STATIC RUNFLAT SYSTEMS · 14 Inflate tyre in tyre inflation safety cage and check for air leaks. Please see page 02 for Fitting Tools 04 07 13 10 05 08 11 06 09 12 11 01 02 03. REMOVAL

INTERNATIONAL

MOBILITY & SECURITY EXPERTS

MAXIMUM RECOMMENDED SPEED WITH DEFLATED TYRES: 50km/h

STATIC RUNFLAT SYSTEMS

FITTING INSTRUCTIONS AND USER GUIDE(Remember to carry fitting instructions & fitting tool with the vehicle tool kit)

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FITTING TOOLS

Static RunFlat systems are designed to be fitted to multi piece wheels (either 2 piece bolt together or 3 piece demountable flange) and tubeless tyres.

These instructions apply to 3 segment Static RunFlat systems.

IMPORTANT. The fixing bolt locking method is a combination of Loctite thread adhesive and double locking washers under the head of each fixing bolt.

Both methods must be used.

STATIC FITTING RIG PART NO. RFI 043

THREAD LOCKING ADHESIVE PART NO. RFI 013

TORQUE LIMITING TOOL PART NO. RFI 009

HIGH TEMPERATURE GREASE PART NO. RFI 054

BEADSPREADER PART NO. RFI 016/A

EQUIPMENT NEEDEDFOR FITTING:A) STATIC FITTING RIG (Required for 3 Piece Demountable Flange Wheels, Optional for 2 Piece Bolt Together Wheels)B) TORQUE LIMITING TOOLC) HIGH TEMPERATURE GREASE (Supplied with RunFlat)D) LOCTITE THREAD ADHESIVE (Supplied with RunFlat)E) BEADSPREADER (Only required if no fitting rig available)

If Static RunFlat systems are fitted in accordance with these fitting instructionsthey will give good service.

READ THIS USER GUIDE CAREFULLY AND BRING IT TO THE ATTENTION OF ALLDRIVERS USING VEHICLES FITTED WITH STATIC RUNFLATS.

Vehicles are fitted with RunFlat systems for twopurposes:

1 To assist a driver to maintain control if a tyre should fail at speed. Because the vehicle drops onto the RunFlat system instead of directly onto the wheel, a higher level of control is possible than is the case ifno RunFlat system is fitted; and2 To enable a driver to continue travelling to a place of safety with a deflated tyre so that the damaged wheel can be changed. With security vehicles, it may be necessary to travel some distance to reach a place of safety.

Static RunFlat systemsare designed to meetextended run flat conditions.

The Static RunFlatsystem is designed to cover runflatdistances at speeds up to 50km/h.

With two front tyres deflated,steering control should be adequate to clear an area of hazard at lower speed (typically 20km/h). In a serious emergency, traction and control can be maintained with all four tyres deflated.

This Statement of Claim is theonly claim to RunFlat performance.

IMPORTANT: Underinflated and fully deflated tyres fitted with RunFlat systems behave differently to fully inflated tyres and the handling of the vehicle is markedly different. Therefore do not attempt violent manoeuvres or sudden changes of direction with one or more tyres deflated.

IMPORTANT: As a quality control measure, the following information should be recorded in the vehicle log or service book at the time of fitting of the RunFlat systems:i) Make and model of vehicle of vehicle and registration number.ii) RunFlat system batch number.iii) Date, location of fitting agency and name or quality control stamp details of fitter.iv) Vehicle mileage at time of fitting.

STATIC RUNFLAT SYSTEM

USER GUIDE

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STATIC FITTING RIG

SAFETY INSTRUCTIONSThe Static Fitting Rig has been designed to allow the installation of Static RunFlat systems into multi piece wheels (2 piece bolt together and 3 piece demountable flange wheels) and tubeless tyres. The compression bracket is required for 3 piece demountable flange wheels but not necessary for 2 piece bolt together wheels.

SAFETY INSTRUCTIONS RunFlat International always recommend to use the Static Fitting Rig for Static RunFlat system installation as it makes the process safer, easier and quicker. Failure to follow the recommendations and working methods given here and ignore warnings can lead to serious injury to the operator and other persons.

If using the fitting rig, do not turn the device on before reading the instructions thoroughly and all information provided on it regarding safe work.

The device may only be operated by qualified persons authorised to operate it. A qualified operator is a person who has read the exact contents of these operating instructions, went through the appropriate training, has knowledge of work safety and service and adjusting the device.

It is forbidden to operate the device by persons who are under the influence of alcohol or drugs that worsen their physical or mental abilities.

Observe the following conditions:• The operator must be able to read and understand all information contained in these operating instructions.• The operator must have full knowledge of the functioning and characteristics of the unit.• Unauthorised persons should maintain a safe distance from the operator unit.• The device should be installed in accordance with the applicable regulations and standards.• All persons operating the device must be properly trained in terms of its service.• Any modifications to the device are made without authorisation and automatically relieves the producer from liability in the event of damage or accident.

Type of wheel rim 3 piece wheels with demountable flange 2 piece bolt together wheels

Main tyre sizes 335/80R20, 365/80R20, 395/85 R20, 12.00R20, 14.00R20, 16.00R20

Nominal working pressure air supply 7.0 bar

Air supply connection ¼”

Max pressure exerted on wheel rim 10 T

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Components of a Static Fitting Rig

FITTING RIG

COMPRESSION BAR

HYDRAULIC PUMPTOP PIECE EXTENSION

METAL TYRE LIFTING ARM

LOCKING NUT

HYDRAULIC HOSESHYDRAULIC CYLINDER REMOVAL BLOCK

COMPRESSION PLATES

COMPRESSION BRACKET

THE COMPONENTS OF A STATIC FITTING RIG INCLUDE:A) FITTING RIG B) METAL TYRE LIFTING ARM C) COMPRESSION BARD) LOCKING NUT E) COMPRESSION BRACKET F) TOP PIECE EXTENSIONG) COMPRESSION PLATESH) HYDRAULIC PUMPI) HYDRAULIC CYLINDERJ) HYDRAULIC HOSESK) REMOVAL BLOCK

STATIC FITTING RIG

Please see page 02 for Fitting Tools

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Keep these instructions with the fitting tools in the vehicle tool kit

01 Grease the inside tread of the tyre as uniformly as possible (1 tub per tyre as supplied).

02 Insert the 3 segments inside the tyre.

03 Assemble the 3 wedge bolts and 3 clamping plate bolts making sure double locking washers are fitted under the head of each bolt. Apply the supplied thread adhesive to bolts.

04 Put the wedge bolts in place to connect the 3 segments (4 to 5 threads).

05 Place the tyre and the pre-assembled RunFlat around the wheel rim.

06 Lift the top bead of the tyre (ideally with bead spreader RFI 016/A) and insert plastic or wooden blocks to access the fixings, whilst keeping the RunFlat in contact with the bottom bead of the tyre.

07 Use torque limiting tool to tighten down each wedge bolt in turn to torque setting marked on the identification label.

08 Fit clamping plate bolts at each joint position and tighten down the clamping bolts to torque setting marked on the identification label.

09 Remove blocks from wheel.

10 Place the O-ring seal before completing the fitting of the 2-piece wheel (ring to be bolted on the body of the rim). Using long studding tighten ring evenly until flange nuts can be fitted.

11 Working in a criss-cross pattern, tighten opposite bolts until all flange nuts are hand tight and then repeat in stages until the specified torque has been reached.

12 Inflate tyre in tyre inflation safety cage and check for air leaks.

FITTING INSTRUCTIONS

FOR 2 PIECE BOLT TOGETHER WHEELS (NO FITTING RIG)

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01 Place the wheel rim on the centre plate of the fitting rig and drop it down with the hydraulic piston.

02 Place the tyre on the fitting rig.

03 Lift the upper bead with the 3 metal tyre lifting arms.

04 Grease the inside tread of the tyre as uniformly as possible (1 tub per tyre as supplied)




08 Lift the upper bead with the 3 metal tyre lifting arms.

09 Continue until the bottom of the wheel rim is level with the bottom tyre bead.

10 Use metal tyre lifting arms to lift up top bead of the tyre.



13 Each joint should look like this when completed correctly. Release the 3 metal tyre lifting arms to release the upper tyre bead.

14 Place the O-ring seal before completing the fitting of the 2-piece wheel (ring to be bolted on the body of the rim). Using long studding tighten ring evenly until flange nuts can be fitted.

15 Working in a criss-cross pattern, tighten opposite bolts until all flange nuts are hand tight and then repeat in stages until the specified torque has been reached.



FOR 2 PIECE BOLT TOGETHER WHEELS (WITH FITTING RIG)


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FOR 3 PIECE DEMOUNTABLE FLANGE WHEELS(WITH FITTING RIG)

01 Place the wheel rim on the centre plate of the press and drop it down with the hydraulic piston.

02 Place the tyre of the fitting rig and lift the upper bead with the 3 metal tyre lifting arms.

03 Grease the inside tread of the tyre as uniformly as possible (1 tub per tyre as supplied).






09 Release the 3 metal lifting arms of the press to release the upper tyre bead. Place the seal in position on the edge of tyre bead.

10 Screw in the compression bar and place the compression bracket on the de-mountable flange. Screw locking nut onto compression the bar.

11 Place the two 40mm square tube section or compression plate under the wheel rim.

12 Compress the flange with the hydraulic piston and fit the locking ring.

13 Release the pressure. Remove the locking nut, the compression bracket and the compression bar and fit the safety locking clip to the locking ring.



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REMOVAL INSTRUCTIONS


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01 Deflate the tyre and undo all of the flange nuts in turn.

03 Lift the top bead of the tyre (ideally with bead spreader RFI 016/A) and insert plastic or wooden blocks to access the fixings. Undo all of the fixing bolts.

04 After all of the fixing bolts have been removed, lift the tyre and Runflat off the rim. Spread the tyre bead apart (ideally with bead spreader RFI 016/A) and remove the Runflat segments.

02 Remove the ring of the wheel.

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FOR 2 PIECE BOLT TOGETHER WHEELS



REMOVAL INSTRUCTIONS


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01 Deflate tyre and compress flange using the compression bracket, compression rod and compression nut.

04 Remove RunFlat system from the wheel and tyre assembly.

02 Remove flange and seal. 03 Insert metal tyre lifting arms. Using the compression nut and removal block, use the hydraulic cylinder to push the wheel rim down.

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FOR 3 PIECE DEMOUNTABLE FLANGE WHEELS

Static RunFlat systems are designed to bereturned to service after runflat use, subject to the following conditions.

01 If the system has been subjected to any form of ballistic or explosive attack, it is recommended that the complete system should be changed. Alternatively the RunFlat system may be returned to the local RunFlat International distributor or agent with an account of the runflat incident for detailed inspection by the distributor or agent. On no account should it be returned to service without this inspection process.

02 Otherwise the following measures must be carried out by the workshop manager:

i) The system(s) involved in the runflat use should be cleaned and examined carefully for cracks, fissures or any mechanical damage sustained during run flat use. If there is any sign of damage the unit must be returned to the RunFlat International distributor or agent for detailed examination.

ii) If there is no sign of surface damage, the system(s) should be fitted to a bare wheel (wheel with no tyre) from the vehicle to the RunFlat systems were originally fitted. The wedge fixing bolts should then be tightened to the recommended torque setting. If the units can be rotated on the wheel the RunFlat system(s) must be returned to the RunFlat International distributor or agent for detailed examination.

iii) If there is no movement of the RunFlat system on the wheel, remove it, and fit to the original wheel with new fixing bolts and double locking washers. The fitting should be recorded as for an initial fitting.

INTERNATIONAL

INSPECTION & REUSE

Static RunFlat systems after operation.

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a) As soon as you become aware of a deflated tyre, SLOW DOWN immediately.

b) If circumstances permit, stop immediately to establish the cause of the tyre failure.

c) If an emergency requires you to continue, reduce speed to a maximum of 50km/h and drive to the nearest point of safety. Avoid sharp turns or other violent manoeuvres.

d) At the first opportunity, stop and inspect the deflated tyre for damage. If there are obvious signs of serious tyre damage, do not continue, but change the wheel.

e) After any runflat use, report the occurrence to the workshop manager, who will arrange for the system to be inspected by the authorised RunFlat International distributor.

To reduce the risk of misuse of RunFlat systems, advice sheets should be issued as follows:

MISUSE OF RUNFLAT SYSTEM

VEHICLE DASHBOARDRUNFLAT SYSTEMS

For your safety and securitythe wheels on this vehicle arefitted with RunFlat systemsinside the tyres. These helpyou to maintain control if a tyre fails at speed, or to continue with a deflated tyre to a place of safety to have the wheel changed. DO NOT exceed 50km/h with a deflated tyre. Stop as soon as you can to change the wheel.Read the OperatingInstructions in the VehicleLogbook. Check tyrepressures daily.

VEHICLE LOGBOOKRUNFLAT SYSTEMS

For your safety and securitythe wheels on this vehicle arefitted with RunFlat systems.They give improved drivercontrol if a tyre fails at speedand allow the vehicle tocontinue in an emergencywith a tyre deflated. Vehicleshandle differently withdeflated tyres. DO NOT swerve sharply or carry out violent manoeuvres with a deflated tyre. DO NOT exceed 50km/h with a deflated tyre. Stop as soon as possible to have the damaged wheel changed.Check your tyre pressuresdaily and report any runflatuse to the workshop manager.

Note: The RunFlat systems have to be removed to change tyres.

DRIVER’S RESTROOMRUNFLAT SYSTEMS ONSECURITY VEHICLES

This vehicle is fitted with RunFlat systems for your safety and security. These assist in controlling the vehicle after a tyre blow-out at speed and allow drivers to continue with a damaged tyre in an emergency. Vehicles handle differently with deflated tyres. Sudden turns or other violent manoeuvres with underinflated tyres cancause the vehicle to becomeunstable. For this reason, assoon as you become aware ofa deflated tyre, SLOW DOWNimmediately. DO NOT exceed50km/h with a deflated tyre.In an emergency you are ableto continue at a reduced speed to a place of safety to have the damaged wheel changed. RunFlat systems have to be removed to change tyres. Tyre pressures must be checked daily to avoid damage to the RunFlats and the tyres.Ask for more details from the Workshop Manager

All of the below parts are supplied with new RunFlat systems. They are also available as spares when changing tyres, etc. For specific RunFlat systems, some of the spares may be different to those below; it is strongly recommended to provide as much information as possible about the vehicle, wheel rims, tyres and RunFlat system itself (if known) when ordering spares.

STORAGE OF RUNFLAT SYSTEMSAll systems must be stored before use in the following conditions:

• Relative humidity of 60 or higher.• Out of direct sunlight.• Not subject to water exposure, e.g. rain, floods.• Covered to ensure systems are dust and contamination free, in low light levels.• Ideal storage temperature between 10ºC and 25ºC.

SPARES

CLAMPING PLATE

WASHER

WEDGE

FIXING BLOCK

FIXING BLOCK PIN

BOLT

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Inside of tyre greased

Washers on every bolt

Loctite applied to every bolt

Wedge torqued to correct level

Clamping plate fitted at each segment

Clamping plate torqued to correct level

RunFlat part number label attached

Wheel seal fitted

Tank valve seal fitted (if applicable)

Tyre inflated

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FITTING CHECKLIST

CHECKLIST FOR FITTING STATIC RUNFLAT SYSTEMS

Procedure 3

The following checklist is to ensure you have completed each stage of the fitting procedure.

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TECHNICAL DETAIL

DOVETAIL GROOVESOn some forged aluminum bolt together rims supplied by RunFlat International, you may find a dovetail goove, designed to lock the O-ring in place enabling parts to be inverted without any risk of affecting the seal position or integrity. As a result, the installation of our wheels and RunFlats is faster, easier and less prone to operator error.

To install the O’ ring in the dovetail groove, we recommend the following steps:

01 Check the groove visually for signs of any damage or sharp edges.

02 Apply a thin layer of grease on the O-ring to ease the installation.

03 Align the O’ ring with the groove.

04 Simultaneously push the O-ring into the groove at two points diametrically opposite each other.

05 Once the first two sections are inserted, push the O-ring at the mid points of the uninstalled area (90 degrees either side of the installed sections).

06 Continue to insert the O-ring inside the groove at the mid-points of the uninstalled areas until the O-ring is fully installed inside the groove.

07 Check that the installed O-ring is evenly proud of the machined surface.

08 Fill the round hole (entry/exit hole) of the groove with clear silicon to prevent air leakages from this area.

04 0805

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NOTES

INTERNATIONAL

RunFlat International LimitedGawne Lane, Cradley Heath, West Midlands B64 5QY, United Kingdom.

Tel: +44 (0)1384 414845 Fax: +44 (0)1384 414849Email: [email protected]

www.runflatinternational.com

RunFlat International’s products are regularly, arduously tested according to militarystandards such as Finabel as well as other standards established by certain countries

and manufacturers (e.g TUV, Mercedes 150km, Plasan 300 km tests). Originally designed and manufactured for highly demanding military requirements,

RunFlat systems are now sold to broader markets (Police vehicles, VIP cars, high value cargo carriers, aid agency vehicles, etc) all around the World.

Documents

STATIC RUNFLAT SYSTEMS · 14 Inflate tyre in tyre inflation safety cage and check for air leaks. Please see page 02 for Fitting Tools 04 07 13 10 05 08 11 06 09 12 11 01 02 03. REMOVAL