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Safe Work for install of truck tire

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Truck Tire Installation and Maintenance =======================================

Document Number: \[SWP-NUMBER]

Revision Date: \[DATE]

Next Review Date: \[NEXT REVIEW DATE]

Department: \[DEPARTMENT NAME]

1\. Scope

This safe work procedure outlines the guidelines for the safe installation and maintenance of tires on trucks, including inspection, inflation, and replacement. It applies to all personnel involved in these tasks and aims to prevent injuries and ensure regulatory compliance.

2\. Definitions

PSI Pounds per square inch, a unit of pressure. Clip-on Chuck A device used to attach an air hose to a tire valve for inflation, designed to clip onto the valve securely. [1]

Restraining Device A safety cage or other structure used to contain a tire and wheel assembly during inflation, minimizing the risk of injury in case of a tire explosion. [1]

3\. Responsibilities

3\.1 Supervisors

  • Ensure that all workers are properly trained and competent to perform tire installation and maintenance tasks.
  • Provide the necessary tools and equipment in good working order.
  • Enforce the use of required personal protective equipment (PPE).
  • Ensure that pre-work inspections are conducted.

3\.2 Workers

  • Follow all safe work procedures and instructions.
  • Use required personal protective equipment (PPE).
  • Conduct pre-work inspections of tools and equipment.
  • Report any hazards or unsafe conditions to the supervisor immediately.

3\.3 Health and Safety Representative

  • Assist in the development and review of safe work procedures.
  • Participate in safety inspections and audits.
  • Investigate incidents and recommend corrective actions.

4\. Potential Hazards and Risks

HazardRiskControl Measures
Tire ExplosionSerious injury or death from flying debris.Use a restraining device during inflation. Inflate tires in a safe area away from personnel. Do not exceed manufacturer's recommended inflation pressure.
Incorrect Tire/Rim Matching [1]Tire failure during inflation or use.Ensure correct tire to rim size match prior to inflation.
Over-inflation [1]Tire explosion due to excessive pressure.Use an in-line regulator and gauge. Do not inflate beyond manufacturer's recommendations.
Manual HandlingBack injury, strains, and sprains from lifting heavy tires and wheels.Use proper lifting techniques. Get assistance when lifting heavy tires. Use mechanical aids such as tire dollies or lifts.
Flying DebrisEye or face injury from debris during tire removal or installation.Wear appropriate eye and face protection. Ensure work area is clear of obstructions.
Pinch PointsCrush injuries to hands and fingers during tire and wheel assembly.Keep hands clear of pinch points. Use appropriate tools and equipment.
Chemical ExposureSkin irritation or respiratory issues from tire cleaning products or lubricants.Use appropriate gloves and respiratory protection. Work in a well-ventilated area.

5\. Personal Protective Equipment (PPE)

The correct PPE must be worn at all times.

  • Safety Glasses: ANSI-approved safety glasses with side shields to protect eyes from flying debris.
  • Gloves: Heavy-duty work gloves to protect hands from cuts, abrasions, and chemical exposure.
  • Steel-toed Boots: Safety boots with steel toe protection to prevent foot injuries from falling objects.
  • Hearing Protection: Earplugs or earmuffs to protect hearing in noisy environments.
  • Apron: Wear an apron to protect clothing from battery acid.

Inspect PPE before each use for damage or wear. Replace damaged PPE immediately. Clean and store PPE properly.

6\. Equipment and Tools

All equipment and tools must be inspected before use.

  • Tire Inflation Cage: A safety cage designed to contain a tire and wheel assembly during inflation, minimizing the risk of injury in case of a tire explosion.
  • Clip-on Chuck with In-line Gauge: Used for safe and accurate tire inflation, ensuring the operator can maintain a safe distance during inflation. [1]
  • Tire Iron/Wrench: Used to loosen and tighten lug nuts during tire removal and installation. Ensure the wrench is the correct size for the lug nuts.
  • Torque Wrench: Used to tighten lug nuts to the manufacturer's specified torque to ensure proper wheel attachment.

Inspect all tools and equipment before each use. Remove any damaged or defective equipment from service. Follow the manufacturer's instructions for maintenance and repair.

7\. Pre-Job Requirements

7\.1 Training and Competency

Training and Competency: All personnel must be trained and competent in tire installation and maintenance procedures. Training records must be maintained.

7\.2 Pre-Job Briefing

Pre-Job Briefing: Conduct a pre-job briefing to discuss the task, hazards, and control measures. Ensure all personnel understand the procedure.

7\.3 Work Area Preparation

Work Area Preparation: Ensure the work area is clean, well-lit, and free of obstructions.

8\. Safe Work Procedure Steps

  1. Pre-Work Inspection: Inspect the tire for any signs of damage (cuts, bulges, or uneven wear). Check the rim for cracks or deformities. Ensure all tools and equipment are in good working order.
  2. Vehicle Preparation: Park the vehicle on a level surface. Engage the parking brake. Use wheel chocks to prevent movement.
  3. Tire Removal: Loosen the lug nuts with a tire iron. Use a jack to lift the vehicle. Remove the lug nuts completely and remove the tire.
  4. Tire Mounting: Clean the rim and tire bead. Apply lubricant to the tire bead. Mount the tire onto the rim using a tire mounting machine or appropriate tools.
  5. Tire Inflation: Place the tire and wheel assembly inside the inflation cage. Connect the clip-on chuck to the valve stem. Inflate the tire to the manufacturer's recommended pressure, using an in-line gauge to monitor the pressure. [1]
  6. Wheel Installation: Mount the wheel onto the vehicle hub. Hand-tighten the lug nuts in a star pattern. Lower the vehicle and remove the jack.
  7. Torqueing Lug Nuts: Use a torque wrench to tighten the lug nuts to the manufacturer's specified torque in a star pattern.
  8. Post-Installation Check: Re-check the lug nuts after 50-100 miles of driving to ensure they remain properly torqued.

9\. Precautions and Safety Measures

  • Always use a clip-on chuck with a minimum 24-inch length hose to an in-line foot or hand valve and gauge during tire inflation. [1]
  • Ensure the tire inflation control valves automatically shut off the air flow when the valve is released or are of the preset regulator type. [1]
  • Provide specific employee instruction to ensure the employee makes the correct tire to rim size match prior to inflating the tire. [1]
  • Do not inflate tires to more than the inflation pressure recommended by the manufacturer. [1]
  • Unless otherwise recommended by the manufacturer, do not inflate tires beyond a maximum of 40 psi to seat the beads. [1]
  • Inspect tire beads for proper seating at intervals not to exceed 20 psi during inflation. [1]
  • Completely deflate tires not properly seated at 40 psi (or the manufacturer's maximum recommended psi) before adjusting tire, rim, or wheel components. [1]
  • Use a restraining device when seating the beads, except as permitted in Section 3326\. [1]
  • Do not try to install, remove, charge or service your truck battery unless you are trained and authorized. [6]
  • Never smoke or use an open flame around batteries. [6]
  • Your company should provide an area where it is safe to work on batteries. Use that area for all battery work. [6]
  • Use protective equipment such as gloves, eye shields, aprons etc. [6]
  • Make certain you use the correct size and weight battery. Never operate a truck that has an underweight or undersized battery installed. [4]
  • Never let anything metal touch the top of the cells. You could cause sparks or do damage to the battery. Use an insulator (such as plywood) when necessary. [4]
  • Use an approved spreader bar to place a battery in, or remove it from, the battery compartment. Make sure you adjust the spreader bar hooks to fit the battery. [4]
  • Replace the battery retainers. Make certain the retainers on both sides of the truck are in place. [3]
  • Connect the battery. Turn the truck ON and check truck operation. [4]
  • Be sure the coast selector is off and the brake is on before removing or installing a battery. [5]
  • Check for missing lug nuts. Remove debris from the tire tread. Do not operate the truck if the tires are damaged. [2]
  • Check the tire pressure. Do not add air if the tire pressure is low. Report the problem to your supervisor. [2]
  • Batteries produce explosive gas. Do not smoke, use open flame, or create an arc or sparks near this battery. Ventilate well in enclosed areas and when charging. [7]
  • Batteries contain Sulfuric Acid which causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush immediately. Get medical attention if your eyes are affected. [7]
  • Make certain the charger is the same voltage and amperage as your battery. [7]
  • Be sure the charger is turned OFF before connecting the battery to the charger. Otherwise you might create a spark which could cause the battery to explode. [7]
  • Only Crown approved power sources are permitted to be used in your truck. Only authorized service personnel are permitted to modify the power source installed in your truck. [8]
  • Follow the manufacturer's specification and instructions when handling power sources. [8]
  • Your company should provide an area that is safe to work on power sources. Use that area for all power source work and charging. [8]
  • Do not charge or refuel a power source unless you are trained and authorized. [8]
  • Do not remove or install a power source unless you are trained and authorized. [8]

10\. Emergency Procedures

10\.1 General Emergency Response

In the event of a tire explosion, evacuate the area immediately and ensure that all personnel are accounted for.

10\.2 Specific Emergency Scenarios

  • Tire Explosion: Evacuate the immediate area. Check for injuries and provide first aid. Report the incident to the supervisor.
  • Chemical Spill: Contain the spill using absorbent materials. Wear appropriate PPE. Report the spill to the supervisor and follow the SDS guidelines.
  • Fire: Activate the nearest fire alarm. Evacuate the area. Use a fire extinguisher if safe to do so. Call emergency services.

11\. Incident Reporting and Investigation

All incidents, including near misses, must be reported to the supervisor immediately. A written report must be submitted within 24 hours.

A thorough investigation will be conducted to determine the root cause of the incident and to implement corrective actions to prevent recurrence.

Approved by: \[NAME AND POSITION]

Date: \[APPROVAL DATE]

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8 source record(s)

Sources used for this answer

[1] Reach Truck - RM 6000 (PF18573-C) - Operator Manual

Page 43

Open source document

Source excerpt

# Flooded Lead Acid Batteries (cont.) ## 41 Flooded Lead Acid Batteries (cont.) Know the Hazards A DANGER Batteries produce explosive gas. Do not smoke, use open flame, or create an arc or sparks near this battery. Ventilate well in enclosed areas and when charging. Batteries contain Sulfuric Acid which causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush immediately. Get medical attention if your eyes are affected. 107 ## TRUCK BATTERIES CAN BE DANGEROUS Lead acid batteries produce gas that can explode. They also contain acid that could burn or disfigure you. • Do not try to install, remove, charge or service your truck battery unless you are trained and authorized. • Never smoke or use an open flame around batteries. • Your company should provide an area where it is safe to work on batteries. Use that area for all battery work. • Use protective equipment such as gloves, eye shields, aprons etc. ## BEFORE CHARGING YOUR TRUCK BATTERY - Charge the battery only in areas designated for that use. • Make sure the truck key switch is turned off and all other controls are in the off or neutral position. • See that the battery cells are filled to the proper level. Never use an open flame to check the battery. • Make certain the charger is the same voltage and amperage as your battery. • Read the battery charger instructions. • Be sure the charger is turned OFF before connecting the battery to the charger. Otherwise you might create a spark which could cause the battery to explode. Continued next page... ## Flooded Lead Acid Batteries 42

[2] Pallet Truck TWR 3000 (PF12504) - Operator Manual

Page 12

Open source document

Source excerpt

# Battery Maintenance ## WHEN YOU INSTALL OR CHANGE BATTERIES • Turn the truck OFF. Be sure the coast selector is off. Check that all controls are in neutral and disconnect the battery. • Make certain you use the correct size and weight battery. Never operate a truck that has an underweight or undersized battery installed. • Never let anything metal touch the top of the cells. You could cause sparks or do damage to the battery. Use an insulator (such as plywood) when necessary. • Use an approved spreader bar to place a battery in, or remove it from, the battery compartment or stand. Make sure you adjust the spreader bar hooks to fit the battery. ## USING A ROLLER STAND If f you use a roller stand to install or remove a battery make sure the roller stand is the same height as the rollers in the truck's battery compartment. Also make sure the roller stand is at least as long as your battery. ## AFTER INSTALLING YOUR BATTERY - Replace the battery retainers. Make certain the retainers on both sides of the truck are in place. • Connect the battery. Turn the truck ON and check truck operation. ## BATTERY CHARGE METER OPTION The lighted bar shows how much charge is left in your battery. A flashing light will warn you that the battery is getting low. Two flashing lights mean you must have the battery changed or recharged. ## ▲ Know the Hazards //// A DANGER Batteries produce explosive gas. Do not smoke, use open flame, or create an arc or sparks near this battery. Ventilate well in enclosed areas and when charging. Batteries contain Sulfuric Acid which causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush immediately. Get medical attention if your eyes are affected. ## TRUCK BATTERIES CAN BE DANGEROUS Your truck battery produces a gas that can explode. It also contains acid that could burn or disfigure you. • Do not try to install, remove, charge or service your truck battery unless you are trained and author…

[3] Pallet Truck WP 2300 (PF14248-WEB) - Operator Manual

Page 15

Open source document

Source excerpt

# Battery Maintenance continued ## WHEN YOU INSTALL OR CHANGE INDUSTRIAL BATTERIES • Turn the truck OFF and disconnect the battery. • Make certain you use the correct size and weight battery. Never operate a truck that has an underweight or undersized battery installed. • Never let anything metal touch the top of the cells. You could cause sparks or do damage to the battery. Use an insulator (such as plywood) when necessary. • Use an approved spreader bar to place a battery in, or remove it from, the battery compartment. Make sure you adjust the spreader bar hooks to fit the battery. • Connect the new battery. Turn the truck ON and check truck operation. ▼▲ Know the Hazards A DANGER Batteries can produce explosive gas. Do not smoke, use open flame, or create an arc or sparks near this battery. Ventilate well when in an enclosed area and when charging. This battery contains Sulfuric Acid which causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush immediately and thoroughly with water. Get medical attention if your eyes are affected. ## TRUCK BATTERIES CAN BE DANGEROUS Your truck battery produces a gas that can explode. It also contains acid that could burn or disfigure you. • Do not try to install, remove, charge or service a truck battery unless you are trained and authorized. • Never smoke or use an open flame around batteries. • Your company should provide an area where it is safe to work on batteries. Use that area for all battery work. • Use protective equipment such as gloves, eye shields, aprons, etc. ## BATTERY SIZE IS IMPORTANT Make certain you use the correct size, weight and type of battery. Never operate a truck that has an underweight or undersized battery installed. AWARNING Recommended battery size 175 to 185 mm (6.9 to 7.3 in) wide 265 to 305 (104 to 12.1) long 225 to 285 (8.8 to 11.3) high Min. batt, wt. 22.7 kg (50 lbs) each. A WARNING Minimum battery size allowed XXX mm (XX.XxX in.) wide…

[4] Internal Combustion Truck - C5 Pneumatic (600034) - Operator Manual

Page 32

Open source document

Source excerpt

# Traveling continued (cont.) ## 30 Traveling continued (cont.) # Daily Safety Check ## CHECK YOUR TRUCK BEFORE STARTING WORK You must make sure your truck is safe to use. 1. Walk around your truck and check it over. • See that all wheels and tires are in good condition. • Make sure all lights are working. • Check that both forks are secure and not bent, cracked or badly worn. • Inspect all lift chains for damage. • Look under the truck for signs of fuel, oil, or coolant leaks. • Inspect the seat belt for wear. • Turn the key to TEST. Make certain the display warning alarm and all indicator lights are working. • Test the horn. ## For LPG Trucks • Check for propane gas leaks. (Gas odor or frost on the cylinder or fuel valve). • Check that fuel hoses are not cracked or worn. • Inspect the fuel system and other parts for damage. • Make certain the propane cylinder is properly installed and secure. ## When raising the seat deck Tilt the steering wheel up, remove the storage tray (if present), and move the seat and armrest towards the rear. Raise the seat deck to the open position. Note: A seat deck can fall. Make certain the gas struts are working properly and will hold the seat deck securely in the open position. ## When using air-filled tires • Check for missing lug nuts. Remove debris from the tire tread. Do not operate the truck if the tires are damaged. • Check the tire pressure. Do not add air if the tire pressure is low. Report the problem to your supervisor. ## 32 Daily Safety Check

[5] Reach Truck - RR 5700 (PF18340-D) - Operator Manual

Page 42

Open source document

Source excerpt

# Flooded Lead Acid Batteries # A know the Hazards A DANGER Batteries produce explosive gas. Do not smoke, use open flame, or create an arc or sparks near this battery. Ventilate well in enclosed areas and when charging. Batteries contain Sulfuric Acid which causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush immediately. Get medical attention if your eyes are affected. 107 ## TRUCK BATTERIES CAN BE DANGEROUS Lead acid batteries produce gas that can explode. It also contains acid that could burn or disfigure you. • Do not try to install, remove, charge or service your truck battery unless you are trained and authorized. • Never smoke or use an open flame around batteries. • Your company should provide an area where it is safe to work on batteries. Use that area for all battery work. • Use protective equipment such as gloves, eye shields, aprons etc. ## 41 Flooded Lead Acid Batteries

[6] Cal/OSHA Regulations | Chapter 4 | Subchapter 7: General Industry Safety Orders | §3325. Tire Inflation

Page 1

Open source document

Source excerpt

This information is provided free of charge by the Department of Industrial Relations from its web site at www.dir.ca.gov. These regulations are for the convenience of the user and no representation or warranty is made that the information is current or accurate. See full disclaimer at https://www.dir.ca.gov/od_pub/disclaimer.html. Subchapter 7. General Industry Safety Orders Group 2. Safe Practices and Personal Protection Article 7. Miscellaneous Safe Practices Return to index New query ## §3325. Tire Inflation. ## Tailgate/Toolbox Topics: Servicing Single, Split Rim & Multi-Piece Rims or Wheels (a) Tire inflation shall be accomplished by means of a clip-on chuck with a minimum 24-inch length hose to an in-line foot or hand valve and gauge. A clip-on chuck and an in-line regulator (factory preset at 40 psi maximum for passenger car tires or a restraining device may be used as an equivalent. EXCEPTIONS: (1) Automatic tire inflation machines that inflate the tire in a pressurized chamber through the bead seat annulus. (2) Where passenger car or truck tires are serviced at the same facility, an adjustable in-line regulator is allowed as long as the regulator pressure is properly set in each case. (b) Tire inflation control valves shall automatically shut off the air flow when the valve is released by the operator or be of the preset regulator type. (c) Specific employee instruction shall be provided which will ensure the employee makes the correct tire to rim size match prior to inflating the tire. (d) Tires shall not be inflated to more than the inflation pressure recommended by the manufacturer. (e) Unless otherwise recommended by the manufacturer, tires shall not be inflated beyond a maximum of 40 psi to seat the beads. During inflation, tire beads shall be inspected for proper seating at intervals not to exceed 20 psi. Tires not properly seated at 40 psi, or at the maximum psi recommended by the manufacturer, shall be completely deflated before making …

[7] Pallet Truck PR 4500 (PF14867) - Operator Manual

Page 32

Open source document

Source excerpt

# Power Sources ## POWER SOURCES Your truck can be designed to use the following power Sources: • Flooded Lead Acid Batteries • Thin Plate Pure Lead Acid Batteries • Lithium-Ion Batteries • Fuel Cell Power Packs If your truck is equipped with a V-Force lithium-ion battery, see the data plate installed on your truck. Only Crown approved power sources are permitted to be used in your truck. Only authorized service personnel are permitted to modify the power source installed in your truck. See the power source data plate for the approved power source installed in your truck. Note: Follow the manufacturer's specification and instructions when handling power sources. ## WORKING WITH POWER SOURCES Your company should provide an area that is safe to work on power sources. Use that area for all power source work and charging. • Do not charge or refuel a power source unless you are trained and authorized. • Do not remove or install a power source unless you are trained and authorized. # 31 Power Sources

[8] Pallet Truck PE 4500 (PF14692-B) - Operator Manual

Page 41

Open source document

Source excerpt

# Flooded Lead Acid Batteries (cont.) ## 39 Flooded Lead Acid Batteries (cont.) Note: DELAY ON LIFT When the battery is connected to the truck, there is approximately a 10 second delay before lift is available. Know the Hazards he Hazard A DANGER Batteries produce explosive gas. Do not smoke, use open flame, or create an arc or sparks near this battery. Ventilate well in enclosed areas and when charging. Batteries contain Sulfuric Acid which causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush immediately. Get medical attention if your eyes are affected. 107 ## TRUCK BATTERIES CAN BE DANGEROUS Your truck battery produces fumes that can explode. It also contains acid that could burn or disfigure you. • Do not try to install, remove, charge or service your truck battery unless you are trained and authorized. • Never smoke or use an open flame around batteries. - Your company should provide an area where it is safe to work on batteries. Use that area for all battery work. • Use protective equipment such as gloves, eye shields, aprons etc. ## BATTERY RETAINERS MUST BE IN PLACE The battery could slide out if all retainers are not in place. Check that both retainers are installed before operating your truck. ## COAST SELECTOR MUST BE OFF Be sure the coast selector is off and the brake is on before removing or installing a battery. Continued next page... ## Flooded Lead Acid Batteries 40

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