SEHS0346-00 Bridgestone Maintenance Manual

BRIDGESTONE GLOBAL MINING & CONSTRUCTION
OEM SOLUTION SUPPORT CENTER (BSPEO)

401 Main Street
Suite 920
Peoria, IL 61602
SEHS0346-00
DEC2016ED01
Ultraclass Mining Truck Tire
Maintenance Manual
59/80 R63
Published for:
Cat 797F Mining Trucks
For Caterpillar and Caterpillar Dealer internal use only, not for distribution.
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December 15, 2016
Caterpillar Dealer Mining Teams,
We have created this 797F specific tire manual to increase tire education and improve tire awareness with
Caterpillar mining dealers globally. This manual is not intended to make Caterpillar dealers 797F tire experts or
to address specific conditions at every mine site, so please always defer all tire technical and application
questions to a Bridgestone representative.
Tire-related costs represent a significant percentage of a 797F’s operating cost-per-hour, and it is in our
combined best interest to encourage customers to safely maximize their tire life and receive the full value of
their Bridgestone tires.
The hope is, that after reading this manual, Caterpillar dealer teams and their local Bridgestone service teams
can work together with our 797F customers identify operational opportunities where tire life can be extended
and total cost-per-hour can be reduced.
If you have questions regarding tires at your jobsite, please contact the local Bridgestone Representative.
Sincerely,
Bridgestone Global Mining & Construction

OEM Solution Support Center (BSPEO)
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Contents
I. Introduction
II. Proper Tire Selection
III. Appropriate Tire Use
IV. Proper Maintenance
V. Appropriate Tire Rotation
VI. Off-the-Road Tire Limited Warranty
©2016 Bridgestone Global Mining and Agricultural Solution Company, Tokyo, Japan.
All rights reserved.
No part of this manual may be reproduced in any form by any electric or mechanical means, including
information storage and retrieval devices or systems, without prior written permission from Bridgestone
Global Mining and Agricultural Solution Company, Tokyo, Japan.
Notice: Although great care has been taken in producing this manual, we can accept no responsibility for any loss or
damage resulting from undetected errors or misprints
Pagewhich
4 may have occurred. Due to constant advance of tire
technology, the contents of this maintenance manual are subject to change without notice.
401 Main Street
Suite 920
Peoria, IL 61602
Introduction
1. Industry Standard
Bridgestone Corporation (hereinafter referred to as “Bridgestone”) has developed a wide range of tire
patterns and specifications, so that the proper Off-the-Road tire can be matched to any vehicle, service, or
operating conditions.
Bridgestone’s Off-the-Road tires are designed and produced to meet the commonly accepted international
standards, those set by the TRA(Tire and Rim Association) in U.S.A., by the ETRTO(European Tire and
Rim Technical Organization) in Europe and/or by the JATMA(Japan Automobile Tire Manufactures’
Association) in Japan*. Load capacities, inflation pressures, dimensions such as overall tire diameter and
width, as well as the relative rims and tube valves follow these standards. If a tire is to be used for a
purpose other than that for which it is originally intended, please consult Bridgestone Corporation for
advice.
*Where differences exist between the TRA, ETRTO and JATMA standards, Bridgestone selects
the most applicable standard.
2. Effective Tire Use

In order to permit the effective utilization of tires, all tires must at first be selected properly according to
the operating conditions and the type of vehicle on which they are intended for use, and then mounted,
used and maintained properly. If these basic rules are observed, tire damage will be minimized. This in
turn will prolong the serviceability of tires, prevent accidents, reduce maintenance costs and minimize
downtime.
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3. Basic Tire Definitions
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Proper Tire Selection

Bridgestone offers a wide range of Off-the-Road tires suitable to meet every possible use, 797F customers
need to work with a Bridgestone Representative to select the optimum tire, tread and rubber compounds
for their application.
In selecting the tire best suited for your specific requirements, all factors which may affect the tire must
be taken into account.
1. How to select New Tires for 797F.

 GMW : 1,375,000lb
 Gross Power: 4,000hp
 Nominal Payload Capacity: 400tons
 Top Speed (Loaded): 42mph
 Tire Size: 59/80R63 *2
Consider the Operating Conditions:

a. Climate: Hot season temperature and yearly average temperature, weather conditions (rainy season,
dry season, snowing etc.), Altitude etc.
b. Operating Route: Haulage road surface condition, spillage frequency, loading area, dumping area,
gradient, road width, tight cornering condition, etc.
c. Operating Speed: Dispatch data, GPS study data etc.
d. Operating Load: Weight study data, VIMS data, Dispatch data etc.
e. Operating TKPH(TMPH):
f. Maintenance Shop: Tire handler machine, air compressor, safety, cleanness, repair shop condition
(cleanness), etc.
g. Tire Data Base Analysis: Treadstat data, Klinge data, Tire Card Record etc.
h. When operating route changes, above b/c/d/e should be reviewed.
Document Expected Tire Performance;

a. Expected Service
b. Heat and Cut Resistance
c. Maneuverability
d. Customer Requirements
Then Select the Appropriate 797F Tire:

a. Correct Tread Pattern selection: VRF(E3), VRPS(E4)
b. Correct tread compound selection: E2A(cut resistance), E1A(Standard), E3A(Heat resistance)
c. Correct inflation pressure selection: 102 psi is a standard inflation pressure, and should be adjusted
by actual payload conditions. The inflation pressure should not exceed 116psi.
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Standard Minimum Reco.

Inflation Dual Rim/Flange Tire Load
pressure OTD Spacing Height Limit
Star TRA kpa mm kg
Tire Size Pattern Rating Code (psi) mm (inch) inch (lbs) Spec. TKPH* TMPH*
VRF *2 (E/M) 700 71 1780 44.00/5.0 100000 E1A 1784 1222
E3 (102) (70) (220500) E3A 2050 1404
41.00/5.0 96000 E1A 1686 1155
(211650) E3A 1937 1327
59/80R63 VRPS *2 (E/M) 700 116 1780 44.00/5.0 100000 E2A 1228 841
Tubeless E4 (102) (70) (220500) E1A 1515 1038
E3A 1773 1214
41.00/5.0 96000 E2A 1160 795
(211650) E1A 1431 980
E3A 1675 1147
*Please consult with local Bridgestone Representative for

actual operating TKPH(TMPH).
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59/80R63
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2. Tire Matching of Rear Duals
Dual mounting of same brand tires, type and size is recommended. Dual mounting of different brands is
not recommended since each tire has a specific and different amount of sidewall deflection.
In the picture, tire No.1 has a larger outer diameter than tire No.2. Tire
No.1 will have fast and irregular wear, due to overloading, and tire No.2,
with a smaller diameter, will quickly wear from the middle inward.
Tolerance of tires mounted on vehicles can be verified by the following

methods described below. Before any measurements, confirm that all tires
are inflated to recommended pressure.
No.1 No.2
The acceptable outer diameter tolerance for dual mounting of 59/80R63 is:
 Difference in outer diameter is less than 19mm.
 Circumferential difference is less than 60mm.
Difference in outer diameters can be Differences in diameter can also be

measured using a rectangular square, as obtained by placing a cord between right
the shown following picture. and left duals and measuring the distance
to the cord, as the following graphic
shows.
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Appropriate Tire Use

1. Inflation Pressure Influence
Tire Performance depends on maintaining correct inflation pressure.
 Correct inflation pressure is determined by truck type (ex. 797F), tire load capacity and truck speed.
 Correct inflation pressure has a direct relationship to tire life. Inflation pressure must be set with
considering maximal speed allowed for truck operation.
The graph shows the relationship between tire temperature and inflation pressure.
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a. Tires with low inflation pressure are

subject to excessive distortion and
excessive movement between the layers
and cables in the tire, this leads to short
tire life.
b. Inflation pressure must be compensated, due to the temperature differential between the inside and
outside of the tire. Initial inflation pressure must be modified based on ambient temperature as
shown in the following table.
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2. Payload
Shovel Operator’s are responsible for controlling the specified payload on each truck and for the equal
distribution of load on each tire of truck.
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a. Each truck load must stay within the specified limits described for each truck. By all means,
overloading must be avoided.
b. In order to obtain maximum load per tire, refer to the pressure-load table and determine the
permissible tire load or contact a Bridgestone Representative.
c. Conduct a weight studies regularly.
Excess loads may result from factors such as actual empty truck weight exceeding specification, varying
material density, field modifications to the truck, load imbalance, etc.
In case of 59/80R63 for 797F, please consult with a Bridgestone Representative.
For correct loading,

a. Maintain an even load distribution
b. Protect tires from falling stones during loading.
c. When loading with a shovel, maintain rated bucket loads, and keep weight distribution in mind.
INCORRECT CORRECT
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3. Ton Kilometer Per Hour (TKPH)

a. Operating TKPH
797F tires are a key part of the truck’s development. The primary task of these heavy-duty tires is to
haul heavy loads faster and over longer distances. Heavy hauling inevitably causes heat built-up in
tires. Tires have limited heat resistance, premature deterioration of the tire may occur if the tire is used
beyond the rated TKPH limits.
 It is necessary when selecting tires, to determine the amount of work that keeps the tire within
a safe operating range, to avoid over-heating under actual mine conditions.
 The amount of work done under the given conditions and within a safe range is shown as
“Operating Ton-Kilometer-Per-Hour (Operating TKPH)” which can be determined by
following formula:
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b. Tire TKPH
Tire TKPH varies depending on the tire’s design (size,
tread pattern and type of compound).
 High TKPH tires generate less heat a lower
TKPH tire.
 Low TKPH tire will have greater cut and wear
resistance compared to the higher TKPH tire.
TKPH applies to the following situations.

1) One way distance: within 16km(10miles)
2) Ambient temperature: 38℃ (100℉)
3) Maximum speed : 50km/h(30mph)
Additionally, Tire TKPH should be adjusted in following condition;
i. If the round-trip distance is less than 5km (3miles), Tire TKPH figures can be increased
by 12%.
ii. For ambient temperature other than 38 ºC (100ºF), the Tire TKPH rating should be
revised based on the following formula.
Revised TKPH rating = Revising Coefficient × Tire TKPH
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Revising Coefficient
Ambient Tire Size
Temperature 59/80R63 **
°C °F
14 57 1.216
15 59 1.207
16 61 1.198
18 64 1.180
20 68 1.162
22 72 1.144
24 75 1.126
26 79 1.108
28 82 1.090
30 86 1.072
32 90 1.054
34 93 1.036
36 97 1.018
38 100 1.000
40 104 0.982
42 108 0.964 For all ambient temperatures below
44 111 0.946 14 °C (57°F), the same TKPH value
46 115 0.928 as calculated at 14 °C (57°F) should
be used.
48 118 0.910
50 122 0.892
iii. As for Maximum speed, no revision is needed up to the speed of 67km/h(42mph).

iv. Please consult a Bridgestone Representative when you need more than above
conditions.
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Proper Maintenance
1. Tire Inspection
Necessity and Frequency for Inspection
Operating conditions for 797F’s are extremely severe for tires, easily causing damage such as deep cuts,
impact breaks, or cut-bursts. For this reason, frequent inspection is required for safety and to maximize
tire life.
 Tire foreman and truck operator: Daily inspection is required for external appearance, rim and
valve condition and inflation pressure. The operator also needs to be aware and call attention to
any steering wheel vibration or wheel shaking while driving. If this is found contact the mine
maintenance department immediately.
External Appearance and Tire Care

Constant inspection of each tire is necessary. Early discovery of minor tire damage saves you from high
costs in maintenance. Please consult with local Bridgestone Representative whenever you found tire
damage.
The followings are the typical tire damages as an example.
Category : Worn-Out
Definition :Tread is worn out
and in good conditions,
without tear, and remaining
tread depth is around 0 mm.
Category : Chunking
Definition :Tread rubber is
broken in flakes.
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Category : Irregular Wear

Definition :Asymmetric tread
wearing in left, in right.
Category : Cut Penetration

Definition :Cut penetrates in or
through carcass in tread
area.
Category : Shoulder Cut

Definition :Cut at shoulder
portion on tread area.
Category : Cut Separation

Definition : Deep cut
separation at tread.
Category : Sidewall Cut

Definition : Cut in sidewall.
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Category : Bulge
Definition : Bubble in sidewall
or in bead area.
Category : Tread Separation

Definition : Separation
between tread and belt.
2. Tire Storage And Transportation

a. Storage of New & Partially worn Tires
i. General Storage
a) Indoor storage --- a cool, dark, dry place.
b) Outdoor storage --- covered with waterproof tarpaulin.
c) Tires not mounted on rims must not be laid on top of one another. If doing this, it may
be difficult to mount them. Tires need to be placed vertically. Take appropriate
measures to block the tires so they do not roll over and fall down.
d) Keep away from motors, power switch boxes and cables, oil, fuels and lubricants. If
exposed to oil, fuel or lubricants, carefully wash them out.
e) Do not expose tires to water, oil, sunlight and ozone or heat sources.
f) Do not let water, stones, sand, metal or wood be stored or left inside the tires. Remove
any foreign material immediately.
g) Keep a fire extinguisher ready for use.
h) Do not remove the bead protector or steel band until you are ready to mount the tire.
i) For storage of used tires, draw on the tire tread (or sidewall) showing remaining tread
depth for easy reference when the tire is used again for rear position.
ii. Precautions for Transporting Tires

 Transport new tires as they come packed from factory with bead protector and steel
band in place.
 Use fiber slings or wide strap to raise the tires. Do not use cords, ropes or chains.
 When using forklift, lift the tire from its outer circumference. Do not insert the forks
through the center or inner of the tire. It is advisable to use tire handler machine.
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Correct Incorrect
3. Road Design
a. Road Grade --- Estimation of Road slope average
Vertical Distance ÷ Horizontal Distance × 100 =
Road Grade %
b. The grade should not exceed 10%.
c. When the grade increases, a tire is more likely to

slip. This increase tire wear and reduces fuel
efficiency. The ideal road grade is no more than
5-6%.
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d. Road camber and Lane Width
e. Recommended Haul Road Width, the 797F operating width is 9.5m:
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f. Recommended Curve Radius and Super Elevation
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Appropriate Tire Rotation
 Generally Bridgestone recommends

using 1/3 of the tire life at front
position and 2/3 at rear position in
order to maximize total tire life.
 New replacement tires should be

installed in front position, then
rotated to rear position after 1/3
used.
 Please consult a Bridgestone

Representative for best rotation
practice. Because the total life stage
will be depending on projected tire
life of front and rear positions and
average scrap life.
 Standard rotation practice below:
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Off-the-Road Tire Limited Warranty
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Page 27

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BRIDGESTONE GLOBAL MINING & CONSTRUCTION

OEM SOLUTION SUPPORT CENTER (BSPEO)

Ultraclass Mining Truck Tire

Cat 797F Mining Trucks

December 15, 2016

Caterpillar Dealer Mining Teams,

Bridgestone Global Mining & Construction

II. Proper Tire Selection

III. Appropriate Tire Use

IV. Proper Maintenance

V. Appropriate Tire Rotation

VI. Off-the-Road Tire Limited Warranty

2. Effective Tire Use

3. Basic Tire Definitions

Proper Tire Selection

1. How to select New Tires for 797F.

Consider the Operating Conditions:

Document Expected Tire Performance;

Then Select the Appropriate 797F Tire:

Standard Minimum Reco.

*Please consult with local Bridgestone Representative for

2. Tire Matching of Rear Duals

Tolerance of tires mounted on vehicles can be verified by the following

Difference in outer diameters can be Differences in diameter can also be

Appropriate Tire Use

considering maximal speed allowed for truck operation.

a. Tires with low inflation pressure are

For correct loading,

3. Ton Kilometer Per Hour (TKPH)

TKPH applies to the following situations.

iii. As for Maximum speed, no revision is needed up to the speed of 67km/h(42mph).

External Appearance and Tire Care

The followings are the typical tire damages as an example.

Category : Irregular Wear

Category : Cut Penetration

Category : Shoulder Cut

Category : Cut Separation

Category : Sidewall Cut

Category : Tread Separation

2. Tire Storage And Transportation

ii. Precautions for Transporting Tires

b. The grade should not exceed 10%.

c. When the grade increases, a tire is more likely to

e. Recommended Haul Road Width, the 797F operating width is 9.5m:

f. Recommended Curve Radius and Super Elevation

Appropriate Tire Rotation

 Generally Bridgestone recommends

 New replacement tires should be

 Please consult a Bridgestone

 Standard rotation practice below:

Off-the-Road Tire Limited Warranty

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