Military Tire Disassembly & Runflat Machine

1. Preparation & Safety

• Confirm the wheel assembly is removed from the vehicle.
• Place it in a designated work area or machine cradle.
• Verify the assembly is fully deflated per TM guidance.

2. Initial Bolt & Hardware Removal

• Loosen and remove outer beadlock or rim clamp bolts in a controlled sequence.
• Retain hardware for inspection or replacement.

3. Bead Separation

• Separate the tire bead from the rim seat.
• In a manual workflow, this involves heavy pry bars and bead breakers; in a machine workflow, hydraulic arms perform this bead-breaking step.

4. Runflat Exposure

• Once the beads are broken and the rim halves start to separate, the internal run flat inserter interface or ring becomes visible.
• Carefully separate rim halves to access the runflat insert.

5. Runflat Extraction

• Support the weight of the insert and remove it from the tire cavity.
• Inspect for cracks, cuts, or deformation; tag for reuse or disposal.

6. Tire Removal

• Fully remove the tire from the rim.
• Clean mating surfaces and inspect for corrosion.

7. Documentation & Disposition

• Record findings, condition codes, and maintenance actions in the appropriate maintenance information system.
• Prepare components for reassembly or replacement.

Manual Workflow

Where no dedicated machine is available, technicians typically rely on:

• Floor-mounted bead breakers
• Long pry bars and hammers
• Improvised stands or wooden supports
• Multiple personnel to restrain, rotate, and lift assemblies

Challenges:

• High physical strain and injury risk
• Significant variation in technique and quality between teams
• Risk of rim damage if force is misapplied
• Slow cycle times, especially on large 20"+ MRAP/APC wheels

Manual methods can be made safe with training and discipline, but they do not scale well in high-tempo operations with large fleets.

Machine-Based Workflow

A dedicated military tire disassemble tool combined with a powered runflat machine changes the process:

• Controlled clamping: The wheel is locked in a cradle that supports the weight.
• Hydraulic bead-breaking: Beads are depressed by actuators, not pry bars.
• Integrated run flat disassembly: The machine's arms and tooling heads are designed to push, pull, and rotate the tire relative to the runflat insert.
• Run flat inserter mode: The same machine is used as a run flat inserter when reassembling, aligning the insert and tire with repeatable force and position.

Benefits:

• Consistent process across all shifts and locations
• Dramatically reduced risk of crushed fingers, back injuries, and rim warping
• Clean integration with platform-specific tooling — e.g., JLTV/MRAP adapters and hmmwv tire tool fixtures

• Removal and transport of the wheel
• Runflat removal and assembly work
• Reinstallation and verification

Indicative example for one heavy runflat wheel:

If a maintenance company processes 10 runflat wheels per day:

• Manual: 10 × 105 min ≈ 1,050 minutes (17.5 labor hours)
• Machine: 10 × 37.5 min ≈ 375 minutes (6.25 labor hours)

• Increased vehicle availability
• Reduced backlog in maintenance queues
• More time to focus on higher-value tasks (diagnostics, inspections, upgrades)

• Musculoskeletal injuries (lifting, twisting, pulling)
• Pinch/crush injuries from slipping pry bars
• Flying debris if stored energy is released unexpectedly
• Rim spring-back if bolts are loosened unevenly

Mechanical Load-Bearing

• The machine cradle supports the full weight of the wheel.
• Technicians manipulate controls, not the entire assembly.

Controlled Force Application

• Bead-breaking and run flat disassembly are done via actuators with defined force limits.
• Movement is predictable and repeatable.

Standoff Distance

• Operators can stand clear of pinch points while the machine separates components.

Integrated Training and SOPs

• Standardized procedures reduce variance between crews and sites.
• Safety interlocks and emergency stops further reduce risk.

• Set up quickly for HMMWV
• Reconfigured for JLTV or MRAP wheels with a change of adapters
• Used both for run flat disassembly and as a run flat inserter for reassembly

1. Operational Availability

• Faster turnaround on wheels → more vehicles ready for tasking.
• Reduced risk of tire-related downtime during intense operations.

2. Lifecycle Cost Reduction

• Less damage to rims and inserts from improvised techniques.
• Better consistency leads to fewer repeat repairs.

3. Personnel Safety & Retention

• Reduced injuries, fewer lost workdays, lower compensation risk.
• Better working conditions support retention of skilled maintainers.

4. Standardization & Compliance

• A dedicated military tire disassemble tool supports compliance with OEM/DoD maintenance guidance.
• Easier to pass audits and inspections when procedures are documented and repeatable.

5. Scalability

• Single machine can support multiple platforms (HMMWV, JLTV, MRAP, APC, LAV).
• Additional machines can be deployed to high-volume depots or theater hubs.

1. Labor Savings

ΔMTTR (manual vs machine) × number of wheels per year × labor cost per hour.

2. Asset Protection

Reduction in damaged rims/runflats per year × replacement cost.

3. Availability Value

Additional vehicle-available days × value per day (mission, training, readiness).

Example:

• Wheels processed per year: 1,000
• Manual labor per wheel: 1.5 hrs
• Machine labor per wheel: 0.6 hrs
• Labor rate (fully burdened): 50 USD/hr

Labor savings:

• Manual = 1,000 × 1.5 × 50 = 75,000 USD
• Machine = 1,000 × 0.6 × 50 = 30,000 USD
• Annual labor saving = 45,000 USD

• Baseline data from current manual operations
• Pilot/early deployment results
• Projected ROI over 5–10 years, with conservative assumptions