Warning
/ For safety precautions that should be followed when servicing tyres and rims, comply with “8.
Procedures for servicing tyres and TOPY rims”.
9.2.2 Cleaning prior to inspection
Cleaning rim components using a wire brush makes examination and tyre installation easier.
Pay particular attention to cleaning the O-ring grooves and lock ring grooves on the gutter.
56
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9.2 inspections when servicing tyres and rims
9.2.3 Inspection
Perform inspections based on the check methods and checkpoints presented in the tables that
follow.
Warning
/ Perform inspections based on the check methods and checkpoints in the tables below.
/ For tyre inspections, check the “Tyre and Rim Handling Manual”, published by the tyre manufacturer.
Rim base inspections
Base R part (including 3-piece rim)
Tyre side outer
surface
Contact zone with side ring
Contact zone with tyre bead
Rim circumference
weld zone
Rim
circumference
weld zone
Lock ring
groove
O-ring
groove
Weld zone for
accessories
Disc weld zone
Valve hole
Disc bolt hole
Inspected part
Check method
Cracking
Wear
Checkpoint
Deformation/
Ellipse
Corrosion
Surface
roughness
+
Visual inspection
+
+
Non-destructive inspection
+
Visual inspection
+
+
+
+
Lock ring groove
Non-destructive inspection
+
+
+
+
+
Contact zone with side Visual inspection
ring
Non-destructive inspection
+
Visual inspection
+
+
+
+
Base R part
Non-destructive inspection
+
Visual inspection
+
Rim circumference
weld zone
Non-destructive inspection
+
Visual inspection
+
+
Valve hole
Non-destructive inspection
Visual inspection
+
Disc weld zone
Non-destructive inspection
+
Visual inspection
+
+
+
Disc bolt holes
Non-destructive inspection
+
+
Contact zone with tyre Visual inspection
bead
Non-destructive inspection
Visual inspection
+
Tire side outer surface
Non-destructive inspection
Visual inspection
+
Weld zone for
accessories
Non-destructive inspection
Note: Non-destructive inspections include magnetic particle inspections, ultrasonic inspections,
and dye penetrant inspections, etc.
* Always verify the actual product for the weld zones of rim components as they vary by type.
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O-ring groove
57
9.2 Inspections when servicing tyres and rims
Lock ring inspections
For 3-piece rims
For 5-piece rims
Contact zone with side ring
Contact zone with
bead seat band
Contact zone with gutter section
Inspected part
Check method
Cracking
Contact zone with gutter section
Wear
Checkpoint
Deformation/
Ellipse/
Spread Edges
Corrosion
Surface
roughness
Visual inspection
+
+
+
Non-destructive inspection
Visual inspection
+
+
+
+
Contact zone with gutter of
rim base
Non-destructive inspection
Visual inspection
+
Overall form
Non-destructive inspection
Note: Non-destructive inspections include magnetic particle inspections, ultrasonic inspections,
and dye penetrant inspections, etc.
Contact zone with bead seat
band or side ring
58
(2008.08)
9.2 Inspections when servicing tyres and rims
Bead seat band inspections
Contact zone
with side ring
Contact zone
with tire bead
Weld zone for
accessories
Base R part
Inner and
outer surface
Contact zone with lock ring
Inspected part
Check method
Cracking
Wear
Checkpoint
Deformation/
Ellipse
Corrosion
Surface
roughness
+
Visual inspection
+
+
+
Non-destructive inspection
+
+
+
+
+
Contact zone with side Visual inspection
ring
Non-destructive inspection
+
+
+
+
Contact zone with lock Visual inspection
ring
Non-destructive inspection
+
+
Contact zone with tyre Visual inspection
bead
Non-destructive inspection
Visual inspection
+
Inner and outer
surface
Non-destructive inspection
Visual inspection
+
Overall form
Non-destructive inspection
Visual inspection
+
Weld zone for
accessories
Non-destructive inspection
Note: Non-destructive inspections include magnetic particle inspections, ultrasonic inspections,
and dye penetrant inspections, etc.
* Always verify the actual product for the weld zones of rim components and accessories as they
vary by type.
Base R part
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59
9.3 Inspections when servicing tyre
9.2
tiresand
andrims
rims
Side ring inspections
For 5-piece rims
For 3-piece rims
Contact zone with tire
Contact zone with tire
Base R part
Inner and
outer surface
Contact zone with rim base
Inspected part
Contact zone with bead seat band
Check method
Cracking
Wear
Checkpoint
Deformation/
Ellipse
Corrosion
Surface
roughness
+
Visual inspection
+
+
Non-destructive inspection
+
+
+
+
Contact zone with bead seat Visual inspection
band (for 5-piece rims)
Non-destructive inspection
+
Visual inspection
+
+
+
+
Base R part
(for 3-piece rims)
Non-destructive inspection
+
Visual inspection
+
Inner and outer surface
(for 3-piece rims)
Non-destructive inspection
Visual inspection
+
+
Contact zone with tyre
Non-destructive inspection
Visual inspection
+
Overall form
Non-destructive inspection
Note: Non-destructive inspections include magnetic particle inspections, ultrasonic inspections,
and dye penetrant inspections, etc.
Contact zone with rim base
(for 5-piece rims)
60
(2008.08)
9.3 Action as a result of inspection
9.3
After inspection
If any problems are found as a result of inspection, take appropriate measures to correct them.
Warning
/Any rim components with cracks or wear/damage/deformation/corrosion judged to be unusable, should
be clearly labeled to indicate their condition and disposed.
/Lock rings with open ends (ends aren't touching) will not set correctly. Clearly label such rings to
indicate they are unusable and dispose them.
/For installation and removal of rim drivers, valve guards, etc. or to perform other repairs, obtain approval
from your TOPY rim dealer and be sure to remove the tyre before carrying out any work.
Caution
/Recoat parts where anti-corrosive oil or paint is peeling off.
/ Anti-corrosive oil and paint may contain toxic ingredients. Follow the instructions provided by the
manufacturers of the anti-corrosive oil or paint.
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61
TOPY INDUSTRIES, LIMITED
WHEEL DIVISION, GENERAL SALES DEPT.
CONSTRUCTION & INDUSTRIAL EQUIPMENT
WHEEL SALES DEPT.
2-3-1 Ogami, Ayase, Kanagawa 252-1104
Phone: 0467(78)9611 Fax: 0467(78)9609
E-mail: rims@topy.co.jp
TOPY AMERICA, INC.
OTR DIVISION
1200 Mark Street, Elk Grove Village, IL 60007 U.S.A.
Phone: 1-847-439-4420 Fax: 1-847-439-4476
E-mail: sales@topywheels.com
WESTERN SALES OFFICE
1096 N. Redwood Rd. North Salt Lake, UT 84054 U.S.A.
Phone: 1-801-292-6620 Fax: 1-801-292-7189
E-mail: sales@topywheels.com
Issued in Sep. 2008. 4,000
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