TECHNICAL MANUAL HANKOOK TIRE TRUCK AND BUS TYRE. hankooktire.com

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1 hankooktire.com HANKOOK TIRE TRUCK AND BUS TYRE TECHNICAL MANUAL Introduction I Product information I Regrooving guide I Rim and accessories I Maintenance and care

2 PREFACE This manual provides information about truck and bus tyres that can help Hankook Tire customers achieve safe, economical use of our products and maximise tyre life. The purchase of truck and bus tyres should be looked at as an investment to be protected by thorough maintenance and care in order to produce the best return on your investment and fleet operating efficiency. Information covered in this manual includes how to achieve the best efficiency through a program of regular tyre inspection, servicing, repairing and so on. Specific safety related information regarding mounting and demounting tyres is also included. Careful attention on a regular basis can provide you with added safety and economy. We hope the information is helpful to all tyre service men and fleet operators.

3 CONTENTS 01 Introduction 06 About Hankook Tire 08 Hankook tyre segmentation 10 Load index and speed symbol 12 Truck tyre markings 14 Smartec technology 02 Product Information 18 Truck and bus tyre range 20 Introduction of each segment 32 Technical table legend 34 Technical data of all tyres 03 Regrooving Guide 50 Regrooving introduction 52 Regrooving technical data 04 Rim and Accessories 74 Technical data of rims 78 Demounting and mounting 80 Tubeless tyre demounting / mounting 84 Tubeless rim valve mounting 86 About dual spacing 05 Maintenance and Care 90 About tyre inflation 92 Truck alignment and tyre wear 97 Abnormal tread wear 98 Tyre damage

4 INTRODUCTION TRUCK AND BUS TYRE I TECHNICAL MANUAL INTRODUCTION

5 About Hankook Tire Hankook tyre segmentation Load index and speed symbol Truck tyre markings Smartec technology INTRODUCTION

6 INTRODUCTION About Hankook Tire HISTORY OF HANKOOK 1941 Founded 1979 Built Daejeon (Korea) plant 1982 Established the main R&D Center 1997 Built Geumsan (Korea) plant 1999 Built Jiangsu (China) and Jiaxing (China) plant 2005 Built G Trac (proving ground) in Geumsan 2006 Ranked seventh-largest tyre maker in the world 2008 Begun production at Hungary plant 2008 Expanded Geumsan plant 2009 Launched e-cube, the environment-friendly tyre 2013 Launched e-cube MAX, the second generation of our environmental friedly tyre 2014 Supply to Mercedes Benz Trucks OE 2015 Supply to MAN OE 2016 Launching of e-cube Blue 2016 Supply to Scania OE GLOBAL RANKING Bridgestone Michelin Goodyear Continental Pirelli Sumitomo Hankook Tire Co., Ltd. Yokohama Cooper Tyre Kumho Tyre

7 TECHNICAL MANUAL North America Service : NAP network Retreading : HK dealership network Europe Distribution : HTM network Retreading : alphatread Pan-European breakdown service : Road Assist 24h TBX : Truck and Bus Express HTM : Hankook Truck Masters HHH : Hankook Highway Helpline Korea / China Service : TBX network (Korea) Hankook Truck masters (China) Retreading : alphatread Australia Service : HHH network Retreading : Reclamation warranty

8 INTRODUCTION Hankook Tire segmentation Product brand Position Circumstance Sequence No. Position Long haul Regional haul Urban Mixed service, off road Winter A AL AH AU AM AW D DL DH DM DW T TL TH TM TW L Long haul H Regional haul U Urban M Mixed service, off road W Winter Long distance driving Medium distance driving City bus, urban traffic On and off road, construction, off road Winter road conditions SEVERITY

9 TECHNICAL MANUAL e-cube Environmentally friendly tyre enhanced with fuel efficiency and high mileage attributes. e-cube (e 3 ) = energy x economy x environment energy economy environment Improved fuel efficiency. The highest economic efficiency, through lower fuel consumption and high mileage. Reduced harmful emissions through improved fuel efficiency. E-CUBE SERIES (LONG HAUL PRODUCT)

10 INTRODUCTION Load index and speed symbol SIZE MARKINGS Markings 295/80R /147L 295 Tyre section width (mm) 80 Aspect ratio [(section height / section width) x 100] R Radial structure 22.5 Rim diameter (inch) 152 Max. load index when mounting single wheels (3,550kg) 147 Max. load index when mounting dual wheels (3,075kg) L Tyre max driving speed symbol (120km/h) SPEED SYMBOLS [km/h and mph] Symbol G J K L M km/h mph VARIATION IN LOAD CARRYING CAPACITY Speed (km/h) Variation in load carrying capacity Speed symbol F G J K L M Inflation pressure compensation (%)* Static * Increments to be applied in the absence of any specific agreement with the tyre manufacturer

11 TECHNICAL MANUAL CONVERSION OF LOAD INDEX (LI) INTO LOAD CAPACITIES PER TYRE LI kg Ibs LI kg Ibs

12 INTRODUCTION Truck tyre markings TYRE SIZE MARKINGS All truck tyres are marked represent their structure, construction type, dimensions and manufacturer / brand. In addition they should carry the U.S. Department of Transport code and/or ISO symbols. Below is a typical Hankook tyre that illustrates ISO markings. T.W.I mark Brand tyre here DOT code Country name Safety warning Material Province Safety Warning Serious injury may result from tyre failure due to under inflation or overloading. Follow the tyre placard instructions on the vehicle and check inflation pressures frequently.

13 TECHNICAL MANUAL Brand name E mark and No Korean industrial standard mark Regroovable Tubeless Radial tyre Pattern name Tyre size Test pressure Load and speed symbol Load and inflation pressure Load range Due to Improper mounting - only specially trained persons should mount tyres. Follow all safety procedures, inflate using a safety cage and a remote clip-on extension hose.

14 INTRODUCTION

15 TECHNICAL MANUAL Safety Robust structure Mileage Cover more distance Anti chip & cut Sturdy compound Retreadability Saving costs Tration Enhanced safety Experience, Smartec! Hankook Tire is sustainably developing new truck and bus tyres. We offer a wide range of different tyre solutions to meet the demands of various road conditions and different customer needs. In order to provide enhanced multi-performance to our customers, Hankook Tire has high quality standards for all our products. The newly launched Smartec concept is a combination of the best Hankook truck and bus tyre technologies. Smartec is based on the five main tyre performances: safety, mileage, anti chip & cut, retreadability and traction. These benefits are usually being considered by customers when choosing tyres. From research to development throughout production, all Hankook truck and bus products are based on Smartec and aim to provide customers with the best and safest driving experiences!

16 PRODUCT INFORMATION TRUCK AND BUS TYRE I TECHNICAL MANUAL PRODUCT INFORMATION

17 Truck and bus tyre range Introduction of each segment Technical table legend Technical data of all tyres TECHNICAL INFORMATION

18 PRODUCT INFORMATION Truck and bus tyre range This chart will help you choose the most appropriate tyre for your driving conditions and the region. If you have any questions, please contact your nearest Hankook representative. EU : Europe Driving conditions / Axle All Position Drive Trailer Long-distance transport (above 500km) AL10+ / AL10 AL20 / AL20w DL10+ / DL10 DL20 / DL20w Coach AL22 DL22 National and regional transport (below 500km) AH11 / AH22 AH31 / AH35 / AH33 DH03 / DH05 / DH16 DH31 / DH35 / DH33+ TL10+ / TL10 / TL20 TH22 / TH31 Mixed service (Below 10% Off Road) AM06 / AM09 AM15 / AM15+ / AM11 DM06 / DM09 DM11 TM15 / TM11 Off road DM04 / DM07 City bus AU03 / AU03+/AU04+ Winter AW02 DW07 / DW06 TW01 Note : The tyres for front axle can be used for all position. However, if you want to use them on drive or trailer axle, please contact your nearest Hankook representative. NOTES T/T : Tube type T/L : Tubeless type M + S : Mud and snow : 3PMSF (Three Peak Mountain Snowflake) This data can be changed by manufacturer without prior notice. The Tyre Labelling Regulation introduces : Fuel efficiency / wet grip / external rolling noise of tyres. Its aim is to : Improve safety. Improve environmental and economic efficiency of road transport by promoting fuel efficient and safe tyres. Lower noise levels. Actual fuel saving and road safety depends heavily on the behaviour of drivers, and in particular the following : Eco-driving can significantly reduce fuel consumption. Tyre pressure should be regularly checked to optimise wet grip and fuel efficiency performance. Stopping distances should always be strictly respected.

19 TECHNICAL MANUAL No matter how far you drive, Hankook Tire has the solution.

20 PRODUCT INFORMATION Segment L LONG HAUL M + S Long haul all position tyre with extra low rolling resistance and superb fuel efficiency. Enhanced block stiffness results in better rolling resistance performance. Thanks to smart shoulder block design abnormal tread wear is being reduced. M + S Long haul drive axle tyre with extra low rolling resistance and superb fuel efficiency. Solid 4 block centered design ensures improved rolling resistance. Centre zigzag grooves create a binding effect on each tread block contributing to better rolling resistance and traction. Long haul trailer tyre with extra low rolling resistance and superb fuel efficiency. The low rolling resistance compound reduces the loss of energy and results in increased fuel efficiency. Multi-kerfs prevent irregular wear from external forces and provide rib stiffness.

21 TECHNICAL MANUAL The long haul tyre is ideally suited for long distance driving on express motorways and good road conditions. It not only saves fuel but also provides excellent riding comfort and handling performance. All position tyre for long haul usage with excellent fuel efficiency and a high mileage capability. An enhanced eco-friendly product designed with e-cube technology for long haul steer service without compromising mileage, durability or safety. M + S Long haul drive tyre for superior traction and greater fuel efficiency. A specially designed product for long haul driving conditions, providing excellent traction, higher mileage, uniform tread wear and greater fuel efficiency. Trailer tyre with superb fuel efficiency and traction. e-cube trailer product with a high mileage capability and significant fuel savings for long haul operations. Premium long haul line up with extra low rolling resistance and superb fuel efficieny.

22 PRODUCT INFORMATION Segment L LONG HAUL All position tyre for long haul trucking applications with high fuel efficiency. An enhanced eco-friendly product designed with e-cube technology for long haul steer service without compromising mileage, durability or safety. M + S Drive axle tyre for long haul trucks and buses with extra high fuel efficiency. A specially designed product for long haul driving conditions, providing excellent traction, higher mileage, uniform tread wear and greater fuel efficiency. M + S Trailer tyre for long haul trailer with extra high fuel efficiency. e-cube trailer product with a high mileage capability and significant fuel savings for long haul operations.

23 TECHNICAL MANUAL Segment L COACH M + S Long distance coach tyre for excellent handling performance and a high driving comfort on highways. A combination of zigzag and straight grooves provides excellent traction on highways whilst the center rib ensures high mileage and supreme handling performance. M + S Long distance coach drive axle tyre for excellent handling performance and a high driving comfort on highways. Main 4 zigzag grooves improve block-stiffness and traction. Square and interlocking centre blocks enable longer mileage, and improve riding and handling. Centre V-shaped 3D kerf and lateral groove detail improve winter performance.

24 PRODUCT INFORMATION Segment H REGIONAL HAUL M + S All season steer axle tyre for variable road conditions. Wide tread and wide shoulders for a long mileage and an excellent handling performance. M + S All season drive axle tyre for variable road conditions. Self Regenerating kerf (S.R. kerfs) control the tearing and wearing with the help of hidden grooves whilst maintaining traction even at the end of the groove wear. M + S All season trailer axle tyre for variable road conditions. Provides excellent traction and water drainage under various road conditions.

25 TECHNICAL MANUAL The regional haul tyre is designed for a reliable driving pleasure on state roads whilst providing excellent traction and grip. M + S Premium regional tyre developed for superior control and extended tread life. Combined pattern with straight and zigzag grooves provides better traction and driving performance and reduces stone retention. Waved kerf family pattern for hankook premium regional haul steer tire M + S Drive tyre provide improved mileage and excellent braking performance. Directional pattern provides better traction and braking performance. Optimized block size and shape sustain optimized block stiffness and provide better driving stability. M + S All season steer axle tyre for variable road conditions. The special tread pattern design with a combination of 4 wavy and straight grooves provide outstanding traction and drainage performance on long and regional haul multi-applications. Wide tread width offers high pattern volume resulting into a high mileage performance. M + S All season drive axle tyre for variable road conditions. Rib type tread pattern design and multi 3 dimensional sipes ensure low rolling resistance and excellent driving performance. Wide tread with 4 zigzag grooves enables high mileage and excellent driving performance in variable conditions.

26 PRODUCT INFORMATION Segment H REGIONAL HAUL M + S M + S Regional haul trailer tyre with enhanced driving performance. Regional drive position tyre for exceptional traction and mileage performance. All position tyre for regional haul with extra long mileage. All position tyre for regional haul application with high mileage. M + S M + S Drive axle tyre with superior grip and outstanding traction. Drive axle tyre for regional haul application with excellent traction performance.

27 TECHNICAL MANUAL Segment M ON and OFF, OFF M + S All position tyre for mild on and off road conditions. Improves traction and braking performance by expanding the point of intersection through 3 zigzag grooves and an optimized unique kerf design without chipping or cutting. M + S Drive axle tyre for mild on and off road conditions. The directional pattern is adopted for excellent handling meaning better traction performance is provided even in wet and muddy conditions. M + S Trailer axle tyre for mild on and off road conditions. Improves traction and braking performance by expanding the point of intersection through 3 zigzag grooves and an optimized unique kerf design without chipping or cutting.

28 PRODUCT INFORMATION Segment M ON and OFF, OFF M + S Wide-based single tyre for mixed operation with high mileage. All-wheel-position wide base tyre designed to deliver high mileage and traction in mixed operations. The tyre has outstanding casing durability and retreadability due to its low heating tread compound application. Thick shoulders help to provide added sidewall protection and minimise casing damage from impacts. Square shoulder shape and ideal contact pressure / contact shape also help prevent irregular wear: Realisation of improved durability through the open-shouldered structure and increased inner-volume of tyres. Improved tyre durability by applying a compounding technology for tread rubber. Optimum hydroplaning and traction performance supported under various road conditions. M + S All position tyre for mixed usage and enhanced on/off road performance. Polygonal blocks and zigzag grooves for excellent traction and braking performance. Wide shoulder design for improved handling performance. Stone ejector for reduced stone drilling. Closed shoulder design with lugs for driving stability and an even wear M + S Designed for mixed usage and enhanced on/off performance. The directional pattern is adopted for excellent handling. The best traction performance is provided even in wet and muddy conditions : The first directional type tyre for on and off road application. Improved performance for on and off road. Increased resistance to cuts and chips on the tread and sidewalls. Adopted new technology of less stone retention. Best durability realised through an optimised casing design.

29 TECHNICAL MANUAL The on and off / off road tyre shows distinguished traction on an unpaved road so that it boasts high performance and resists cutting and chipping. M + S Trailer tyre for on and off road usage. Trailer tyre designed for demanding on and off road conditions. Remarkable groove width for enhanced traction performance. Stone ejector rib in the middle of the grooves prevents stone drilling. Adoption of linear grooves for maximum stability and performance with excellent water dispersal. M + S All position for on and off road operations. Structural design for On & Off condition featuring excellent traction and durability. M + S Drive axle tyre for off road conditions with excellent traction and durability. Drive axle tyre for off road conditions.

30 PRODUCT INFORMATION Segment W WINTER The winter tyre gives road hugging traction on snowy and icy roads to provide secure control. Its braking performance is unbeatable due to its excellent grip and traction. It delivers precise handling and prevents skidding on slippery roads. M + S M + S All position winter tyre for severe weather conditions. Zig-zag 5 groove design supports excellent water abrasion. 3D kerfs provide even wear and a high mileage as well as superb traction on snowy and icy roads. Tie bars ensure a high block stiffness and a reliable handling performance. Unique semi-open shoulder design. Drive tyre for maximum grip on snowy and icy conditions. Drive axle tire for severe winter conditions. Large amount of multi 3D kerfs with jaggy edge design for excellent grip and traction on snow. Pentagon block design and special new tread compound for high mileage. M + S M + S Wide-based single tyre for mixed operation with high mileage. Zigzag type and 5-groove pattern provice excellent traction on snow and ice. 3D kerfs provide reliable traction and even wear. Winter tyre for severe snow conditions. 4 groove zig-zag design provides excellent traction on snow and ice. Wide shoulder rib provides excellent wet grip performance and high mileage.

31 TECHNICAL MANUAL Segment U URBAN BUS The urban tyre is primarily used for driving through city streets. With greater wear resistance, the urban tyre has a long life and is designed to show great braking and driving performance. * M + S * partly PMSF All position tyre for urban service with extra long mileage. Optimised design technology for urban operations involving frequent stop and go driving. Uneven wear is minimised by optimised kerf arrangement : Expanded shoulder width and adoption of pitch allocation increase stiffness on shoulder area. Horizontal kerfs are inserted at the tread rib. These kerfs offer equilibrium of centre and shoulder block stiffness. M + S All position tyre for urban transport. Optimized design technology for urban operations involving frequent stop and go driving : Special pattern design for economic benefit of reduced downtime and easy fitting performance

32 PRODUCT INFORMATION Technical table legend VALUE AND QUALITY TO CUSTOMERS! (S) SECTION WIDTH (mm) The linear distance between the outsides of the sidewalls of an inflated tyre excluding elevations due to labeling (marking), decorations, protective bands or ribs. (H) SECTION HEIGHT (mm) Half the difference between the overall diameter and the nominal rim diameter. (OD) OVERALL DIAMETER (mm) The diameter of an inflated tyre at the outermost surface of the tread. (RST) STATIC LOADED RADIUS (mm) The distance between the wheel centre and road surface referring to a tyre inflated and loaded at the values shown in the table under static conditions. (RC) ROLLING CIRCUMFERENCE (mm) The distance covered in one complete revolution of the tyre under load and pressure conditions indicated in the tables. (D) MINIMUM DUAL SPACING FOR TWIN FITMENTS (mm) Dual spacing is the distance between the center lines of the twin tyres. The D min values refer to tyres without chains and may also be applied in the case of the fitment of chains for twin tyres. If chains are fitted on one tyre only, the "D min" values must be increased so that the sidewalls of the tyre under load do not trap the chain and become damaged.

33 TECHNICAL MANUAL S H OD Rst D The values in the tables are approximate and may vary in practice, including a possible growth in service. They do not, however, exceed the following limits : CONVERSION FACTORS TO CONVERT FROM INTO MULTIPLY BY mm inch inch mm 25.4 kg lbs lbs. kg bar kg/cm kg/cm 2 bar bar lbs./sq. inch (psi) lbs./sq. inch (psi) bar bar kpa 100 lbs./sq. inch (psi) kpa km/h m.p.h m.p.h km/h

34 PRODUCT INFORMATION Technical data of all tyres TUBE TYPE Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 10.00R20 AH11 147/143L TT C C W DH05 147/143L TT D C W R20 AH11 150/146L TT C C W DH05 150/146L TT D C W R20 AM06 154/150K (156/150G) TT D C W DM09 154/150K TT E C W2 75 DM04 154/150G TT 8R17.5 AH11 117/116L TL D C W DH05 117/116L TL D C W R17.5 AH35 131/129L TL D C W DH35 121/120L TL D C W R17.5 AH35 131/129L TL D C W DH05 131/129L TL E C W2 75 DH35 131/129L TL D C W1 70 TH22 143/141J TL D B W1 70

35 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) S L= D S L= D K= S K= S G= D S L= D S L= D S L= S J= D S D D D D

36 PRODUCT INFORMATION TUBELESS CONVENTIONAL Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 8R19.5 AH35 124/122L TL D C W R22.5 AH11 141/139M TL C C W AM09 144/142K TL C B W1 70 AH33 141/139M TL C C W R22.5 AL10 148/145M TL C B W DL02 148/145M TL D C W2 74 AH22 148/145L TL C B W1 70 DH03 148/145M TL D C W2 75 DH05 148/145L TL D C W2 75 AM09 148/145K TL D B W1 67 DM04 148/145G TL DM09 148/145K TL E C W1 70 DM09 148/145K TL E C W1 70 AU03 148/145J TL C B W1 71 TH22 148/146L TL C B W2 70 AH33 148/145L TL C B W R22.5 AL10 152/148L TL C C W DL02 152/148L TL D C W2 74 AH22 152/148L TL C C W1 70 DH05 152/148L TL D C W2 75 DH16 152/148L TL D C W2 71 DH05 152/148L TL D C W2 75 DH16 152/148L TL D C W2 71 AM09 152/149K TL D B W1 69 DM04 152/148K TL DM09 152/148K TL E B W1 70 DW07 152/148L TL D C W1 72

37 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) S L= D D M= S K= S L= D S K= D D G=90 J=100 L= S L= D K= D

38 PRODUCT INFORMATION TUBELESS CONVENTIONAL Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 12R22.5 AH33 152/148L TL C C W1 70 DH /149L TL E C W R22.5 AH11 156/150L TL C C W AM09 156/150K TL D C W1 70 DM09 156/150K TL D C W2 75 DM04 154/150G TL AH33 156/150L TL C C W /65R17.5 TH22 129/127K (132/132F) TL C C W /75R17.5 AH35 124/122M TL C C W DH35 124/122M TL D C W /75R17.5 AH35 126/124M TL D C W AH35 128/126M TL D C W1 65 DH35 126/124M TL D C W1 66 TH22 135/133J TL D B W1 70 TL /133J TL C B W /75R17.5 AH35 129/127M TL C C W DH35 129/127M TL D C W /75R17.5 AH35 132/130M TL C C W DH35 132/130M TL D C W1 73 TH22 143/141J TL C B W1 70 TL /141J TL B B W /70R17.5 AH35 136/134M TL C C W DH35 136/134M TL D C W1 73 TH22 143/141J TL C B W1 70 TL /141J TL B B W /70R19.5 AH35 136/134M TL C C W DH35 136/134M TL D C W1 73

39 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) S L= S K= D G= S K= S F= D D S M= D S M= S J= S M= D J= D D S M= D S M= S J= D D S M= S J= D F= D S M=130 S J=100

40 PRODUCT INFORMATION TUBELESS LOW SECTION Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 245/70R19.5 TH22 141/140J TL C B W1 67 AU03 136/134M TL D C W /70R22.5 AL10 140/137M TL C B W /70R17.5 AH35 140/136M TL C C W * DH35 140/138M TL D B W /70R19.5 AH35 140/138M TL D B W DH35 143/141J TL D B W2 74 AM15 143/141J TL C B W1 70 TH22 143/141J TL B B W1 69 TL /138M TL D C W /80R22.5 AH22 149/146L TL C C W AU03 149/146J TL D C W /70R22.5 AL10 148/145M TL C C W DL10 148/145M TL D C W2 75 TL10 152/148J TL C B W1 69 AH31 148/145M TL C C W1 69 DH31 148/145M TL D C W2 75 TH31 152/148J TL C C W1 69 AM15 148/145K TL D B W2 74 AW02 150/145J TL D C W1 70 DW07 148/145J TL D C W1 72 AU /145J (154/148E) TL D C W1 71 AU /148J TL D B W /70R19.5 AH35 146/144M TL C B W DH35 146/144M TL D B W1 70 TH22 150/148J TL C B W /55R22.5 * DL /145K TL C C W * under development

41 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) 136 S D D S M= D S M= D S M= S J= D D S J= D S M= S K= S J= S M= D S M= S J= D D S K= D

42 PRODUCT INFORMATION TUBELESS LOW SECTION Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 295/60R22.5 AL /147L TL C B W DL /147L TL C C W1 73 DH31 150/147K TL D C W /80R22.5 AL10 152/148M (154/149L) TL C C W DL10 152/148M TL C C W2 75 AL22 154M TL C B W1 71 DL22 154/149M TL C C W1 70 AH31 154/149M TL C B W1 73 AH31 152/148M (154/149L) TL C B W1 73 DH03 152/148M TL D C W2 75 DH05 152/148M TL E C W2 75 DH31 152/148M TL D C W2 75 AM09 152/148K(154/150J) TL C B W1 70 DM09 152/148K TL E B W1 70 AW02 154/149M TL D C W1 70 DW06 152/148L TL D C W2 76 DW07 152/148L TL D C W1 69 AU03 152/148J TL C C W /70R19.5 AH35 148/145M TL C C W DH35 148/145M TL D B W /70R22.5 AL10 152/148L TL C C W /45R22.5 * DL /145L TL D C W /60R22.5 AL /148L TL C B W DL /148L TL C C W2 75 AH31 154/148L TL C B W1 70 DH31 152/148L TL D C W2 75 AU /148J TL C B W1 73

43 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) S L= S K= D D S M= S L= D K= D J= S M= D S M= S L= D S L= D S L= S D J=100

44 PRODUCT INFORMATION TUBELESS LOW SECTION Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 315/70R22.5 AL /150L TL B B W DL /150L TL C C W1 73 DL20 154/150L TL A C W1 72 DL22w 154/150L TL B C W1 70 AH31 156/150L TL C B W1 73 DH05 154/150L TL E B W2 75 DH31 154/150L TL D C W2 75 DW06 154/150L TL D C W2 76 AW02 154/150L TL D C W1 70 DW07 154/150L TL D C W /80R22.5 AL /150L (154/150M) TL B B W * AL22 156/150L TL C B W1 71 DL20w 156/150L (154/150M) TL C C W2 75 * DL22w 156/150L TL AH31 156/150L (154/150M) TL C B W1 73 DH05 154/150M (156L) TL E B W2 75 DH31 156/150L (154/150M) TL D C W2 72 AM09 156/150K TL D B W1 67 DM09 156/150K TL D C W1 70 DM04 156/150K (156L) TL DW06 156/150L TL D C W2 76 AW02 156/150L TL D C W1 70 DW07 156/150L TL D C W1 72 AM11 156/150K TL C B W1 72 DM11 156/150K TL C B W /95R24 DM06 162/160K TL D C W /50R22.5 AL L TL B B W * under development AH31 156L TL B B W /55R22.5 AL20 160K TL A C W TL20 160K TL A B W1 66

45 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) S M= S L= S D D S L= S K= D S K= D S L= S L= S K=110

46 PRODUCT INFORMATION TUBELESS LOW SECTION Tyre Labelling Class Rim Tyre Dimensions Tyre Size Tread Pattern Load Index & Speed Symbol TT/ TL Rim width Distance between rim centres (D) Max. Standard Value in service Width (S) Outer diameter (OD) 385/55R22.5 AH31 160K (158L) TL C B W1 69 * under development TH22 160K (158L) TL W B W1 71 AW02 160K TL C C W1 70 * TW01 160K TL C C W /65R22.5 AH31 164K TL C B W AH31 160K TL C B W1 69 AL K(158L) TL B B W1 70 TL K (158L) TL B B W1 69 * TH31 160K TL B B W1 69 TL20 160K TL A C W1 66 AM L TL C C W2 74 TM15 160K TL D C W1 69 AW02 160K(158L) TL C C W1 70 TW01 160K(158L) TL B C W1 69 TM11 160K(158L) TL C B W /65R22.5 TH22 165K TL C B W AM15 165K TL C C W /50R19.5 TL J TL B B W * TH31 160J TL B B W2 445/45R19.5 TL10 160J TL B B W TW01 160J TL C C W /65R22.5 AM15 169K TL C C W TL10 169K TL C B W /40R22.5 TL J TL B B W

47 TECHNICAL MANUAL Tyre Dimensions Load capacity (kg) per axle at tyre pressure (bar/psi) Actual Value Width Overall Static diameter radius (S) (OD) (Rst) Rolling circumference (Rc) +1% ±1% ±1.5% ±2% Load Index (LI) Tyre fitment (S,D) (65) (73) (80) (87) (94) (102) (109) (116) (123) (131) Speed symbol (km/h) J= S L= S K= S J= S K= S J= S J= S J= S K= S J=100

48 TRUCK AND BUS TYRE I TECHNICAL MANUAL REGROOVING GUIDE

49 Regrooving introduction Regrooving technical data REGROOVING GUIDE

50 REGROOVING GUIDE Regrooving introduction INTRODUCTION A regrooved tyre means a tyre, either new or retreaded, on which a tread pattern has been produced by cutting into the tread in accordance with the tyre manufacturer s recut tread pattern. Recut tread patterns for Hankook tyres are contained in this manual. Regrooving of truck tyres requires fully trained operators : - Use only regrooving tools with electrically heated blades. - Determine the blade setting depth for each individual tyre by referring to the following tables. - Set the blade in the cutter head to the specified depth. - While regrooving, hold the cutter so that the underside of the cutting head is flat against the tread surface. Heating of the blade starts automatically as the blade penetrates the rubber. A minimum depth of remaining undertread rubber is required to avoid : - Damage of the top steel belt - Rib tearing caused by groove cracking - Stone damage After regrooving, the tyre should be free of any defects (cracks, separations exposed ply or cord) visible on either the mounted or demounted tyre.

51 TECHNICAL MANUAL TECHNICAL REQUIREMENTS The tyre must be demounted from the rim before regrooving. Inspection : - Before regrooving check there is no damage on any part of the tyre. - Remove stones and any other foreign objects such as nails from the tread which may have embedded in to the grooves. Repair if necessary. - Particular care should be exercised in selecting a tyre for regrooving where the tread area is damaged in any way (eg : chipping, tearing, and cutting due to abnormal operating conditions) - Where a tyre has worn abnormally it may be possible to regroove that part of the worn tyre, provided that a sufficient amount of the original groove is visible before regrooving. It is recommended that the minimum remaining tread depth be between 2mm and 3mm before regrooving. The tread depth should be measured around the circumference at 4 places to find the minimum remaining depth. Set the cutter blade for the recommendations as shown in this publication. Please make sure that you regroove Hankook tyres Steel Radials to the patterns, depths and widths recommended in this manual to ensure good service from your tyres. After regrooving, your tyre should be free from defects. It is most important to ensure that the belts under the tread have not been exposed. REGROOVING RECOMMENDATIONS Before regrooving After regrooving

52 REGROOVING GUIDE Regrooving technical data LONG HAUL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /55R K * ~9 AL20w TUBELESS /60R22.5 * * 315/60R22.5 * * * Available in Q1/2019 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /70R /150L * DL20w TUBELESS /80R22.5 * 156/150L * /70R /150L * /60R22.5 ** * 315/60R22.5 ** * * Available in Q4/2018 ** Available in Q1/2019

53 TECHNICAL MANUAL Worn tread B A A B New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /65R K * ~ /55R K * A6~8 / B12~ /50R19.5* 160J * A2.5 / B6~ /45R19.5* 160K * A2.5 / B6~7 * Available in Q4/2018 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /150L (154/150M) * ~ /70R /150L * ~ /65R K * ~ /60R /147L * ~10 315/60R /148L * ~ /50R L * ~11

54 REGROOVING GUIDE LONG HAUL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /150L (154/150M) * ~ /60R /147K * ~7 315/60R /148L * ~ /55R /145K * ~ /45R22.5 ** 147/145L * ~8 ** Available in Q1/2019 Worn Tread New Tread Regrooved Tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /75R /133J * /75R /141J * /70R /141J (146/146F) * /70R /141J * /65R K * ~ /50R J * ~ /40R J * ~12

55 TECHNICAL MANUAL Worn Tread New Tread Regrooved Tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 12R /148L * ~ /80R /148M * ~ /70R /137M * ~10 275/70R /145M * ~10 305/70R /148L * ~10 Worn Tread New Tread Regrooved Tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /148M * ~ /70R /145M * ~12

56 REGROOVING GUIDE LONG HAUL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /70R /148J * ~ /65R K * ~ /45R J * ~10

57 TECHNICAL MANUAL COACH Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R M * ~10 315/80R /150L * ~10 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /149M * ~8

58 REGROOVING GUIDE REGIONAL HAUL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /148M(154/149L) * ~11 315/80R /150L * ~ /70R /150L * ~11 275/70R /145M * ~ /65R K * ~11 385/65R K(158L) * ~ /60R /148L * ~ /55R K * ~ /50R L * ~8 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /148M * ~8 315/80R /150L * ~ /70R /150L * ~11 275/70R /145M /60R /147K * ~6 315/60R /147L * ~7

59 TECHNICAL MANUAL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /70R /148J * /65R K * /50R J * ~ /40R22.5 * 160J * Available in Q4/2018 Worn tread New tread Regrooved tread SRS Size LI/SS TUBELESS Type Tread Depth Regrooving T/T T/L m/m Depth Width 10R /139M * ~8 11R /145L * ~8 12R /148L * ~9 13R /150L * ~8

60 REGROOVING GUIDE REGIONAL HAUL Worn tread New tread Regrooved tread Type Tread Depth Regrooving SRS Size LI/SS T/T T/L m/m Depth Width TUBELESS 12R /149L * ~5 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 8.5R /120L * ~6 9.5R /129L * ~6 8R /122L * ~ /75R /122M * ~7 215/75R /124M * ~7 215/75R /126M * ~7 225/75R /127M * ~8 235/75R /130M * ~ /70R /134M * ~9 265/70R /136M * ~9 245/70R /134M * ~9 265/70R /138M * ~9 285/70R /144M * ~7 305/70R /145M * ~8

61 TECHNICAL MANUAL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 8.5R /120L * ~7 9.5R /129L * ~ /75R /122M * ~7 215/75R /124M * ~8 225/75R /127M * ~8 235/75R /130M * ~ /70R /134M * ~8 265/70R /136M * ~7 245/70R /134M * ~7 265/70R /138M * ~7 285/70R /144M * ~8 305/70R /145M * ~8 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 8R /116L * ~10 10R /139L * ~13 13R /150L * ~13 TUBE TYPE 1000R20 147/143L * ~ R20 150/146L * ~10

62 REGROOVING GUIDE REGIONAL HAUL Worn tread New tread Regrooved tread SRS Size LI/SS TUBELESS Type Tread Depth Regrooving T/T T/L m/m Depth Width 11R /145L * ~10 12R /148L * ~10 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 11R /145M * ~ /80R /148M * ~13 Worn tread New tread Regrooved tread Type Tread Depth Regrooving SRS Size LI/SS T/T T/L m/m Depth Width TUBELESS 12R /149K * ~10

63 TECHNICAL MANUAL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 8R /116L * ~8 11R /145L * ~12 12R /148L * ~ /80R /148M * ~12 315/80R /150M (156L) * ~ /70R /150L * ~12 TUBE TYPE 1000R20 147/143L * ~ R20 150/146L * ~12 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 9.5R /141J * ~7 11R /146L * ~ /75R /133J * ~8 235/75R /141J * ~ /70R /141J (146/146F) * ~8 245/70R /140J * ~8 265/70R /141J * ~9 285/70R /148J * ~ /65R /127K (132/132F) * ~7 425/65R K * ~ /55R K (158L) * ~14

64 REGROOVING GUIDE MIXED SERVICE (ON AND OFF) Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /70R /141J * ~10 275/70R /145K * ~ /65R K * ~12 445/65R K * ~12 AM15+ TUBELESS /65R K (158L) * ~14 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R22.5 * 156/150K * ~12 * Available in Q2/2019

65 TECHNICAL MANUAL Worn tread A B B A New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 10R /142K * A9~11 / B8~10 11R /145K * ~14 12R /149K * ~10 13R /150K * A13~15 / B10~ /80R /148K (154/150J) * A11~13 / B8~10 315/80R /150K * A12~14 / B9~11 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /95R24 162/160K * ~9 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R22.5 * 156/150K * ~13 * Available in Q2/2019

66 REGROOVING GUIDE MIXED SERVICE (ON AND OFF) Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 11R /145K * ~11 12R /148K * ~11 13R /150K * ~ R20 154/150K * ~ /80R /148K * ~10 315/80R /150K * ~12 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /95R24 162/160K * ~22

67 TECHNICAL MANUAL Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS R20 152/148K * ~ /95R24 * 162/160G * Available in Q3/2018 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 11R /145G * ~16 12R /148G * ~16 13R /150K * ~ /80R /150K * ~17 TUBE TYPE 1200R20 154/150G * ~ R24 156/153G * ~16

68 REGROOVING GUIDE MIXED SERVICE (ON AND OFF) Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /65R K (158L) * ~9 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /65R22.5 * 160K(158L) * ~12 * Available in Q2/2019

69 TECHNICAL MANUAL WINTER Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /149M * ~11 315/80R /150L * ~ /70R /145J * ~6 315/70R /150L * ~ /65R K * ~ /55R K (158L) * ~10 Worn tread A B A B A New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 12R /148L * A4~6 / B4~ /80R /150L * A5~7 / B4~6 295/80R /148L * A5~7/ B4~ /70R /145J * ~5 315/70R /150L * A6~8 / B4~6

70 REGROOVING GUIDE WINTER Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /80R /148L * ~12 315/80R /150L * ~ /70R /150L * ~12 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /65R K (158L) * /55R K/158L * /45R J *

71 TECHNICAL MANUAL URBAN Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS 11R /145J * ~ /80R /146J * ~11 295/80R /148J * ~ /70R /134M * ~9 265/70R /138M * ~10 AU03+ TUBELESS /70R /145J (152/148) * ~11 Worn tread New tread Regrooved tread SRS Size LI/SS Type Tread Depth Regrooving T/T T/L m/m Depth Width TUBELESS /70R /148J * ~ /60R /148J * ~8

72 TRUCK AND BUS TYRE I TECHNICAL MANUAL RIM AND ACCESSORIES

73 Technical data of rims Demounting and mounting Tubeless tyre demounting / mounting Tubeless rim valve mounting About dual spacing RIM AND ACCESSORIES

74 RIM AND ACCESSORIES Technical data of rims DROP-CENTRE RIMS WITH 15 TAPERED BEAD SEATS DIMENSIONS(MM) DIMENSIONS(MM) Rim A Rim A DIAMETERS Nominal diameter code Diameter D (mm)

75 TECHNICAL MANUAL The rim is part of the wheel which supports the tyre. MULTI-PIECE RIMS WITH 5 TAPERED BEAD SEATS Rims with detachable lateral rings are equipped with flange and bead seat removable on one side of the rim. DIMENSIONS(mm) BASIC OPTIONAL Rim A G R G R V V DIAMETERS Nominal diameter code Diameter D (mm)

76 RIM AND ACCESSORIES Technical data of rims DROP-CENTRE RIMS WITH 5 TAPERED BEAD SEATS DIMENSIONS (mm) Rim A G H mim 4.00B B B B B C C J ½ J J ½ J J ½ J J ½ J L ½ L DIMENSIONS (mm) Rim A 3.2 G P mim 4.50E E E G H DIMENSIONS (mm) + Rim A H mim G P mim DIAMETERS Nominal diameter code Diameter D (mm)

77 TECHNICAL MANUAL The rim is part of the wheel which supports the tyre. FLAT BASE RIMS DIMENSIONS (mm) Rim A G R max S T V V V Nominal diameter code DIAMETERS Diameter D (mm)

78 RIM AND ACCESSORIES Demounting and mounting SAFETY INSTRUCTIONS Do not demount or mount tyres without proper training. Wall charts containing demounting and mounting instructions for all on-highway rims should be available through your normal rim supplier. REMOVE ALL CRACKED WHEELS FROM SERVICE LUBRICATED AREAS SHOWN BY ARROWS USE OF A GG RING INDICATES CORRECT MOUNTING

79 TECHNICAL MANUAL PROPER SEQUENCE FOR TIGHTENING STUD RUTS ON AN 8 STUD SYSTEM NOTE : Always use a securely held safety cage and extension hose with a clip on air chuck for airing the tyre. Rapid air loss can propel the assembly. CROSS SECTION THROUGH TYPICAL DUAL INSTALLATION Section width Tyre clearance Section width Spacer width Offset Offset Section width PROPER MATCHING OF RIM PARTS Motor wheel or accuride "CR" or "FL" side ring Accuride 5 or motor wheel "CR" or "FL" flange Motor wheel or accuride "CR" or "FL" lock ring Figure 3.12 Correct and incorrect matching of rim parts Proper fit Motor wheel or accuride "CR" or "FL" base Motor wheel LW and LB base accuride or budd lb base Proper fit Motor wheel LW side ring accuride or budd LB side ring Proper fit

80 RIM AND ACCESSORIES Tubeless tyre demounting The tyre should be completely deflated before demounting, which is done by loosening and removing the valve stem core. Be careful there is no foreign matter left in the valve and that the valve stem is not cracked or damaged. Do not stand near the valve stem during the deflating process. BEAD DEMOUNTING Place the tyre assembly on a clean and flat surface with the valve facing upwards using a tyre demounting leaver between the tyre bead and rim flange. BEAD DEMOUNTING

81 TECHNICAL MANUAL OUTSIDE BEAD DEMOUNTING Lay the wheel on a clean flat surface with the valve facing upward. Work the bead over the rim flange, using your hands and knees as in the illustration to the right. If it is difficult to fit over the flange, use the proper tyre mounting lever as per the illustration. OUTSIDE BEAD DEMOUNTING INSIDE BEAD DEMOUNTING Turn the tyre assembly over, then lubricate between the bead and the rim. Insert the tip of the tyre between the tyre lever and rim, then add pressure. Use the second lever about 15cm away from the first lever to remove the rim from the tyre. Repeat this procedure until the bead is completely demounted. INSIDE BEAD DEMOUNTING

82 RIM AND ACCESSORIES Tubeless tyre mounting RIM PREPARATION Rims must not be broken or damaged. Remove the rubber bushing from the valve stem hole and inspect the valve stem for any signs of damage or wear. Remove rust, dirt and any foreign materials from the rim. Clean and sand smooth the area marked /// in the picture below. If rusted, clean and repaint the rim surface to protect it from rusting. If required, replace any worn or damaged valve stem. Lubricate the inner parts of the rim surface where the tyre mounts (marked /// ). BASE PART OF TUBELESS RIM BASE PART OF TUBELESS RIM Parts marked /// are to be cleaned and re-lubricated TYRE PREPARATION In the case of new tyres, wipe the bead clean with a dry cloth, checking at the same time that there are no damage, kinks or breakages. Apply the recommended lubricant to the tyre bead as per the illustration to the right. TYRE BEAD CROSS SECTION

83 TECHNICAL MANUAL INSIDE BEAD ASSEMBLY Lay the wheel on a clean flat surface with the valve facing upward. Work the bead over the rim flange, using your hands and knees as in the illustration to the right. If it is difficult to fit over the flange, use the proper tyre mounting lever as per the illustration. INSIDE BEAD ASSEMBLY OUTSIDE BEAD ASSEMBLY Start the outside bead placement over the outside rim flange by hand, beginning at the point where the valve stem is located. Once hand placement becomes difficult, use the proper tubeless tyre bead mounting lever to complete the job as per the following illustrations. When mounting tyres, do not use excessive force and avoid heavy tools or impact such as hammering on the rim. OUTSIDE BEAD ASSEMBLY TUBELESS TYRE INFLATION Use an inflation gauge, suitable remote air hose nozzle and a safety cage when inflating the newly mounted tyre. The lubricated bead should sit firmly to the rim flange at about 10 PSI inflation. Do not stand near or in front of tyre while inflating. Use the safety cage and stand a safe distance for your protection. If the bead fails to sit first, then rotate the tyre a few degrees around the rim, ensuring the bead and rim flange is lubricated and try again. If for any reason the bead is not evenly seated with a comfortable fit, do not attempt to inflate further. Repeat the entire assembly process with more lubricant on the bead and rim areas. Once it sits and you are assured the bead and rim flange are at a snug and even fit all the way around, inflate the tyre to the recommended inflation pressure to the axle load. Check that the tyre or valve are not leaking, if so, tighten the valve cap.

84 RIM AND ACCESSORIES Tubeless rim valve mounting A-TYPE RIM VALVE The valve hole in the rim must be clean, smooth and not damaged. Apply a recommended lubricant to the rubber brushing off the valve and insert the valve stem through the rim hole which will assemble the washing and lock-nut on the inside. Tighten the lock-nut with a wrench so that the valve stem is secured in to the rim. A-TYPE RIM VALVE Washer Rubber bushing Valve stem Lock nut Valve cap B-TYPE RIM VALVE The valve hole in the rim must be clean, smooth and not damaged, as per the illustration below. Place a lubricated O-ring on the valve stem and insert the stem into the valve stem hole so that the valve faces perpendicular to the rim. The valve stem hole can be found in the rim. Tighten the lock nut with a wrench from the opposite side of the rim until the valve stem is secure. B-TYPE RIM VALVE Lock nut O-ring Valve Valve cap

85 TECHNICAL MANUAL C-TYPE RIM VALVE The valve hole in the rim must be clean, smooth and not damaged, as per the illustration below. Lubricate the O-ring and insert a new valve stem going through the O-ring. This should go through the valve stem hole in the rim from the inside. From the other side securely hand tighten the lock nut. C-TYPE RIM VALVE Valve O-ring Lock-nut Valve cap

86 RIM AND ACCESSORIES About dual spacing Mismatched duals have the same effect on the life of tyres as low inflation or overload. An underinflated tyre on a dual assembly shifts its share of the load to the adjacent tyre, which then becomes overloaded and frequently fails prematurely. When mounting duals on a truck, there will generally be some difference in the diameter of the 2 tyres (within the limits described below). Mount the small tyre on the inside, the outside tyre wears faster than the inside tyre. As it wears its diameter will approach that of the inside tyre. Additionally, any crown on the road will favor the placement of the smaller diameter tyre on the inside. The difference in dimensions of the tyres on a dual assembly should never exceed the figures shown in the table below. The measurement and pairing of duals is very important when mounting a new set of radial recaps. All caps are on the same tyre type and all have the same overall diameter. The service they were subjected to prior to capping may have an effect on the size of the retreaded tyre. DUAL MATCHING TOLERANCE Tyre size Diameter (in.) Circumference (in.) Radius (in.) 8.25R20 and under 0 to 1/4 0 to 3/4 0 to 1/8 9.00R20 and up 0 to 1/2 0 to 1-1/2 0 to 1/4 Twin screw (all sizes) 0 to 1/4 0 to 3/4 0 to 1/8

87 TECHNICAL MANUAL Rim width and tyre spacing Tyre size Alternate rim (wide) Design rim alternate rim (narrow) RADIAL AND BIAS PLY TYRES Tyre section width Minimum dual spacing without chains * * * * * Tyre size Tyre size TUBELESS (HIGHWAY SERVICE) Alternate rim (wide) Design rim alternate rim (narrow) Alternate rim (wide) Design rim alternate rim (narrow) LOW PROFILE TUBELESS Tyre section width Tyre section width Minimum dual spacing without chains * * * * Minimum dual spacing without chains 225/ * / * / * / * / * / / / * / * / *

88 TRUCK AND BUS TYRE I TECHNICAL MANUAL MAINTENANCE AND CARE

89 About tyre inflation Truck alignment and tyre wear Tyre damage TECHNICAL INFORMATION

90 MAINTENANCE AND CARE About tyre inflation ONE OF THE MOST IMPORTANT ASPECTS OF TYRE MAINTENANCE IS CORRECT INFLATION. Correct inflation is needed to carry the load and avoid damage. Driving with improper inflation (particularly grossly under inflated or over inflated tyres) is dangerous and can cause critical damage or sudden failure of the tyre(s). PROPER INFLATION SHOULD BE MAINTAINED AND CHECKED AT LEAST ONCE A WEEK AS WELL AS BEFORE A LONG DISTANCE DRIVE. It is also advisable to take into account the axle load and driving conditions when setting inflation pressures. Compensation for heavier loads can be made by increasing inflation pressures. Make sure to not exceed the maximum inflation rates for the tyre or maximum load axle. IN THE SPACE OF JUST ONE MONTH A TYRE CAN LOSE 10 POUNDS OF AIR PRESSURE. It is important to check your air pressure regularly to make sure your tyres are neither under nor over-inflated.

91 TECHNICAL MANUAL INFLATION AND TYRE LIFE UNDER-INFLATION The worst enemy your tyre can have. It causes increased treadwear on the outside edges (or shoulders) of the tyre and generates excessive heat, reducing tyre durability. Soft tyres make your vehicle work harder, meaning that fuel efficiency is reduced as there is an increased rolling resistance. OVER-INFLATION Is detrimental to the tyre as too much air pressure causes the centre of the tread to bear the majority of the truck s weight. This leads to faster deterioration and uneven wear. Any kind of uneven wear will also shorten the life span of your tyres.

92 MAINTENANCE AND CARE Truck alignment and tyre wear The two major things that affect tyre wear are : Inflation pressure Wheel alignment COMPONENTS OF ALIGNMENT Toe Camber Caster Ackermann Axle parallelism - Thrust angle - Scrub angle TOTAL WHEEL ALIGNMENT Definition : The process whereby the vehicle and all the tyres are travelling in the same direction. Steering axle alignment alone is not sufficient. ALIGNMENT AND WEAR

93 TECHNICAL MANUAL CAMBER Camber is the inward or outward tilt of the steering axle tyres when viewed from the front. Positive camber is the top of the tyre tilted out. Camber becomes more negative as the load increases. The angle that a centre line of the wheel is inclined from, the vertical centre line perpendicular to a flat road, is called camber angle. If the top of the wheel leans out from the perpendicular then it is positive camber. If the top of the wheel leans in from the perpendicular then it is negative camber. Camber is meant to compensate for the downward forces of added loads. Correct camber settings help the tyre maintain a firm and even tread contact with the road while the vehicle is travelling under loaded conditions. Often wear at the outside or inside edge of the tyre may indicate incorrect camber setting. POSITIVE NEGATIVE Camber angle measured in degree Positive camber Center line of tyre Vertical line Negative camber

94 MAINTENANCE AND CARE TOE Toe is the inward or outward pointing of the wheels when viewed from the top of the vehicle. The goal is to have zero toe when the vehicle is loaded to its normal operating condition. Front of vehicle Toe-in refers to the inclination of the wheels of a vehicle so that the pair of front wheels (viewing from the front as per the illustration to the left), are closer together at the front than at the rear of the wheels. The purpose of toe-in is to relieve or counteract some of the force which pulls wheels outwards as they roll along the road. Correct toe-in will ensure the rotation direction and direction of travel are as similar as possible at driving speed. Insufficient toe-in settings will result in steering instability. Front of vehicle The opposite is considered toe-out, see diagram as per the illustration to the left. If toe-in or toe-out is insufficient or excessive the tyre wear will be effected and appear as feathering at the edges of the tread.

95 TECHNICAL MANUAL CASTER Caster is the forward or rearward tilt of the king pin of the steering axle when viewed from the side. Caster is generally not considered to have a great effect on the tyre wear. Caster is the condition where the king pin is inclined with the top of the pin angled rearward similar to the front forks of a bicycle. Caster angle is meant to compensate for the resistance which the tyre(s) encounters as a result of drag forces against the road. Caster angle should be the same for both wheels on a given axle or the result will be vibration and abnormal tyre wear. Too much caster will more than compensate for the amount of drag but it will also create additional difficulty in steering. Too little caster makes steering become lighter but also unstable and can cause it to wonder. The caster angle should be checked as it can be distorted by impacts on the tyre or by driving in rough conditions. NEGATIVE POSITIVE Vertical center line C/L of king pin Caster angle Front Shim

96 MAINTENANCE AND CARE ACKERMANN The Ackermann Principle shows that in any turn the inside tyre needs a sharper turn angle than the outside tyre. The difference in turn angles between the tyres is determined by the actual turn angle and the vehicle wheel base. Improper Ackermann causes side force, excessive scuffing and fast or irregular wear. Ackermann THRUST ANGLE Thrust angle is the difference between the line perpendicular to the axle and vehicle centre line. Each drive axle has its own thrust angle. The target is to have zero thrust angle. TANDEM SCRUB Tandem scrub is the difference in the thrust angles of the drive axles. The target is zero. Tandem scrub errors cause constant side force on the steer tyres. This leads to irregular wear. Scrub angle Thrust Angle

97 TECHNICAL MANUAL Abnormal tread wear Under inflation and over inflation of the tyre is the prime cause of tread wear. However there are other conditions that influence tread wear and produce irregular wear patterns. ABNORMAL WEAR COMPONENTS OF ALIGNMENT Imbalance of the tyre or tyre and wheel assembly. Improper wheel alignment. Breaking system problems that may cause the wheel to lock up or flat spotting. Bent of round rims. Worn or damaged bearings. Broken or worn shock absorbers, springs or steering components. DIAGONAL WEAR SHOULDER WEAR CAUSED BY WRONG CAMBER OR MISALIGNMENT

98 MAINTENANCE AND CARE Tyre damage With tubeless tyres it is often possible, even with a slow air leak, to use the tyre carefully enough to get to a service centre. Small punctures in the tread area, if detected early enough, can usually be repaired as to avoid air loss and further problems. However sufficient loss of air can cause a rapid heat build up which can damage the tyre. This may result in tyre failure or separations between the tread and carcass piles. Care should be taken to avoid road debris, dirt or moisture penetrating any puncture or getting trapped inside the tyre or between the wheel rim and tyre. Damaged tyres should always be repaired or replaced at the earliest possible opportunity to avoid further tyre damage, possible tyre failure, vehicle or personal injury. Check for and correct any of the following conditions : DAMAGE DUE TO CONTACT WITH THE VEHICLE Improper tyre inflation. Overloading. Improper vehicle maintenance. Brake system abnormalities. Differences of tyres sizes or circumferences on the same axle. Improper mounting of tyre or wheel. Improper, worn or damaged valve. Improper use of tube or flap. FLAT SPOTTING DUE TO LOCKED BRAKES

99 TECHNICAL MANUAL BEAD DAMAGE FROM CURBING BURNED BEADS RIPPED SIDEWALL SIDEWALL DAMAGE DUE TO RUN FLAT OR SEVERE UNDER INFLATION

100 MAINTENANCE AND CARE HEAT CAN DAMAGE TYRES Under inflation, overloading or excessive speed can cause damage because of heat build up. Tyre parts such as cord, the bonding between carcasses, belts and treads can be easily damaged by excessive heat. Most tyre cords lose strength at temperatures above 120 C making the tyre more vulnerable to a failure. Excessive heat can either weaken or damage cords and rubber compounds or even cause separation between the piles. The following pictures show some of the possible damage conditions. SHOULDER SECTION DAMAGE OR SEPARATION DUE TO HEAT TREAD DAMAGE DUE TO EXCESSIVE HEAT

101 TECHNICAL MANUAL TREAD SEPARATION CAUSED BY EXCESSIVE HEAT MOISTURE DAMAGE Moisture inside the tyre or penetrating through to the steel belts of a radial tyre can cause rust damage to the steel cord or rim. Therefore always : Store tyres indoors in a dry place. Ensure all wheels, flaps, tubes, valves and the inner tyre surface are clean and dry before and during mounting. Use the recommended mounting lubricant on the rim and tyre bead during the mounting process. Maintain inflation and keep the valve stem capped or protected so as not to allow moisture to enter the tyre.