Otr Mining & Earth Mover Wheels

MINING AND MINING AND EARTHMOVER EARTHMOVER

WHEELSWHEELS

PRODUCTS & SERVICESPRODUCTS & SERVICESI 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 SECTION I UNDERGROUND & SURFACE UNDERGROUND & SURFACE

MINING WHEELSMINING WHEELSOTR WHEEL OFFERS A WIDE VARIETY OF MINING WHEELS FROM 15” TO 63” IN STANDARD AND HEAVY DUTY DESIGNS FOR ANY MINING APPLICATION

WE ALSO OFFER CUSTOM DESIGNED WHEELS FOR SPECIFIC CUSTOMER REQUIREMENTS

PRODUCT LINEPRODUCT LINE

HEAVY DUTY UNDERGROUND MINING WHEELS

GFM HEAVY DUTY LARGE DIAMETER MINING WHEELS

GFM QUICK CHANGE HAUL TRUCK RIMS AND WHEELS

HEAVY DUTY UNDERGROUND HEAVY DUTY UNDERGROUND MINING WHEELSMINING 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 HEAVY DUTY UNDERGROUND MINING WHEELSMINING WHEELS

••Available In 10Available In 10””,15,15””, 20, 20”” And 24And 24”” DiametersDiameters

••Standard Lock Ring Or Tapered Lock Ring Designs AvailableStandard Lock Ring Or Tapered Lock Ring Designs Available

••Wheels Can Be Customized To Fit Any ApplicationWheels Can Be Customized To Fit Any Application

GFM HEAVY DUTY LARGE GFM HEAVY DUTY LARGE DIAMETER MINING WHEELSDIAMETER 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

••GFMEGFME - 100% COMPATIBLE WITH TITAN, RIMEX MES, AND TOPY EU

••GFMTGFMT - 100% COMPATIBLE WITH RIMEX TSR DESIGN

••GFMWGFMW - 100% COMPATIBLE WITH TOPY 63” WTR (Wedge Type) DESIGN

GFME STANDARD DESIGNGFME STANDARD DESIGN

FORGED AND FULLY MACHINED SECTIONS MADE FORM HSLA STEEL100% COMPATIBLE WITH STANDARD DESIGNS IN THE MARKET TODAY FROM OTHER MANUFACTURERS100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY

GFME QUICK CHANGE GFME QUICK CHANGE DESIGNDESIGN

FORGED AND FULLY MACHINED SECTIONS MADE FORM HSLA STEELDESIGNED TO BE 100% COMPATIBLE WITH STANDARD DESIGNS IN THE MARKET TODAY FROM OTHER MANUFACTURERS100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY

GFME QUICK CHANGE GFME QUICK CHANGE DESIGNDESIGN

BENEFITS OF OUR GFME QUICK CHANGE DESIGN

REDUCE TIRE CHANGE AND ROTATION TIMES BY UP TO 60%ELIMINATES THE NEED TO DEMOUNT THE OUTSIDE DUAL WHEEL TO CHANGE INSIDE TIREDECREASES DOWNTIME AND INCREASES PRODUCTIVITY FOR HAUL TRUCKSELIMINATES THE NEED TO USE ADAPTER RINGS ON OUTSIDE DUAL WHEELSFULLY COMPATIBLE WITH STANDARD WHEEL COMPONENTS

GFME QUICK CHANGE DESIGNGFME QUICK CHANGE DESIGN

80 minutes165 minutesTOTAL TIME

0152ND RETORQUE

0151ST RETORQUE

55REMOVE JACKS

010TORQUE NUTS

1010INFLATE OUTSIDE TIRE

010TIGHTEN NUTS WITH IMPACT GUN

010INSTALL NUTS ONTO BOLTS

55INSTALL OUTSIDE WHEEL & TIRE ON HUB

010DEMOUNT & MOUNT OUTSIDE TIRE ON WHEEL

1010INFLATE INSIDE TIRE

55INSTALL INSIDE TIRE

55CLEAN & INSPECT HUBS

55REMOVE INSIDE TIRE

55REMOVE OUTSIDE TIRE & WHEEL

015REMOVE NUTS - OUTER WHEEL

2020DEFLATE INSIDE & OUTSIDE TIRES

1010JACKING

Avg. Minutes using OTR GFM Quick Change wheels

Avg. Minutes using standard 5 piece wheelsTask

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.

GFME QUICK CHANGE DESIGNGFME QUICK CHANGE DESIGNSavings in Minutes when using GFM Quick

Change Wheels vs Standard Wheels

52%Time Savings Percentage

85 MINUTES

Time Savings In Minutes

80 MINUTES

Total Time Using OTR GFM Quick Change Wheels

165 MINUTES

Total Time Using Standard Wheels

GFMT TAPER DESIGNGFMT TAPER DESIGN

GFMT STYLE WHEEL COMPATIBLE WITH RIMEX TSRSAFETY LIP INCORPORATED IN BACK SECTION AND BEAD SEAT BAND.ALSO AVAILABLE IN QUICK CHANGE DESIGN100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY

GFMW TAPER DESIGNGFMW TAPER DESIGN

GFMW 63” WHEELS FEATURE A TAPER LOCK DESIGN TO ELIMINATE INDEXING OF THE WHEEL COMPONENTSALL GFMW WHEELS ARE 100% COMPATIBLE WITH THE TOPY WTR (WEDGE TYPE) DESIGN.100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY

KOMATSU 930E 63KOMATSU 930E 63”” WHEELSWHEELS

OUR 63OUR 63”” 930E2, 930E3 & 930E4 WHEELS 930E2, 930E3 & 930E4 WHEELS CURRENTLY RUNNING AT;CURRENTLY RUNNING AT;

Codelco Chuquicamata – ChileCodelco Radomiro Tomic – ChileBHP Escondida – ChileMinera Los Bronces – ChileMinera Pelambre - ChileSouthern Peru Copper Cuajone Mine – PeruSouthern Peru Copper Toquepala Mine – PeruMinera Collahuasi – ChileFreeport Mine – IndonesiaMinera Gaby - Chile

KOMATSU 930E 63KOMATSU 930E 63”” WHEELSWHEELS

SECTION IISECTION II

RIM AND WHEEL REPAIRS

RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS

Why Repair Rims and Wheels?

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. 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. 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 By repairing, the overall cost per hour will also be reduced vsbuying a new Rim/WheelIn 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.


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

INSPECTION REPORTINSPECTION REPORT


INTERNAL INSPECTION CRITERIA FOR RIMS INTERNAL INSPECTION CRITERIA FOR RIMS AND WHEELSAND 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 INSPECTION MANUALRIM AND WHEEL INSPECTION MANUAL


NDT CERTIFICATE NDT CERTIFICATE


ALL CRITICAL AREAS ARE

INSPECTED USING NON DESTRUCTIVE

MAGNETIC PARTICLE TESTING

BY A CERTIFIED TECHNICIAN IN OUR

QUALITY DEPARTMENT

INTERNAL REPAIR PROCEDUREINTERNAL REPAIR PROCEDURE


REPAIRS OR RIMS AND WHEELS ARE PERFORMED

ACCORDING TO OUR INTERNAL DOCUMENTED REPAIR PROCEDURE TO

ENSURE CONSISTENCY IN OUR PROCESSES.

FINAL QUALITY CONTROL REPORTFINAL 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.

FULLY MACHINED FORGED SECTIONS USED FULLY MACHINED FORGED SECTIONS USED FOR REPAIRSFOR 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


SUBMERGED ARC WELDINGSUBMERGED ARC WELDINGALL SECTIONS REPLACED ON RIMS AND WHEELS ARE WELDED USING

SUBMERGED ARC WELDING PROCEDURE AS USED IN THE

MANUFCTURING PROCESS FOR NEW RIMS AND WHEELS

WHEEL SAFETY, MAINTENANCE AND

INSPECTION

SECTION IIISECTION III

HISTORYHISTORY

Heavy equipment over the years have been scrapped or sold as surplus.Many useable parts or spares, such as wheel assemblies remained in the inventory.Rim failures began to be noticed in 1990’s.Rims from the late 1960’s and 1970’s were still in the inventory.

PLAN TO REDUCE RIM FAILURESPLAN TO REDUCE RIM FAILURES

Remove all rims manufactured prior to 1985, immediately.Visually inspect all rims, before returning to service.Identify all rims by manufacturer (design).Number and track all rims.Begin NDE testing and maintenance program.

WHY TRACK AND MAINTAIN RIMS?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 SMALLACCIDENT when it comes to Rim Failure!

WHEEL I.D. LOCATIONWHEEL I.D. LOCATION

Rim Brand

Valve Hole

Cross Section of Rim

Rim Brand

Valve Hole

Rim Brand

Front View of Rim

•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.

•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)

RESPONSIBILITIES RESPONSIBILITIES –– TIRE SHOPTIRE SHOP

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

FIELD / TIRE SHOP INSPECTIONFIELD / TIRE SHOP INSPECTION

POINTS TO CONSIDERPOINTS TO CONSIDER

Hardware is considered as consumable product.Hardware is defined as:Bead Seat BandsRim FlangesLock Rings. Hardware, which is suspected of having defects or distortion, shall be discarded. All hardware shall be inspected by Field and Tire Shop Personnel prior to its' reuse.

VISUAL RIM INSPECTION CRITERIAVISUAL RIM INSPECTION CRITERIAGutter sectionBack section Puller nutsStud holesBolting plate weldRim base weldsGeneral conditionRim Components (lockring, flange and beadseat)Run flat Check last NDE

Lock RingsLock 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 INSPECTIONGUTTER INSPECTION

Go-No Go gauge

Lock ring groove

Lock ring grooves are inspected using a Go- No go gauge for wear & damage

WORN LOCKRING GROOVEWORN LOCKRING GROOVE

Non-consistent lock ring groove

BACK SECTION / BEAD SEAT BACK SECTION / BEAD SEAT INSPECTIONINSPECTION

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 SECTIONWORN BACK SECTION

Worn out flange mating surface

Washed out lock ring groovesStress fatigue fracturesCaused by:– Friction welding

(Fretting, Galling)– Aggregate– Corrosion

Great reasons for doing a safety inspection of the rim

Non PressureZone –Extreme Danger

Pressure Zone

LOCK RING GROOVE PROBLEMSLOCK RING GROOVE PROBLEMS

RIM COMPONENTSRIM COMPONENTSProper Improper

OTR can provide charts to match rim components to ensure the proper hardware is put on to the right rim base.

HARDWAREHARDWARE

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.

Worn Side ringGood Side RingWorn Side ring

BOLT HOLESBOLT HOLES

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.

Elongated

DAMAGED GUTTER SECTIONDAMAGED GUTTER SECTION

RUN FLATRUN FLAT

•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 whendamaged)•Repair or replace any wheel or wheel component when needed

RESPONSIBILITIES RESPONSIBILITIES –– OTR WHEELOTR WHEEL

2525””X15 WHEEL FAILUREX15 WHEEL FAILURE

When this wheel failed it killed 1 mechanic and seriously injuredthe second. The crack on this wheel was in the lock ring grooveabove the pressure zone.

TIRE SIZE 17.50X25TIRE SIZE 17.50X25

This tire was aired with the lock ring not seated properly andwhen the lock ring let go there was enough force in this tire that it pulled the axle out of the housing.

TIRE SIZE 10.00X15TIRE SIZE 10.00X15

Tire flew 50 ft from the machine when the wheel failed

RIM TRACKINGRIM TRACKING

All wheels inspected are stamped (branded), recorded and tracked in our database.

The Rim Tracking software allows us to track the number of wheelassemblies held by each customer, where they are located, (ie, at the site, out for repair etc) and what repairs have been done to date.


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 TESTINGCRITERIA FOR MPI TESTING

Test all rims within one year of service to determine warranty claims and annually thereafter.Test any rim prior to major repairs (centre plate change, reface).Visual damage (run flat, rim impact).

SHOT BLASTINGSHOT BLASTING

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) MPI (MAGNETIC PARTICLE) INSPECTIONINSPECTION

After the wheel is shot blasted & passes visual & gauge inspection it is MPI tested for fatigue cracks that are not clearly visible.

REFINISHING REFINISHING -- PAINT LINEPAINT LINE

Once the wheel has passed inspection it is repainted to OEM or Customer preferred colors.

Thank youThank you

From your partners in safety and Service

OTR Wheel Engineering, Inc.

Otr Mining & Earth Mover Wheels

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