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

EMESRT CATEGORY:

Risk of crush injury during maintenance activities. Causal factors include the physical size of the wheels and the need to have people working inside the arms of tire manipulators. Also equipment having impractical and inaccessible jacking points
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TYREgate Reference:1

Site Answers & Comments:

The operator was using a radio remote control transmitter to control the tyre handler, which was mounted on a service truck used for changing tyres on large earth moving machinery
Root & Contributing Causes:
q

LTA positioning of crane operator.

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:
All mines using similar equipment should immediately review their operations. The review should take into account:
q q q

Potential failure modes of radio remote control equipment. Safe positioning of all personnel while remote controlled equipment is in use Possible risk factors arising from operator fatigue

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TYREgate Reference:25

Site Answers & Comments:

Tyre slipped from gripping pads
Root & Contributing Causes:
q q q

Uncontrolled handling of tyre (LTA grip). Confined working environment. Incorrect installation of cranage controls.

Preventative / Recommended / Accepted Steps of Risk Mitigation, Points of Interest:
Discuss work procedures and identify hazards associated with task being performed, Implement measures to ensure people are properly protected. Never work under or near suspended loads. Fasten the load securely to the hoisting attachment. Do not lower the clamping force to reorientate a tyre held in the gripping pads when a tyre is suspended. Carry out prejob hazard analysis. Provide training in the safe installation of tyres
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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 1

Do not use shop made implements e. 15 Mar 2013 Page 2 .g. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. hook to lift tyres. TYREgate Reference:30 Site Answers & Comments: The tyre serviceman was using a shop fabricated (non engineered or certified) bead hook Root & Contributing Causes: q q q Uncontrolled handling of tyre (LTA grip). Points of Interest: No recommendations provided. hardhat to be work while carrying out lifting operations. Uncertified lifting equipment Preventative / Recommended / Accepted Steps of Risk Mitigation.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:27 Site Answers & Comments: Insufficient grip on tyre clamping pads. TYREgate Reference:29 Site Answers & Comments: Failure to adequately grip the tyre. LTA positioning of crane operator. or standing near suspended loads. Have in place safe work procedures that deal with working near suspended loads. Any lifting devices (hooks) to be fitted with a safety latch to prevent the lifted item from slipping off the hook. Click to view this TYREgate record. Preventative / Recommended / Accepted Steps of Risk Mitigation. positioning of body under the suspended tyre Root & Contributing Causes: q LTA positioning of crane operator. 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. Points of Interest: Eliminate people working under suspended loads. Correct PPE i. one gripping pad had only 30 to 40 % contact with the tyre tread Root & Contributing Causes: q q Uncontrolled handling of tyre (LTA grip). Preventative / Recommended / Accepted Steps of Risk Mitigation. Points of Interest: No recommendations provided Click to view this TYREgate record. Click to view this TYREgate record.e. LTA positioning of crane operator.

Confined working environment. 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. Employers and owners must ensure a safe system of work for replacing earthmover tyres using a tyrehand . The minimum operating distance between grab truck and machinery should be specified and complied with. Review tyre lifting and handling equipment for adequacy across the site and across the full range of applications. The ramp may be fixed or portable depending on access requirements. exposing the operator to Potentialhazards Root & Contributing Causes: q q q q Uncontrolled handling of tyre (LTA grip). Preventative / Recommended / Accepted Steps of Risk Mitigation. and operate controls on the opposite side of the truck from the load being lifted or unloaded. Wherever possible workers should stay well clear of suspended loads. Suspended loads must be carefully secured. TYREgate Reference:48 Site Answers & Comments: The tyrehand controls were operated close to the lifting operation. LTA positioning of crane operator. Crane not stabilized. Preventative / Recommended / Accepted Steps of Risk Mitigation. Click to view this TYREgate record.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:37 Site Answers & Comments: Tyre accidentally being stood up to become mobile Root & Contributing Causes: q q Uncontrolled handling of tyre (LTA grip). 15 Mar 2013 Page 3 . Use of unsuitable equipment to handle tyre. Click to view this TYREgate record. Points of Interest: Assess current work practices and procedures and ensure that safe systems of work that include appropriate precautions are in place to prevent the risk of injury to any persons using the ramp. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. Place a physical barrier and signeage across the ramp to prevent vehicles from using the ramp when tyres are being moved or installed. Points of Interest: Tyre fitters must be adequately trained and assessed in the system of work before operating tyrehands.

Points of Interest: Careful inspection of equipment in service and instigation of a check system to be undertaken by the tyre fitter on each occasion prior to using the equipment. All wheels must have external access to valves so that tyres can be deflated prior to any work.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:53 Site Answers & Comments: The axle on the container lifter was chocked up and the tyre fitter had removed the retaining bolts and clamps Root & Contributing Causes: q q q q LTA material testing/fatigue NDT LTA rim integrity LTA deflation practice. by such means as cameras or laser technology. Click to view this TYREgate record. documented training procedures. wear and corrosion. Review the possibility of removing the person from between the wheel and the tyre handler. It is recommended that large rims be crack tested at 2 years of age and re-tested each time a tyre is replaced. Points of Interest: Tyres must be deflated to no more than 35 kPa before wheels are removed from vehicles. 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. No NDT schedule Preventative / Recommended / Accepted Steps of Risk Mitigation.Maintenance and repair. Manufacturers and suppliers of equipment must supply All large rims should be registered in a scheduled maintenance programme. or disassembled. Click to view this TYREgate record. Investigate the possibility of fitting a secondary locking mechanism or updating the design.Off highway rims and wheels . All wheel components should be subject to visual inspections for cracks. provide standard operating procedures for tyre and rim safety. provides useful guidance. 15 Mar 2013 Page 4 . who supplied the 'Wheels of India' rims. Australian Standard 4457: Earth moving machinery . Titan Wheels Australia Pty Ltd. TYREgate Reference:58 Site Answers & Comments: In order to align the wheel in the correct position when it is being fitted to the hub. the tyre fitter must stand between the clamps to give direction to the tyre handler operator Root & Contributing Causes: q LTA integrity tyrehandler Preventative / Recommended / Accepted Steps of Risk Mitigation. All tyre workers must be fully trained in safe working procedures with comprehensive.

when carrying the tyre. STOP. Positive Communication: the operator of the tyrehandler is to clearly communicate what and how he is going to manipulate the tyres. if unsure scrap stacks should be limited to `2 high`. Points of Interest: q q q q q q q q q Only competent operators are permitted to operate the tyrehandler. and vertically while being rocked to check firmness of the tyrehandler grip. Stand Well Clear: Any persons on the ground must ensure they stand well clear of the machine and be in clear view of the operator at all times while tyres are being manipulated. a. Preventative / Recommended / Accepted Steps of Risk Mitigation. Wet or muddy tyres are to be treated with extra caution. Points of Interest: q q q q q Ensure there is a SWP for the vehicle which includes all/any likely use. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. Click to view this TYREgate record. and seek assistance from your supervisor. Particular attention needs to be given to ensure the tyre hands and grip buttons of the tyre hand pads are clean. Ensure the load can be safely carried by the forklift. If not fully supported by the forklift tynes. then operate the forklift in reverse. a. and only if the assembly has been pushed onto the rim/hub and is held in position securely by the tyrehandler. and before being moved. Never allow anyone to stand between the tyrehandler hands while loose tyres are being handled. The same precautions need to be adopted when manipulating fitted tyres/wheel assemblies. or other items being handled. Ensure no personnel is in the direct vicinity of machine and tyre being manipulated. if the load obstructs the drivers view. Drive according to conditions. Tyres must be firmly gripped. Preventative / Recommended / Accepted Steps of Risk Mitigation. with the third tyre being added once the tyre tread has dried off. Click to view this TYREgate record. Note: Tyre service personnel may enter the space between the tyrehandler arms if. it should be held horizontally and as low as possible to the ground. the load needs to be restrained securely using appropriate tie-downs so it cannot move. TYREgate Reference:68 Site Answers & Comments: Tyre was not positioned flat on tynes nor was it tied down while it was being transported Root & Contributing Causes: q Uncontrolled handling of tyre (LTA grip). Only if necessary rotate the tyre into a vertical position. the operator should lift the tyre a short distance off the ground and firmly rock it using the hydraulic controls of the machine. If deemed safe. b. and the machine operator and tyre serviceman have positively communicated the next task steps with each other. The tyre should be held horizontally. 15 Mar 2013 Page 5 . Carry out a prestart inspection of the tyrehandler in line with established proformas and Klinge SWPs. 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. If there are any doubts.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:65 Site Answers & Comments: The root cause was attributed to the tyre not being gripped firmly enough to prevent it from slipping from the handler Root & Contributing Causes: q Uncontrolled handling of tyre (LTA grip).

and carry out a JSA covering all task steps before commencing the work.STOP. 15 Mar 2013 Page 6 . UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. and get assistance. this will ensure that the vehicle will not accidentally jack-knife off the jacks/stands should it be pumped during maintenance. If in doubt .TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:72 Site Answers & Comments: Incorrect jacking of machine using non approved jacking point Root & Contributing Causes: q Incorrect jacking Preventative / Recommended / Accepted Steps of Risk Mitigation. All personnel must be familiar with the task at hand . 4. 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. Points of Interest: Mandatory actions and controls to prevent this accident from recurring are: 1. TYREgate Reference:73 Site Answers & Comments: Support stands were not installed after the vehicle had been jacked nor was the articulation pin fitted to prevent the machine from jack-knifing Root & Contributing Causes: q LTA / No support equipment other than jacks Preventative / Recommended / Accepted Steps of Risk Mitigation. Ensure wheel assemblies and jacking/support points have been cleaned. All personnel must be familiar with the task at hand . 5. and get assistance.refer to the correct safe work procedure and carry out a JSA covering all task steps before commencing the work.Do not use any alternative jacking/stand points unless approved by the OEM. Click to view this TYREgate record. this will ensure the machine is both stable and does not cause any damage to the chassis. the articulation pin must be fitted. 2. 2. unless a suitable `lift and lock` jack is used. 3. If in doubt . Ensure only OEM recommended jacking and vehicle support points are used . Click to view this TYREgate record. All vehicles. after jacking. Ensure correct vehicle jacking and support points are used to support the machines weight.STOP. must be supported by approved vehicle stands of sufficient capacity. Points of Interest: Mandatory actions and controls to prevent this accident from recurring are: 1. If tyre maintenance is being performed on an articulated vehicle.refer to the correct safe work procedure (SWP) for the specific vehicle.

or pry the O-ring out of its groove and pull it off the rim. Before entering the direct work area in front of the tyre handler. 3. Ensure that the work is performed on flat even ground . always use the appropriate tools such as tyre levers or long screwdriver to guide the O-ring into its groove. TYREgate Reference:75 Site Answers & Comments: Not using a small lever to remove O-ring from groove Root & Contributing Causes: q LTA tooling Preventative / Recommended / Accepted Steps of Risk Mitigation. 4. Driving without due care Preventative / Recommended / Accepted Steps of Risk Mitigation. 2. All vehicles leaving the service area are to be guided out. Upon completion of the work the isolation and wheel chocks are to be removed. Click to view this TYREgate record. Use a lever to ensure your hands and fingers are NEVER directly in the pinch (danger) zone should the tyre or bead seat band move unexpectedly. Never use your hands/fingers to insert and or remove an O-ring.ensure the tyre handler does not sit in any type of drain while the work is being performed. Click to view this TYREgate record. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. Points of Interest: q q q Ensure you have been trained in this task and are fully aware of the potential pinch hazards. the following controls will be adopted at all Klinge sites. 1. and the vehicle is to be handed over to the owner/custodian. In addition. TYREgate Reference:76 Site Answers & Comments: Tyrehandler was not chocked Root & Contributing Causes: q LTA chocking of vehicle Preventative / Recommended / Accepted Steps of Risk Mitigation. Wheel Chocks are to be placed in front of and 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. Ensure the park brake is applied.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:74 Site Answers & Comments: Contributing factors were the haste of the driver and less than adequate communication between both parties involved Root & Contributing Causes: q q LTA communication between work teams. For both installation and removal. All vehicles are to be positively isolated and chocked. 15 Mar 2013 Page 7 . If a light vehicle cannot be isolated. Park brakes must be tested regularly to ensure they hold firm. Points of Interest: To access the work area in front of tyre hand while gripping/manipulating a tyre/wheel. ensure that the tyre is adequately and securely clamped in the jaws of the tyre handler. The vehicle driver is not permitted to remain in the work area. Points of Interest: Any vehicle entering the tyrebay must be guided in and positioned in the service area. the ignition keys are to be removed to a safe place.

TYREgate Reference:79 Site Answers & Comments: LTA mechanical integrity of tyrehandler arm causing arm to fall off Root & Contributing Causes: q q LTA material testing/fatigue NDT LTA integrity tyrehandler Preventative / Recommended / Accepted Steps of Risk Mitigation. 15 Mar 2013 Page 8 . support`one axle at a time` and carry out the wheel change. Points of Interest: q q q q Check and Follow Safe Work Procedures at all times .tie down straps before being used at work. Points of Interest: The exact root cause of the failure has not been established. Change wheels `axle by axle`. Ensure good lighting of immediate work area. 6.electrical. 5. Ensure that tyre handler arms are free of oil/grease or mud. forklifts and cranes .g. TYREgate Reference:77 Site Answers & Comments: Uncontrolled raising of loader using bucket controls as supports were withdrawn Root & Contributing Causes: q Incorrect jacking Preventative / Recommended / Accepted Steps of Risk Mitigation. It must be tagged out and removed from service until it has been fully restored for safe service.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 behind one front tyre to eliminate any movement of the machine.e. Click to view this TYREgate record. Implement regular NDT of unit to locate and repair any cracks Click to view this TYREgate record. All equipment must be chocked against accidental movement . vehicle debogging equipment. Particular emphasis must be applied to inspecting any load bearing tools such as o load shifting tools such as tyrehandlers. then support the other axle and carry out the wheel change. pneumatic. Ensure area free of trip hazards eg tools. 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. Click to view this TYREgate record. If in doubt. If defects are found or the equipment does not seem fit for duty do not use it. i. chains. however this incident is a timely reminder that prestart checks and regular servicing must be carried out on all equipment including o mobile machinery and their attachments e.never raise all wheels off the ground unless approved as per manufacturer procedure using manufacturer approved stands/support.both mobile and fixed o slings. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. steps and ladders o vehicle jacks and stands o Load securing equipment . cranes & tyre manipulators o light vehicles o hand tools . chain blocks. hydraulic and manually operated. insert the anti-slew bar or locking pin to prevent articulation of the vehicle. stop and ask your supervisor and carry out a risk assessment! Where fitted. 7.do not improvise or rely on procedures that may apply only to other equipment.

Click to view this TYREgate record. tyres. Points of Interest: In situations where a machine requiring tyre maintenance is parked in locations such as inside a workshop or similar which makes it difficult to use tyre changing machinery safely because of the restricted work area around the vehicle. 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. Ensure that the load can safely be carried by the vehicle . 15 Mar 2013 Page 9 . you must abide by site/relevant government traffic rules and attach a suitable warning flag to the item. In situations where the damaged vehicle cannot be shifted. consider the following: Before you start the job. Preventative / Recommended / Accepted Steps of Risk Mitigation. UQ/MIRMgate does not accept any responsibility for the effectiveness or validity of the suggested recommendations. Loose items in the passenger compartment must be restrained or placed on to the floor of the vehicle.never overload the vehicle! Tools incl. injured or killed. Click to view this TYREgate record. particularly backwards. and allow for increased braking distance. Loads must not protrude from the side of the vehicle and must not interfere with the forward or rearward vision of the driver. check if the damaged vehicle can be shifted safely to a location that allows better and unrestricted access by a forklift or tyrehandler. jacks. Do not commence the work unless you are aware of the limits of the work area and the job can be done safely. ensure you always adhere to the following points: q q q q q q q All loads must be placed into the tray of the vehicle and properly secured using the supplied tie-down straps . without assessing the limited space before the job was started Root & Contributing Causes: q Confined working environment.do a walk around inspection of the work area . You do not leave tools etc. rims etc must not be carried inside the passenger compartment. f a load protrudes from the front or back of the vehicle. There are no persons or other machinery in the immediate work area that could get run over. consider the points below: q q q q Ensure that you assess the job at hand first . the work area is well lit and you can see where you are manoeuvring the machine. stands. Points of Interest: To avoid incidents like this from recurring. particularly in corners. drive at reduced speed. Only use proper tray tie-down points to secure the load. Spotters etc must stand well clear outside of the hazard zone and must maintain visual contact with the moving machinery at all times.check the straps each time you use them and ensure they stay with the vehicle. When loaded.step out the distances around the machine and plan your work.TYREgate Information Phone: +61 7 3346 4081 Fax: +61 7 3346 4067 TYREgate Reference:81 Site Answers & Comments: Operation of a large machine in an area too small for the size of the tyrehandler. TYREgate Reference:78 Site Answers & Comments: Equipment carried in LV tray not secured Root & Contributing Causes: q Equipment in transport not secured Preventative / Recommended / Accepted Steps of Risk Mitigation. lying around as they will get damaged.