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HOME | ATS NEWS & INFORMATION CENTER | BIAS PLY MEDIUM / HEAVY TRUCK TIRE REPAIR TUTORIAL

Step 1:

  • Begin by demounting the tire and locating the injury.
  • Remove any injuring object, and inspect to determine the size, angle and extent of the injury.

Step 2:

  • This chart indicates injuries that require section repairs. Do not attempts section repairs with nail hole repair units, plugs or patches.
  • Determine whether injury is within repairable limits, as specified by the tire manufacturer and/or industry standards.

Step 3:

  • Use a Rema Crayon to mark the injury location with hash marks, as shown.

Step 4:

  • Taking care not to damage the cord plies, use a Rema Gouge on a low speed Rema Pneumatic Buffer, or a low speed electric drill to remove damaged rubber in the area around the injury.

Step 5:

  • Continue using the low speed Rema Pneumatic Buffer, but with a Rema Conical Rasp to complete removal of damaged rubber and ply material.
  • A Rema Skiving Knife may also be used as necessary to remove damaged rubber and ply material.

Step 6:

  • Using the same low speed Rema Pneumatic Buffer, switch to a Rema Pencil Rasp to finish the removal of damaged rubber and cords.
  • Once again, a Rema Skiving Knife may be helpful in this process.

Step 7:

  • Continue using the low speed Rema Pneumatic Buffer and an appropriated buffing wheel to round over the edges of the prepared area.
  • Buff an area about 1/2" larger than the injury all the way around it.
  • Buff just until the surface has a smooth, velvety, uniform texture to provide good adhesion for the repair rubber. Avoid overbuffing or gouging.

Step 8:

  • Prepare the skived area so that in cross-section, it is somewhat bell-shaped, as shown.
  • Round edges slightly for best adhesion of the repair rubber at the edge of the skive.

Step 9:

  • Using a Rema Encapsulated Wire Brush or Light Grit Pencil Rasp, lightly buff the tread grooves adjacent to the injury area to provide a good surface for bonding with the repair rubber.

Step 10:

  • Begin preparing the inside of the tire by using a Rema Conical Rasp on the edge of the injury opening.
  • Double-check that all loose or broken cords have been removed.

Step 11:

  • Spray the area around the injury with Rema Pre-Buff Cleaner.
  • Make sure that the surface is thoroughly wet, and that the spray covers an area about 1" larger than the injury, all the way around it.

Step 12:

  • Allow the spray to stand for a few seconds, but do not allow it to completely evaporate.
  • While the sprayed area is still wet with Pre-Buff Cleaner, use a Rema Scraper to remove mold release compounds, mounting lubricants, dirt, and other innerliner contaminants.
  • Scrape an area larger than the chosen repair. Make sure to clean the area completely.
  • With tube-type bias tires, exercise care not to damage the carcass plies with the scraper.

Step 13:

  • Use the low speed Rema Pneumatic Buffer and aaRema Encapsulated Wire Brush or Buffing Wheel to buff an area about 1" larger than the injury, all the way around it.
  • Buff just until the surface has a smooth, velvety uniform texture to provide good adhesion for the repair rubber, but avoid overbuffing or gouging.
  • As on the other side, round over the edges of the prepared area.
  • Use a Rema Pneumatic Vacuum Cleaner to remove all of the scrapings and dirt created in the previous steps.

Step 14:

  • Using a Rema Crayon, add hash marks around the prepared area to aid in aligning the repair components.

Step 15:

  • Measure the total thickness of the original rubber at the injury location.
  • Using a Rema Crayon, record this measurement (in 32nds of an inch) alongside the prepared area for later reference in calculating the cure time.

Step 16:

  • Also measure the width and length of the injury and longest dimension of damage to top ply, recording these dimensions alongside the prepared area.
  • These dimensions will be helpful in selecting the proper size Rema PNNRepair Unit.

Step 17:

  • Spread a generous coating of either Rema Thermopress Solution or Thermopress MTR Solution over the prepared injury area.

Step 18:

  • Repeat the process on the outside of the tire. Be sure to coat all the surfaces that were buffed earlier.

Step 19:

  • Secure a Rema Contour Plate firmly in place on the inside of the tire.
  • Working from the center of the prepared area outward, fill the injury with extruded rubber.
  • Avoid creating any gaps, voids or air pockets as you fill the area.
  • The extruded rubber should completely fill the injury area, and be about 1/8" higher than the tire surface around it.

Step 20:

  • Working from the center outward, vigorously stitch the extruded rubber into place to drive out air pockets and to help fill the injury completely.
  • Be sure to stitch rubber over the edges of the prepared area as well.

Step 21:

  • Remove the backing plate, and repeat the stitching process on the inside of the tire.
  • Once again, be sure to stitch rubber over the edges of the prepared area.

Step 22:

  • On the tread side, use pieces of scrap rubber, pieces of innertube or pieces trimmed from RemaStem repair units to create dams in the tread grooves.
  • Staples will help secure these damns, which will prevent extruded rubber from flowing out of the repair area during curing.

Step 23:

  • Apply a sheet of Rema Anti-Stick material to the inside of the tire.
  • Be sure to cover the entire stitched area, leaving at least 1/2" of overlap around the edges of the injury.

Step 24:

  • Apply another sheet of Rema Anti-Stick material over the stitched rubber on the outside of the tire, again allowing about 1/2" of overlap around all sides of the area.
  • Place the tire in a properly preheated Rema Thermopress II or Thermopress Duplex vulcanizing unit, centering the inside injury area over the lower heating pad.

Step 25:

  • Center a Rema Contour Plate and Pressure Equalization Cushion over the repair area on the outside of the tire.
  • Orient the heating pads to completely cover the injury in both directions and to provide even pressure during curing.
  • No special treatment is required on the inside of the tire.

Step 26:

  • With a Rema Thermopress II spot vulcanizer make sure that the heating pads are aligned with apply pressure to the repair area.
  • Check again to make sure that the heating pads, Contour Plate and Pressure Equalization Cushion are properly aligned and will not shift during the vulcanizing process.

Step 27:

  • Apply pressure until the indicator is nearly touching the bottom of the groove.
  • On Rema Thermopress Duplex models, apply pressure until the compression washers are completely flattened.

Step 28:

  • Set the timer for 5 minutes of cure time for every 1/32nd of injury thickness. For example, an injury through 5/16" of rubber thickness will require: Note: 1-1/8" = 36/32", 36 x 5 min = 180 min curing time.

Step 29:

  • At the end of the cure time, allow the tire to cool before removing it from the curing press.
  • Remove the anti-stick material. The repaired area should look smooth and completely filled.

Step 30:

  • Prepare the inside surface of the tire by spraying the marked area with Rema Pre-Buff Cleaner.
  • Make sure that the surface is thoroughly wet, and tat the spray covers the entire marked area.
  • Allow the spray to stand for a few seconds, but do not allow it to completely evaporate.

Step 31:

  • While the sprayed area is still wet with Pre-Buff Cleaner, use a Rema Scraper to re-clean the repair area.

Step 32:

  • Determine the area to be buffed, and mark it with an outline approximately 1/2" larger than the repair unit to be used.
  • Hash marks at the center of each side of the repair unit, and at the center of each side of outline will help you position the repair later.

Step 33:

  • Use the low speed Rema Pneumatic Buffer and an appropriate buffing wheel or cup rasp to buff the area marked in the previous step.
  • Work from the center to the outside, and buff the outlined area until the surface has a smooth, velvety, uniform texture. Avoid overbuffing or gouging.
  • Use a Rema Brass Cleaning Brush to clean away any rubber dust left behind by the buffing process.
  • Thoroughly vacuum to remove all debris.

Step 34:

  • Apply Rema Special Cement BL to the entire buffed area.
  • Spread cement evenly and thoroughly, then allow it to dry naturally (Do Not use blow driers, heat lamps or compressed air) until it is slightly tacky.
  • If a large amount of cord is exposed, a second coat may be applied to provide proper adhesion. For tube-type tires, apply a coat of cement and a layer of Rema Blue Floater Gum to the repair unit.

Step 35:

  • If you have been using a bead spreader, be sure to relax the beads.
  • Bend the repair unit to split the backing.
  • Peel back and fold over only about 1" of backing on both sides of the split area.
  • Do not touch the exposed portion of the repair unit, as you may contaminate the bonding layer.
  • Center the unit making sure that the bead arrows are pointing towards the beads.
  • Use the hash marks to help align the unit.
  • Press the center into place, so that it adheres firmly.

Step 36:

  • Use a Rema Ball Bearing Stitcher to begin stitching the PN repair unit to the prepared area.
  • Stitch from the center outward, to force out any trapped air and to secure the unit firmly.

Step 37:

  • Once the center of the repair unit is secured, as shown, peel off the remaining protective backing, and continue stitching until the entire PNNrepair unit is completely stitched into place.
  • Be sure to stitch all edges thoroughly.

Step 38:

  • Apply a generous coating of Rema Repair Sealant to the edge of the PNNrepair unit and to the buffed area around it, to provide a completely seal around the repair and innerline.
  • If you are repairing a tube-type tire, apply a coating of Rema Talc to the repair area before installing the tube, to prevent the tube from adhering to the repair area.

Step 39:

  • On the tread side, remove all staples and dam materials, then buff the repaired area with a low speed Rema Pneumatic Buffer and an appropriate buffing wheel.
  • Buff until the repair material is flush with the surrounding tread area and has a finished appearance.

Step 40:

  • Mark grooves in the repaired area.
  • With a Rema Regroover, cut new grooves to match the depth of the existing grooves. (This will help the tire flex properly in the repaired area, reducing heat.)
  • If the injury exceeded 3/8" or required a reinforced repair unit, allow tire to stand 24 hours. Otherwise, tire may be returned to service.
This tutorial was brought to you by Rema Tip Top (Rematiptop.com)

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