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TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067

EMESRT CATEGORY:

Risk of wheel nuts falling off due to the failure to retorque some time after fitment
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TYREgate Reference:35

Site Answers & Comments:

Reuse of damaged rim components


Root & Contributing Causes:
q

LTA fitment ? insufficient cleaning of mating surfaces.

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:


Manufacturers of multi-piece rims list a number of important procedures. Do not use a hammer or any other object to force rim components in place. Do not attempt to take rim components apart on inflated tyres. Always use a clip on chuck that permits a person to stand clear of the potential path of rim components when inflating tyres on these rims. Always deflate the tyre before removing a wheel from an axle and before removing the tyre from the rim, by removing the valve core. Do not rework or reuse damaged rim components. A rubber type lubricant must be applied to the tyre bead and the contact surfaces of the rim during assembly of wheel and inflation of the tyre. Wherever possible tyres must be inside a cage during inflation. If this is not possible all personnel must stand well clear of the tyre and rim components during the inflation. Do not rest or lean any part of your body or any equipment against the cage during the inflation process. Do not inflate a tyre above 35 kpa whilst it is outside of a cage, unless the area can be isolated. Always inspect the tyre after it has been inflated whilst it is still in the cage to ensure all components are correctly fitted. In addition to these recommended procedures it was recognized that "Sur-Loc" bands which are welded to bead seat bands on some of the multi-piece rim assemblies can cause obstruction to proper visual inspection of the fitment of lock-rings. If the "Sur-Loc" bands have been hammered, the resultant burring and/or deformation can interfere with the fitting of the lock-ring and can move the lock-ring out of the correct position during tyre inflation. Recommendations are also made about the use of special tools to check the profile of lock-ring grooves and lock rings to avoid incidents of this type.
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TYREgate Reference:63

Site Answers & Comments:

Not following established procedures, and using low/wrong torque setting on assembly
Root & Contributing Causes:
q

Inadequate torque

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:


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Only trained and competent personnel are permitted to carry out re-torques. Safe and correct wheel stud/nut torque can only be achieved using purpose designed torque tools, manual or hydraulic. Rattle guns must only be used to tighten the wheel studs/nuts and must not solely be relied on to torque up wheel suds/nuts. Ensure that torque tools are able to deliver the required OEM specified torque, are
15 Mar 2013 Page 1

Disclaimer: The recommendations provided are suggestions only and may not be applicable for the specific situation at site and must be verified using a site specific risk assessment. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations.

TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067

inspected, fit for purpose and fully serviceable before the job commences. The torque tool, manual or hydraulic, must be 'in calibration' and the calibration certificate must be readily available. Note: The work must not proceed if the torque gun is 'out of calibration' - this can be verified by checking its last calibration date, this must be less than 12 months old. All wheel / rim / hub mating surfaces must be thoroughly cleaned and inspected before fitment as per SWP. All wheel studs, Nuts, Cleats etc. are to be inspected individually for damage, corrosion and damage, and be cleaned as per SWP. Damaged/stretched or corroded wheel studs/nuts are to be replaced. Stud holes are to inspected also for ovality or other damage. For hydraulic torque multiplier tools, the air regulator chart must be current, and available at the tyre bay so that the serviceman can correctly set the tool to deliver the OEM required torque, failure to consult with the chart will result in the wheel not being torqued to the correct setting and cause the wheel to become loose in service. Note: Do not proceed unless the chart had been checked and the correct setting has been established. Charts are not interchangeable, and each tool must have its unique chart (refer to serial number of gun) available in the tyrebay. Where required by the OEM, ensure the correct lubricant type and amount is applied to the stud/nut, and never over tighten a wheel stud/nut beyond its OEM specified torque. Failure to abide by these simple steps will not only cause a hazardous condition, putting people and equipment at risk, but may also result in disciplinary action including dismissal.

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TYREgate Reference:69

Site Answers & Comments:

Vehicle was not returned for retorque (as per procedure which caused wheel to become loose and come off during service
Root & Contributing Causes:
q

LTA procedure

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:


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After any wheel assembly has been refitted which requires the attachment system to be retorqued, an information, retorque or mine site specific tag is to be attached by the tyre serviceman in a visible location to the inside of the vehicle cabin (eg. retarder lever). As the vehicle is handed back to production, or the vehicle remains down for further mechanical maintenance, Dispatch and or Operations Supervision is to be notified to raise a retorque alert on the mines dispatch system and or to remind the operator about the vehicles retorque requirements. These actions will alert both the operator and dispatch that a retorque is due should the tag accidentally be overlooked. Tyre service personnel are to maintain up-to-date records of outstanding retorques each shift, and action any outstanding retentions. After a vehicle has been retorqued, the tag is to be signed by the tyre serviceman, stapled to the tyre change documentation and be securely filed. Communication with Operations personnel: all personnel are to be made aware of the importance of wheel retentions and potential risks if retentions are not carried out.

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Disclaimer: The recommendations provided are suggestions only and may not be applicable for the specific situation at site and must be verified using a site specific risk assessment. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations.

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TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067

TYREgate Reference:71

Site Answers & Comments:

Movement of vehicle le partly disassembled


Root & Contributing Causes:
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LTA procedure LTA communication between work teams.

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:


q

When a number of work teams work on the same vehicle, ensure there is clear communication and a common understanding of the job and its impacts before a job is commenced , i.e. a task carried out by one party must not create an adverse situation for the other party. Before a truck can be relocated with Pos 3 and 6 assemblies removed, ensure that at least 20 wheel studs are fitted evenly around the hub to the outside positions - this action is to be adopted for all CAT 785, 789,793 & 797 trucks. Check relevant SWPs and OEM documentation if this precaution also applies to other trucks and type of equipment.

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TYREgate Reference:16

Site Answers & Comments:

Accidental contact with high voltage line


Root & Contributing Causes:
q

Contact with Powerline

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:


Remain clear of all fallen power lines. Isolate supply and alert fire crew. The driver of any vehicle in contact with a power line should remain in the vehicle and summon assistance. If assistance is unavailable, driver should attempt to free vehicle by driving away. Vehicle should be driven into a clear area where it can be left and driver evacuated. Driver rescue may be effected using a similar vehicle which should approach from the front to allow the driver to step across. Vehicle should not be approached within 300 m and 24 hrs Deflation of tyres should not be attempted. Following 24 hours stand down period, all tyres require internal inspection. Avoid erection of powerlines in mobile equipment operating areas. Ensure clearance and height indicators requirements as required by AS3000.7.5. Install tray raised alarms and or interlocks which restrict vehicle movement if a tray is not fully lowered Tyres correctly filled with Nitrogen will minimize risk of explosion. Strict controls and standards are essential for this to be effective. Mobile equipment personnel need to be aware of the hazards associated with powerline contacts and their duties and responsibilities should such occur.
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Disclaimer: The recommendations provided are suggestions only and may not be applicable for the specific situation at site and must be verified using a site specific risk assessment. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations.

15 Mar 2013 Page 3