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 clarications 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
1 (2008.08)
Introduction
This 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.
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.
Read Safety Points in this manual and be sure that you fully understand
them before starting tyre and rim servicing.
When 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 OFF-
THE-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.
In this manual, the word rim is used as a general term which includes
wheels with discs.
Copying this manual for purposes other than ownership transfer is strictly
forbidden.
2 (2008.08)
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
3 (2008.08)
1. Safety precautions
1. Denition 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.
4 (2008.08) 4
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 manufacturers 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.
3. Important warnings
5 (2008.08) 5
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)
3. Important warnings
6 (2008.08) 6
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.
3. Important warnings
7 (2008.08) 7
4. Definitions of rim components
4. Denitions 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
Rim width
Bead seat width
Bead seat width
F
l
a
n
g
e
h
e
i
g
h
t
R
i
m

d
i
a
m
e
t
e
r
F
l
a
n
g
e
h
e
i
g
h
t
R
i
m

d
i
a
m
e
t
e
r
Side ring
Lock ring Rim base
Names and specifications of 5-piece rim components
Rim width
Side ring Side ring
Lock ring Rim base
Bead seat width Bead seat width
Bead seat band
(bead seat ring)
F
l
a
n
g
e
h
e
i
g
h
t
F
l
a
n
g
e
h
e
i
g
h
t
R
i
m

d
i
a
m
e
t
e
r
R
i
m

d
i
a
m
e
t
e
r
8 (2008.08) 8
4. Definitions of rim components
4.2 Names of rim components
VALVE HOLE
(TUBE TYPE)
SIDE RING
BACK FLANGE
KNURLING
BEAD SEAT AREA
GUTTER
RIM BASE
BEAD SEAT BAND
BOLT HOLE
DISC WELD
RIM CIRCUM-WELD
VALVE ACCESS NOTCH
DISC
LOCK RING
OUT BOARD DRIVER KEY
OUT BOARD
DRIVER POCKET
Names of rim component involving an out board driver
LOCK RING DRIVER PRY BAR SLOT
LOCK RING GROOVE
"O" RING
RIM DRIVER
VALVE HOLE
(TUBE-LESS TYPE)
"O" RING GROOVE
The O-ring is not
a rim component
Names of gutter section involving a lock ring driver
9 (2008.08) 9
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)
Side ring
Lock ring
Bead seat band
Markings
Markings
Markings
Markings
Markings
Markings
For 5-piece rim For 3-piece rim
10 (2008.08) 10
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: 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
Composition of markings 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.
11 (2008.08) 11
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 Rim component 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
Bead seat band
(bead seat ring)
Component of 5-piece rim
12 (2008.08) 12
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]
[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.
[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]
[Size]
Indicates the rim diameter of the matching rim base in inches.
[Type]
Indicates the type and identifies the matching rim base and bead seat band.
See 6. Matching charts for rim component combinations.
13 (2008.08) 13
5. Markings
(3) Bead seat band
Example of markings: BB 7557 HS
[Component classification] [Size] [Type]
[Size]
Indicates bead seat width and rim diameter of matching rim base in inches.
Example of [Size]
markings
[Size]
Special comments
Bead seat width Rim diameter
7557
First 2 digits (75)
e.g. 7.5 inches
Next 2 digits (57)
e.g. 57 inches
Decimal places are omitted
from bead seat width
[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]
[Size]
Indicates flange height of side ring and rim diameter of matching rim base in inches.
Example of [Size]
markings
[Size]
Special comments
Flange height Rim diameter
5063
First 2 digits (50)
e.g. 5.0 inches
Next 2 digits (63)
e.g. 63 inches
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 : SR 5063 W or SW
14 (2008.08) 14
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.
15 (2008.08) 15
6. Matching charts
EUW TYPE RIM (Rim diameter 63 inches)
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim component size and type
Rim base Lock ring
Bead seat
band
Side ring
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
EU TYPE (Rim diameter 63 inches)
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim component size and type
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)
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim component size and type
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)
Standard tyre
Rim size
(Diawidth/
Flange height)
Rim component size and type
Rim base Lock ring
Bead seat
band
Side ring
30.00-51 5122.00/4.5 RM2251EJ LR51EJ BB7551HS SR4551
33.00-51 5124.00/5.0 RM2451EJ LR51EJ BB7551HS SR5051
36.00-51 5126.00/5.0 RM2651EJ LR51EJ BB7551HS SR5051
50/65-51 5140.00/4.5 RM4051EJ LR51EJ BB7551HS SR4551
16 (2008.08) 16
6. Matching charts
EV TYPE (Rim diameter 49, 35, 33 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
Rim component size and type
Rim base Lock ring Bead seat band Side ring
18.00-33 3313.00/2.5 RM1333EV LR33EV BB5533EV SR2533
35/65-33 3328.00/3.5 RM2833EV LR33EV BB5533EV SR3533
21.00-35 3515.00/3.0 RM1535EV LR35EV BB5535EV SR3035
24.00-35 3517.00/3.5 RM1735EV LR35EV BB5535EV SR3535
24.00R49 4917.00/3.5 RM1749EV LR49EV BB5549EV SR3549
27.00R49 4919.50/4.0 RM1949EV LR49EV BB5549EV SR4049
ES TYPE (Rim diameter 57, 45, 39 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
Rim component size and type
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)
Rim component size and type
Rim base Lock ring Bead seat band Side ring
33.5-39 3928.00/4.0 RM2839EMR LR39EM BB5539EV SR4039
40/65-39 3932.00/4.5 RM3239EMR LR39EM BB5539EV SR4539
45/65-45 4536.00/4.5 RM3645EMR LR45EM BB5545EV SR4545
EMH TYPE (Rim diameter 33, 29 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
Rim component size and type
Rim base Lock ring Bead seat band Side ring
29.5-29 2925.00/3.5 RM2529EMH LR29EM BB5529EM SR3529
18.00-33 3313.00/2.5 RM1333EMH LR33EM BB4033EM SR2533
24.00-33 3317.00/3.5 RM1733EMH LR33EM BB5533EM SR3533
35/65-33 3328.00/3.5 RM2833EMH LR33EM BB5533EM SR3533
33.5-33 3328.00/4.0 RM2833EMH LR33EM BB5533EM SR4033
17 (2008.08) 17
6. Matching charts
EM TYPE (Rim diameter 25 inches)
Standard
tyre
Rim size
(Diawidth/Flange height)
Rim component size and type
Rim base Lock ring Bead seat band Side ring
14.00-25 2510.00/1.5 RM1025EM(D) LR25EM(D) BB4025EM(D) SR1525
16.00-25 2511.25/2.0 RM1125EM(D) LR25EM(D) BB4025EM(D) SR2025
18.00-25 2513.00/2.5 RM1325EM(D) LR25EM(D) BB4025EM(D) SR2525
17.5-25 2514.00/2.0 RM1425EM(D) LR25EM(D) BB4025EM(D) SR2025
21.00-25 2515.00/3.0 RM1525EM(D) LR25EM(D) BB4025EM(D) SR3025
24.00-25 2517.00/3.5 RM17255EM(D) LR25EM(D) BB5525EM(D) SR3525
20.5-25 2517.00/2.0 RM17254EM(D) LR25EM(D) BB4025EM(D) SR2025
23.5-25 2519.50/2.5 RM1925EM(D) LR25EM(D) BB4025EM(D) SR2525
26.5-25 2522.00/3.0 RM2225EM LR25EM BB5525EM SR3025
29.5-25 2525.00/3.5 RM2525EM LR25EM BB5525EM SR3525
30/65R25 2524.00/3.0 RM2425EM LR25EM BB5525EM SR3025
18.00-33 3313.00/2.5 RM1333EM LR33EM BB4033EM SR2533
*(D) indicates Lock Ring Driver type rims.
WI TYPE (Rim diameter 24, 20 inches)
Standard tyre
Rim size
(Diawidth/Flange
height)
Rim component size and type
Rim base Lock ring Side ring
14.00-20 2010.00WI RM1020WI LR20WIA SR20WI
12.00-24 248.50V-W RM8524VW LR24WIA SRWV24
14.00-24 2410.00WI RM1024WI LR24WIA SR24WI
WI TYPE (for tubeless tyre, rim diameter 24, 20 inches)
Standard tyre
Rim size
(Diawidth/Flange
height)
Rim component size and type
Rim base Lock ring Side ring
14.00-20 2010.00WI-T RM1020WI-T LR20WIA-T SR20WI-T
12.00-24 248.50V-W-T RM8524VW-T LR24WIA-T SRWV24-T
14.00-24 2410.00WI-T RM1024WI-T LR24WIA-T SR24WI-T
TG Rim and Others (Rim diameter 24, 25 inches)
Standard tyre
Rim size
(Diawidth/Flange
height)
Rim component size and type
Rim base Lock ring Side ring
13.5-20 2011.00TG RM1120TG LR20TG SR20TG
12.00-24, 13.00-24 248.00TG RM8024TG LR8024 SR8024
14.00-24, 16.00-24 2410.00VA RM1024 LR1024 SR8024
15.5-25 2512.00 RM1225 LR1225 SR1225
15.5-25 2512.00/1.3(A) RM1225A LR25GR SR1225A
17.5-25 2514.00/1.5 RM1425 LR25GR SR1425
14.00-25 2510.00/1.5 RM1025 LR25GR SR1025
20.5-25 2517.00/1.7 RM1725-1.7 LR25GR SR1725-1.7
18 (2008.08) 18
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.
Diagrams showing the correct assembly of EUW type rim components and EU type rim components
EUW type rim
(reinforced type)
EU type rim
(standard type)
Tapered shape
Not tapered Not tapered
Tapered shape
35 degrees
45 degrees
W type side ring
HSW type bead seat band
EUW type rim base
W type side ring
EUS type lock ring
HS type bead seat band
EU type rim base
Standard type side ring Standard type side ring
EU type lock ring
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
Cross-sectional shape
Grooves for identification
35
45
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.
19 (2008.08) 19
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.
Lock ring
EU type EJ type PHASE2
EJ type
EU type
CORRECT
Gutter band
PHASE2
(manufactured by
another company
Here to refer to
the note below)
CORRECT
CORRECT WRONG WRONG
WRONG WRONG
WRONG WRONG
CORRECT WRONG : Correct combination : Wrong combination
(manufactured by
another company
Here to refer to
the note below)
* 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.
20 (2008.08) 20
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.
EV type EM type
CORRECT
CORRECT WRONG
WRONG
Lock ring
EM type
EV type
Gutter
CORRECT WRONG : Correct combination : 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.
21 (2008.08) 21
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.
ES type EU type
CORRECT
CORRECT WRONG
WRONG
Lock ring
HS type
ES type
Bead
seat band
35
35
45
45
CORRECT WRONG : Correct combination : Wrong combination
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
Cross-sectional shape
Grooves for identification
35
45
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.
22 (2008.08) 22
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.
ES type EM type
CORRECT
CORRECT
CORRECT WRONG
WRONG
WRONG
Lock ring
EV type
ES type
Bead
seat band
35
35
45
45
: Correct combination : Wrong combination
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
Cross-sectional shape
35
45
Identification 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.
23 (2008.08) 23
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
Markings
are not visible
Markings
are visible
CORRECT WRONG
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.
24 (2008.08) 24
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
25 (2008.08) 25
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
Prior to demounting tyre from rim, release all air by removing the valve core housing with the valve tool.
Valve
Valve core housing
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
26 (2008.08) 26
8.1 How to demount tyre from TOPY 3-piece rim

STEP
2
Set up the tyre and rim
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
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.
27 (2008.08) 27
8.1 How to demount tyre from TOPY 3-piece rim

STEP
4
Remove lock ring
Use the tyre lever to lift one end of the locking ring from
the locking ring groove.
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.
Ends are open
Never Reuse
REUSE
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.
28 (2008.08) 28
8.1 How to demount tyre from TOPY 3-piece rim

STEP
5
Remove O-ring
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
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.
29 (2008.08) 29
8.1 How to demount tyre from TOPY 3-piece rim

STEP
7
Turn over tyre and rim
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.
As in Step 3, insert the tyre lever between the tyre bead
and the rim base.
Push down the tyre around the entire circumference, and
detach tyre bead from the rim base.
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.
30 (2008.08) 30
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
Check tyre size and markings on rim base, and make sure that the combination is correct.
Check markings on rim components and matching charts, and make sure that the combination is correct.
Warning
Conrm tyre and rim combinations with your tyre dealer or conrm using the specications 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
Clean rim components with a wire brush so that examination,
maintenance, and mounting can be done correctly.
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.
31 (2008.08) 31
8.2 How to mount tyre onto TOPY 3-piece rim

STEP
3
Recoat
Recoat 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
Place rim base on rim base stand with gutter side up.
Install 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
Confirm 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.
32 (2008.08) 32
8.2 How to mount tyre onto TOPY 3-piece rim

STEP
6
Mount tyre on rim base
Apply a vegetable oil-based lubricant to both tyre
bead seats.
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
Insert side ring into rim base and fit edge section to tyre bead.
Caution
Keep fingers away from side ring.
33 (2008.08) 33
8.2 How to mount tyre onto TOPY 3-piece rim

STEP
8
Fit O-ring
Apply 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.
34 (2008.08) 34
8.2 How to mount tyre onto TOPY 3-piece rim

STEP
9
Fit lock ring
Place 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.
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.
Ends are open
Never Use
USE
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.
35 (2008.08) 35
8.2 How to mount tyre onto TOPY 3-piece rim

STEP
10
Confirm that rim components are assembled correctly
Make 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
Wherever possible, place tyre and rim inside a tyre
inflation safety cage, then inflate tyre. During inflation,
keep away from the tyre.
When tyre has been inflated to a pressure of approximately
35kPa (5psi), check assembly of tyre and rim components.
If assembled correctly, continue inflating up to the rated
value.
Tyre inflation safety cage
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.
36 (2008.08) 36
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
Prior to demounting tyre from rim, release all air by removing the valve core housing with the valve tool.
Valve
Valve core housing
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 xing 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
37 (2008.08) 37
8.3 How to demount tyre from TOPY 5-piece rim

STEP
2
Set up tyre and rim
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
Mount bead breaker on bead seat band.
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.
38 (2008.08) 38
8.3 How to demount tyre from TOPY 5-piece rim

STEP
4
Remove driver key
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
Use a tyre lever to force the bead seat band free from the
locking ring.
Use the tyre lever to leave out one end of the locking ring
from the locking groove.
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.
Ends are open
Never Reuse
REUSE
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.
39 (2008.08) 39
8.3 How to demount tyre from TOPY 5-piece rim

STEP
6
Remove O-ring
Use the tyre lever to push down on the bead seat band so
that the O-ring is freed.
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
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.
40 (2008.08) 40
8.3 How to demount tyre from TOPY 5-piece rim

STEP
8
Remove side ring
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
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.
41 (2008.08) 41
8.3 How to demount tyre from TOPY 5-piece rim

STEP
10
Unseat the tyre bead from the rim base
Mount bead breaker on rim base.
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
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.
42 (2008.08) 42
8.3 How to demount tyre from TOPY 5-piece rim

STEP
12
Remove side ring
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.
43 (2008.08) 43
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
Check tyre size and markings on rim base, and make sure that the combination is correct.
Check markings on rim components and matching charts, and make sure that the combination is correct.
Warning
Conrm tyre and rim combinations with your tyre dealer or conrm using the specications 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
Clean rim components with a wire brush so that
examination, maintenance, and mounting can be done
correctly.
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 modications involving welding, heating, soldering, etc. Such modications 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.
44 (2008.08) 44
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
3
Recoat
Recoat 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
Place rim base on rim base stand with gutter side up.
Install 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
Install 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.
45 (2008.08) 45
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
6
Confirm absence of tyre defects
Confirm 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
Apply a vegetable oil-based lubricant to both tyre bead
seats.
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.
46 (2008.08) 46
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
8
Fit side ring
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.
47 (2008.08) 47
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
9
Install bead seat band
Insert bead seat band into side ring and rim base.
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.
48 (2008.08) 48
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
10
Fit O-ring
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.
49 (2008.08) 49
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
11
Fit lock ring
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.
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.
Ends are open
Never Use
USE
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.
50 (2008.08) 50
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
12
Install driver key
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
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.
51 (2008.08) 51
8.4 How to mount tyre onto TOPY 5-piece rim

STEP
14
Inflating the tyre and rim
Wherever possible, place the tyre and rim
inside a tyre inflation safety cage, then inflate
tyre. During inflation, keep away from the tyre.
When tyre has been inflated to a pressure of
approximately 35kPa (5psi), check assembly
of tyre and rim components.
If assembled correctly, continue inflating up
to the rated value.
Tyre inflation safety cage
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.
52 (2008.08) 52
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
Valve core housing
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
53 (2008.08) 53
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
54 (2008.08) 54
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.
55 (2008.08) 55
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.
Deformation
Crack
Crack
Crack
Friction,
Deformation
Friction,
Deformation
Friction,
Deformation
Friction,
Deformation
Friction
Corrosion
Corrosion
Friction
Friction
Crack
Crack
Crack
Crack
Crack
Crack
Crack
Deformation
Deformation
Deformation
9.1 Regular inspection checkpoints
56 (2008.08) 56
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.
9.2 Inspections when servicing tyres and rims
57 (2008.08) 57
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)
Contact zone with side ring
Contact zone with tyre bead
Rim circumference
weld zone
Tyre side outer
surface
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
Checkpoint
Cracking Wear
Deformation/
Ellipse
Corrosion
Surface
roughness
O-ring groove
Visual inspection
Non-destructive inspection
Lock ring groove
Visual inspection
Non-destructive inspection
Contact zone with side
ring
Visual inspection
Non-destructive inspection
Base R part
Visual inspection
Non-destructive inspection
Rim circumference
weld zone
Visual inspection
Non-destructive inspection
Valve hole
Visual inspection
Non-destructive inspection
Disc weld zone
Visual inspection
Non-destructive inspection
Disc bolt holes
Visual inspection
Non-destructive inspection
Contact zone with tyre
bead
Visual inspection
Non-destructive inspection
Tire side outer surface
Visual inspection
Non-destructive inspection
Weld zone for
accessories
Visual inspection
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.
9.2 inspections when servicing tyres and rims
58 (2008.08) 58
Lock ring inspections
For 3-piece rims For 5-piece rims
Contact zone with side ring
Contact zone with gutter section
Contact zone with
bead seat band
Contact zone with gutter section
Inspected part Check method
Checkpoint
Cracking Wear
Deformation/
Ellipse/
Spread Edges
Corrosion
Surface
roughness
Contact zone with bead seat
band or side ring
Visual inspection
Non-destructive inspection
Contact zone with gutter of
rim base
Visual inspection
Non-destructive inspection
Overall form
Visual inspection
Non-destructive inspection
Note: Non-destructive inspections include magnetic particle inspections, ultrasonic inspections,
and dye penetrant inspections, etc.
9.2 Inspections when servicing tyres and rims
59 (2008.08) 59
Bead seat band inspections
Contact zone with lock ring
Inner and
outer surface
Contact zone
with tire bead
Base R part
Contact zone
with side ring
Weld zone for
accessories
Inspected part Check method
Checkpoint
Cracking Wear
Deformation/
Ellipse
Corrosion
Surface
roughness
Base R part
Visual inspection
Non-destructive inspection
Contact zone with side
ring
Visual inspection
Non-destructive inspection
Contact zone with lock
ring
Visual inspection
Non-destructive inspection
Contact zone with tyre
bead
Visual inspection
Non-destructive inspection
Inner and outer
surface
Visual inspection
Non-destructive inspection
Overall form
Visual inspection
Non-destructive inspection
Weld zone for
accessories
Visual inspection
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.
9.2 Inspections when servicing tyres and rims
60 (2008.08) 60
9.3 Inspections when servicing tires and rims
Side ring inspections
For 3-piece rims For 5-piece rims
Contact zone with tire Contact zone with tire
Contact zone with rim base
Contact zone with bead seat band
Inner and
outer surface
Base R part
Inspected part Check method
Checkpoint
Cracking Wear
Deformation/
Ellipse
Corrosion
Surface
roughness
Contact zone with rim base
(for 5-piece rims)
Visual inspection
Non-destructive inspection
Contact zone with bead seat
band (for 5-piece rims)
Visual inspection
Non-destructive inspection
Base R part
(for 3-piece rims)
Visual inspection
Non-destructive inspection
Inner and outer surface
(for 3-piece rims)
Visual inspection
Non-destructive inspection
Contact zone with tyre
Visual inspection
Non-destructive inspection
Overall form
Visual inspection
Non-destructive inspection
Note: Non-destructive inspections include magnetic particle inspections, ultrasonic inspections,
and dye penetrant inspections, etc.
9.2 Inspections when servicing tyre and rims
61 (2008.08) 61
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.
9.3 Action as a result of inspection
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
TOPY INDUSTRIES, LIMITED
Issued in Sep. 2008. 4,000