MINING AND

EARTHMOVER
WHEELS
 PRODUCTS & SERVICES
I UNDERGROUND & SURFACE MINING
WHEELS FROM 10” TO 63”

II REPAIRS OF UNDERGROUND &

SURFACE MINING WHEELS FROM
15” TO 63”

IIIINSPECTION & CERTIFICATION

PROGRAMS FOR UNDERGROUND &
OPEN PIT MINING WHEELS FROM 15”
TO 63”
 SECTION I
UNDERGROUND & SURFACE
MINING WHEELS
z OTR WHEEL OFFERS A WIDE
VARIETY OF MINING WHEELS
FROM 15” TO 63” IN STANDARD
AND HEAVY DUTY DESIGNS FOR
ANY MINING APPLICATION

z WE ALSO OFFER CUSTOM

DESIGNED WHEELS FOR SPECIFIC
CUSTOMER REQUIREMENTS
 PRODUCT LINE

z HEAVY DUTY UNDERGROUND

MINING WHEELS

z GFM HEAVY DUTY LARGE

DIAMETER MINING WHEELS

z GFM QUICK CHANGE HAUL TRUCK

RIMS AND WHEELS
HEAVY DUTY UNDERGROUND
MINING WHEELS
OTR’s Heavy Duty Underground Mining (UGM) Wheels
Are Manufactured From Seamless Forged & Fully
Machined Sections To Ensure Maximum Performance
And Fatigue Life.
 HEAVY DUTY UNDERGROUND
MINING WHEELS
•Available In 10”,15”, 20” And 24” Diameters
•Standard Lock Ring Or Tapered Lock Ring Designs Available
•Wheels Can Be Customized To Fit Any Application
 GFM HEAVY DUTY LARGE
DIAMETER MINING WHEELS
Our GFM Large Diameter Surface Mining Wheels Are
Available In Up To 63” Diameter And Are Manufactured
From Fully Machined Forged HSLA Steel To Ensure
Maximum Fatigue Life And Are Backed By Our 20,000
Standard Warranty.
GFM Wheels Are Available In The Following Designs
•GFME - 100% COMPATIBLE WITH TITAN, RIMEX MES, AND TOPY EU

•GFMT - 100% COMPATIBLE WITH RIMEX TSR DESIGN

•GFMW - 100% COMPATIBLE WITH TOPY 63” WTR (Wedge Type) DESIGN
GFME STANDARD DESIGN

z FORGED AND FULLY MACHINED SECTIONS

MADE FORM HSLA STEEL
z 100% COMPATIBLE WITH STANDARD DESIGNS
IN THE MARKET TODAY FROM OTHER
MANUFACTURERS
z 100% UT TESTING ON CIRCUMFERENCIAL
WELDS
z STANDARD 20,000 HOUR WARRANTY
 GFME QUICK CHANGE
DESIGN

z FORGED AND FULLY MACHINED SECTIONS

MADE FORM HSLA STEEL
z DESIGNED TO BE 100% COMPATIBLE WITH
STANDARD DESIGNS IN THE MARKET TODAY
FROM OTHER MANUFACTURERS
z 100% UT TESTING ON CIRCUMFERENCIAL
WELDS
z STANDARD 20,000 HOUR WARRANTY
 GFME QUICK CHANGE
DESIGN
BENEFITS OF OUR GFME QUICK CHANGE DESIGN

z REDUCE TIRE CHANGE AND ROTATION TIMES BY UP

TO 60%
z ELIMINATES THE NEED TO DEMOUNT THE OUTSIDE
DUAL WHEEL TO CHANGE INSIDE TIRE
z DECREASES DOWNTIME AND INCREASES
PRODUCTIVITY FOR HAUL TRUCKS
z ELIMINATES THE NEED TO USE ADAPTER RINGS ON
OUTSIDE DUAL WHEELS
z FULLY COMPATIBLE WITH STANDARD WHEEL
COMPONENTS
 GFME QUICK CHANGE DESIGN
The data below is based on changing tires (rotating) off of positions 3 & 4 on a Cat 793C dump
truck in Northern Chile. The table below shows a comparison between a standard horizontal tire
change process versus a vertical tire change process using OTR QUICK CHANGE WHEELS.

Avg. Minutes using standard 5 piece Avg. Minutes using OTR GFM Quick
Task
wheels Change wheels
JACKING 10 10
DEFLATE INSIDE & OUTSIDE TIRES 20 20
REMOVE NUTS - OUTER WHEEL 15 0
REMOVE OUTSIDE TIRE & WHEEL 5 5
REMOVE INSIDE TIRE 5 5
CLEAN & INSPECT HUBS 5 5
INSTALL INSIDE TIRE 5 5
INFLATE INSIDE TIRE 10 10
DEMOUNT & MOUNT OUTSIDE TIRE ON WHEEL 10 0
INSTALL OUTSIDE WHEEL & TIRE ON HUB 5 5
INSTALL NUTS ONTO BOLTS 10 0
TIGHTEN NUTS WITH IMPACT GUN 10 0
INFLATE OUTSIDE TIRE 10 10
TORQUE NUTS 10 0
REMOVE JACKS 5 5
1ST RETORQUE 15 0
2ND RETORQUE 15 0

TOTAL TIME 165 minutes 80 minutes

GFME QUICK CHANGE DESIGN
Savings in Minutes when using GFM Quick
Change Wheels vs Standard Wheels

Total Time Using Standard 165

Wheels MINUTES
Total Time Using OTR GFM 80
Quick Change Wheels MINUTES
Time Savings In Minutes 85
MINUTES
Time Savings Percentage 52%
 GFMT TAPER DESIGN

z GFMT STYLE WHEEL COMPATIBLE WITH RIMEX

TSR
z SAFETY LIP INCORPORATED IN BACK SECTION
AND BEAD SEAT BAND.
z ALSO AVAILABLE IN QUICK CHANGE DESIGN
z 100% UT TESTING ON CIRCUMFERENCIAL
WELDS
z STANDARD 20,000 HOUR WARRANTY
 GFMW TAPER DESIGN

z GFMW 63” WHEELS FEATURE A TAPER LOCK

DESIGN TO ELIMINATE INDEXING OF THE
WHEEL COMPONENTS
z ALL GFMW WHEELS ARE 100% COMPATIBLE
WITH THE TOPY WTR (WEDGE TYPE) DESIGN.
z 100% UT TESTING ON CIRCUMFERENCIAL
WELDS
z STANDARD 20,000 HOUR WARRANTY
KOMATSU 930E 63” WHEELS
KOMATSU 930E 63” WHEELS
OUR 63” 930E2, 930E3 & 930E4 WHEELS
CURRENTLY RUNNING AT;
z Codelco Chuquicamata – Chile
z Codelco Radomiro Tomic – Chile
z BHP Escondida – Chile
z Minera Los Bronces – Chile
z Minera Pelambre - Chile
z Southern Peru Copper Cuajone Mine – Peru
z Southern Peru Copper Toquepala Mine – Peru
z Minera Collahuasi – Chile
z Freeport Mine – Indonesia
z Minera Gaby - Chile
 SECTION II

RIM AND WHEEL

REPAIRS
 RIM AND WHEEL REPAIRS

Why Repair Rims and Wheels?

z Mining Wheels are subject to harsh conditions and many

times fail long before reaching the usage life due in most
cases to poor work conditions and/or maintenance.
z Mining wheels that have failed before reaching there usage
life in one area or section of the rim/wheel and are in good
condition in the other areas are usually good candidates for
repair.
z By repairing the damaged section of the Rim/Wheel, the user
can save an average of 50% of the cost of a new Rim/Wheel
z By repairing, the overall cost per hour will also be reduced vs
buying a new Rim/Wheel
z In short, we can assist our customers in reducing overall
rim/wheel costs by as much as 50% as our company has
done throughout the world for over 20 years In Canada,
Chile, Peru, Brazil and South Africa.
 RIM AND WHEEL REPAIRS
Repair Process For Rims And Wheels At
OTR Wheel Engineering Inc.
1. On-Site Visual Inspection To Determine Eligibility Of
Rim/Wheel Or Parts For Repair.
2. In House Non Destructive Testing (NDT) Of Rim/Wheel Or
Part To Ensure Wheel Can Be Repaired.
3. Inspection And Evaluation Report Based On Internal
Inspection Criteria Sent To The Customer For Approval.
Report Includes Recommendations To Repair Or Scrap
Part.
4. Customer Rejects Repair Or Accepts By Sending Purchase
Order Or Work Order.
5. Rim/Wheel Is Repaired According To Our Internal Repair
Procedure And Internal Repair Manual
6. Repaired Rim/Wheel Goes To Quality Control To Ensure
All Specs Are Within Tolerance Of Original Specs.
7. Final QC & NDT Report Are Generated
RIM AND WHEEL REPAIRS
INSPECTION REPORT
 RIM AND WHEEL REPAIRS
INTERNAL INSPECTION CRITERIA FOR RIMS
AND WHEELS
RIMS AND WHEELS
ARE INSPECTED
USING OUR INTERNAL
INSPECTION CRITERIA
WHICH WE HAVE
DEVELOPED IN
CONJUCTION WITH
END USERS AND
OVER 20 YEARS OF
EXPERIENCE IN
REPAIRING RIMS AND
WHEELS.
 RIM AND WHEEL REPAIRS
RIM AND WHEEL INSPECTION MANUAL
 RIM AND WHEEL REPAIRS
NDT CERTIFICATE

ALL CRITICAL
AREAS ARE
INSPECTED USING
NON DESTRUCTIVE
MAGNETIC
PARTICLE TESTING
BY A CERTIFIED
TECHNICIAN IN OUR
QUALITY
DEPARTMENT
 RIM AND WHEEL REPAIRS
INTERNAL REPAIR PROCEDURE
REPAIRS OR RIMS AND
WHEELS ARE PERFORMED
ACCORDING TO OUR
INTERNAL DOCUMENTED
REPAIR PROCEDURE TO
ENSURE CONSISTENCY IN
OUR PROCESSES.
 RIM AND WHEEL REPAIRS
FINAL QUALITY CONTROL REPORT
ALL REPAIRED RIMS AND
WHEELS ARE INSPECTED
BEFORE AND AFTER THE
REPAIR PROCESS. OUR
FINAL QUALITY CONTROL
REPORT ENSURES
COMPLETE TRACEABILITY
AND THAT ALL CRITICAL
SPECS ARE WITHIN
TOLERANCE FOR EVERY
RIM OR WHEEL REPAIRED
BY OTR WHEEL
ENGINEERING INC.
 RIM AND WHEEL REPAIRS
FULLY MACHINED FORGED SECTIONS USED
FOR REPAIRS
OTR WHEEL USES FULLY
MACHINED FORGED
SECTIONS MADE FROM
HSLA STEEL FOR RIM
SECTION REPLACEMENT
(REPAIRS). THESE
SECTIONS AND
PROCESSES USED IN
REPAIRING WHEELS ARE
IDENTICAL TO THAT OF
NEW WHEEL
MANUFACTURING
RIM AND WHEEL REPAIRS
SUBMERGED ARC WELDING
ALL SECTIONS REPLACED ON RIMS
AND WHEELS ARE WELDED USING
SUBMERGED ARC WELDING
PROCEDURE AS USED IN THE
MANUFCTURING PROCESS FOR NEW
RIMS AND WHEELS
 SECTION III

WHEEL SAFETY,
MAINTENANCE AND
INSPECTION
HISTORY
z Heavy equipment over the years have been
scrapped or sold as surplus.
z Many useable parts or spares, such as
wheel assemblies remained in the inventory.
z Rim failures began to be noticed in 1990’s.
z Rims from the late 1960’s and 1970’s were
still in the inventory.
PLAN TO REDUCE RIM FAILURES

z Remove all rims manufactured prior to 1985,

immediately.
z Visually inspect all rims, before returning to
service.
z Identify all rims by manufacturer (design).
z Number and track all rims.
z Begin NDE testing and maintenance
program.
WHY TRACK AND MAINTAIN RIMS?

A 26.5 x 25 tire at 90 psi has

373,650 ft/lbs of stored energy. Which is
Equal to moving a 200 Lb man
1868 feet in one direction.
There is no such thing as a SMALL
ACCIDENT when it comes to Rim Failure!
 WHEEL I.D. LOCATION
•All rims are branded directly in line with the valve hole. On
rims that have the centre plate in the mid section of the wheel
the front brand # is stamped onto the inner part of the gutter
section. In the case that a rim has a centre plate flush to the
top the brand is directly stamped on the face of the plate.

Rim Brand
Valve Hole RimBrand

Valve Hole

RimBrand Cross Section of Rim

Front View of Rim

RESPONSIBILITIES – TIRE SHOP

•Inspect wheel and wheel components for any

defects
•Any rims without brand #’s automatically are sent
out for a complete inspection (if requested by
customer)
•No tire is to be mounted on a wheel that has not
been branded (if requested by customer)
•All wheels with brand #’s must be verified in the
Rim Tracking System ( Contact OTR Wheel) to see
if an annual inspection is required (if requested by
customer)
FIELD / TIRE SHOP INSPECTION

z Preliminary Inspection
– Visual inspection of rim assemblies should
be done every time it comes in to your shop
– All rim bases which have been dismounted
prior to their annual Nondestructive
Evaluation (NDE) inspection shall be visually
inspected for defects
 POINTS TO CONSIDER
z Hardware is considered as consumable
product.
z Hardware is defined as:
z Bead Seat Bands
z Rim Flanges
z Lock Rings.
z Hardware, which is suspected of having
defects or distortion, shall be discarded.
z All hardware shall be inspected by Field and
Tire Shop Personnel prior to its' reuse.
VISUAL RIM INSPECTION CRITERIA
z Gutter section
z Back section
z Puller nuts
z Stud holes
z Bolting plate weld
z Rim base welds
z General condition
z Rim Components
(lockring, flange
and beadseat)
z Run flat
z Check last NDE
 Lock Rings
Sprung / Stretched Good

Lock Ring - The lock ring shall be visually inspected for

wear, “sprung”, corrosion, flat spots, ovality and warping
misalignment (sprung).
 GUTTER INSPECTION

Go-No
Go gauge

Lock ring
groove

Lock ring grooves are inspected using a Go- No

go gauge for wear & damage
WORN LOCKRING GROOVE

Non-consistent lock ring groove

 BACK SECTION / BEAD SEAT
INSPECTION

Go – No Go gauges
Bead Seat Band - The bead seat band shall be visually
inspected for cracks, wear or corrosion in the area in contact
with the locking ring flange, rim base or any weld. A wire
brush may be used to clean the dirt prior to the use of the Go
No go gauge.
 WORN BACK SECTION

Worn out flange mating surface

LOCK RING GROOVE PROBLEMS

z Washed out lock ring

grooves Non Pressure
z Stress fatigue Pressure Zone –
fractures Zone Extreme
z Caused by: Danger
– Friction welding
(Fretting, Galling)
– Aggregate
– Corrosion
z Great reasons for
doing a safety
inspection of the rim
 RIM COMPONENTS
Proper Improper

OTR can provide charts to match rim components to ensure the

proper hardware is put on to the right rim base.
 HARDWARE
Worn Side ring Good Side Ring
Worn Side ring Good Side Ring

When conducting a visual inspection, do not only look for cracks and
damage But also inspect the hardware to make sure you will achieve
optimal tire performance.
 BOLT HOLES

Elongated

Elongated or worn bolt holes can lead to improper torque,

which in turn can lead to the wheel coming off of the machine.
This can be repaired by re-facing or re-placing the center plate.
DAMAGED GUTTER SECTION
RUN FLAT
RESPONSIBILITIES – OTR WHEEL

•Visually inspect all wheels and wheel components

•Track rims with database
•Issue a report for each individual wheel
•MPI test wheels when needed (annually or when
damaged)
•Repair or replace any wheel or wheel component
when needed
 25”X15 WHEEL FAILURE

When this wheel failed it killed 1 mechanic and seriously injured

the second. The crack on this wheel was in the lock ring groove
above the pressure zone.
 TIRE SIZE 17.50X25

This tire was aired with the lock ring not seated properly and
when the lock ring let go there was enough force in this tire
that it pulled the axle out of the housing.
 TIRE SIZE 10.00X15

Tire flew 50 ft from the machine when the wheel failed

 RIM TRACKING

z All wheels inspected are stamped (branded),

recorded and tracked in our database.
 RIM TRACKING

The Rim Tracking software allows us to track the number of wheel

assemblies held by each customer, where they are located, (ie, at the site,
out for repair etc) and what repairs have been done to date.
 RIM TRACKING

Each wheel is assigned a specific number. This way we can track the
repairs done on each wheel along with the cost of the repairs, and issue a
detailed report to our customers when requested.
 CRITERIA FOR MPI TESTING

z Test all rims within one year of service

to determine warranty claims and
annually thereafter.
z Test any rim prior to major repairs
(centre plate change, reface).
z Visual damage (run flat, rim impact).
 SHOT BLASTING

z The next stage of inspection requires the wheel to

be sent out to be shot blasted to remove all rust,
scale & paint.
 MPI (MAGNETIC PARTICLE)
INSPECTION

z After the wheel is shot blasted & passes visual &

gauge inspection it is MPI tested for fatigue cracks
that are not clearly visible.
 REFINISHING - PAINT LINE

z Once the wheel has passed inspection it is

repainted to OEM or Customer preferred colors.
Thank you

From your partners in safety and Service

OTR Wheel Engineering, Inc.