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020604 English Update.qxd

1. 18 3 1 Recommendations for mounting tubeless tires 18 342 Mounting tubeless IBS e esce rud Cus Cupa a aD E cute ful tust u ord e ca detedr Lao Pc End uu md msc 19 323 Rim width to tire Tate ilb asc cb rec eranc tdd t ed cb ARM ext b nr oie REM bend i C PUHbVE DEDE 21 3 4 Recommendations for demounting tubeless tires seeeeeseeeee 21 35 DEMOUNENG Or tubeless UES caseras ecudbtoim ta andi eui Deb vh dix avt be eeQvtuo A sve rods onto menetton 22 4 Wheel InstalldtlOn asuiisises vasa uuo aula vds wbaEN SCR aaa eaaa Ea ri Caes Cei O 4 1 Recommendations for proper installation of wheels seeee 23 4 2 ANneel cap nuls dio seas caelata rsin Do B oo vede ra Boe va gen ev la Qu v OP CURE DR ERA 24 4 3 How to measule sd SUA ING OUT us eos perta tintuqiccel uma nasa qutt cune OEA RU nep Kt AAT 25 4 4 Stud located ball seats are spherical eseeesesesesee eene nnn 25 4 5 Single wheel stud located ball seat mounting eeeeee 26 4 6 Dualed wheels stud located ball seat mounting eeeen 26 4 7 Dualed wheels inner steel outer aluminum stud located ball seat mounting 28 4 8 Cap nut thread engagement stud located wheels ball seat mounting 29 4 9 Tightening stud located ball seat cap nuts eesesseeseeeeee 29 4 10 Single dualed
2. LIMITED WARRANTY FOR HEAVY DUTY TRUCKS TRUCK TRAILERS BUSES RV and MOTORHOME WHEELS Wheels with bead seat diameters measured in 5 inch increments and Alcoa tube type wheels Alcoa warrants to the original purchaser from Alcoa or its authorized distributor that a new Alcoa aluminum disc heavy duty truck truck trailer bus 19 5 inch and 22 5 inch RV or motorhome wheel is free from defects in material and workmanship Alcoa agrees without charge to repair or replace a wheel that fails in normal use and service because of defects in material and workmanship Truck truck trailer Dura Flange and the Dura Bright Surface Treatment wheels not used in transit service are warranted for 60 months from the date of manufacture as shown on the wheel except the Dura Flange rim flange treatment is warranted for a period of 24 months Alcoa bus mount wheels 10 hole 11 25 inch bolt circle 8 670 inch hub bore with 1 22 inch diameter bolt holes and other wheels used in transit service are warranted for 120 months from date of manufacture except the Dura Bright Surface Treatment on bus and transit service wheels is warranted for a period of 60 months from the date of manufacture and the Dura Flange rim flange treatment is warranted for 24 months Satin finish polished and Dura Bright surface treatment 19 5 inch and 22 5 inch RV and motorhome wheels are warranted for 120 months from the date of manufacture as shown on the wheel Alcoa
3. 2 piece 33mm hex head flange nut Mounts single wheels to wheel centering hubs with 32mm bolt holes Right hand threads used on both sides of vehicle P N 4306 32 M22x1 5 RH threads Inner cap nut inner ur RR je thread 3 4 x16 outer thread 1 1 8 x16 For use with steel inner dual wheel an aluminum outer dual wheel with 1 31 1 5 16 to 1 44 1 7 16 stud standout P N 7896R 7896L Grade 8 Inner cap nut inner thread 3 4 x16 outer thread 1 1 8 x16 For use with standard length studs 1 31 1 5 16 to 1 44 1 7 16 stud Stand out or longer studs not to exceed 1 88 1 7 8 stud standout Full internal and external threads P N 5978R 5978L Grade 8 For studs without exposed shoulders Do not use with steel inner dualed wheel Inner cap nut for use with standard length IS studs 1 31 1 5 16 to 1 44 1 7 16 stud Standout or longer studs not to exceed 1 88 1 7 8 stud standout Full internal and external threads counter bore 5 16 deep at open end Prevents stud from bottoming out in cap nut P N 5988R 5988L Grade 8 For use with studs with exposed shoulders Do not use with steel inner dualed wheel How to measure Stud standout is measured from the axle end mounting surface to the end of the stud stud standout Exposed 4 3 shoulder End of stud Stud Standout Mounting Surface Inboard mounted drum Stud located ball A wy End of d
4. NN NY E Inner Cap Nut P N 7896R or L See 4 2 page 24 1 31 to 1 44 k Correct dual mounting for steel inner aluminum outer stud located ball seat mount WARNING Incorrect inner cap nuts used with steel wheels can bottom out on the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running WARNING wheels can lead to stud breakage Use only cap nut 7896R or L or its equivalent when mounting steel inner duals WARNING Inadequate wheel support surface can lead to stud hole to stud hole fracture resulting in separation of the outer disc and rim from the vehicle Separation of the wheel from the vehicle can cause injury or death WARNING Alcoa aluminum wheels with 11 1 4 diameter bolt circle require a support surface at least 13 3 16 in diameter Check the outer support surface of the inner steel wheel for flatness and adequate diameter before installing the outer wheel When the wheels are serviced check the mounting surfaces of both wheels for stud hole to stud hole cracks If cracks are found remove the wheel from service For the support surface diameter required by other bolt circle sizes ask your Alcoa representative WARNING Use of two piece flange nuts on ball seat wheels or ball seat cap nuts on hub piloted wheels is dangerous Using the wr
5. Recommendations for mounting tubeless tires 3 1 The cross references will help you find related information in the manual For example in section 4 1 you will read the following sentence Make sure all wheel cap nuts are properly torqued check them often see 4 9 page 29 By turning to section 4 subtopic 9 on page 29 you will find information on proper torquing Note The Alcoa Heavy Duty Wheel Service Manual contains information for proper service and operation of Alcoa heavy duty wheels Alcoa heavy duty wheels for heavy duty trucks truck trailers and buses are Alcoa tubeless wheels with bead seat diameters measured in 5 inch increments and Alcoa tube type wheels Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 with bead seat diameters measured in 0 5 inch increments Not all Alcoa wheels are available with the Dura Bright surface treatment WARNING Wheels that are not properly installed or maintained may not work properly Failure to follow proper wheel installation WARNING or maintenance practices may result in injury or death Follow the proper wheel installation and maintenance practices as contained in this Alcoa Service Manual For additional copies of the manual available free of charge from Alcoa or for the most recent updates contact Alcoa Wheel and Forged Products at 1 800 242 9898
6. 3 4 Stud 5995 3 20 5x7 50 15 DC 7200 53 6 28 5 82 120 TRs45D 873100 9 4 016000 5555 L amp R 1 1 8 Stud 5988L amp R 7896 L amp R 5996 L amp R ip Omt eorogis 1 1 8 017000 Rear 077015 5996 L amp R 3 4 Stud 5995 4 22 5x8 25 15 DC 7200 53 6 66 5 68 120 TR545D 883110 9 4 016000 2295 L amp R 1 1 8 Stud 5988L amp R 7896 L amp R 5996 L amp R isp Oera 1 1 8 017000 Rear 077015 5996 L amp R 3 4 Stud 5995 5 22 5x9 00 15 DC 9000 60 694 5 94 130 TR543E 893000 S4 016000 2427 L amp R 1 1 8 Stud 5988L amp R 7896L amp R 5996 L amp R R o eee 1 1 8 017000 Rear 077015 5996 L amp R 3 4 Stud 5995 3 4 Stud 5995 6 22 5x12 25 15 DC 11 400 x eade Z 125 005435 823000 SH ONO L amp R 1 1 8 Stud z L amp R 1 1 8 Stud 150 Qon 079073 5996 L amp R 5996 L amp R 3 4 Stud 5995 3 4 Stud 5995 7 22 5x12 25 15 DC 11 400 66 3 88 2 76 ND ART MEC M L amp R 1 1 8 Stud 2 s L amp R 1 1 8 Stud 150 ont 79073 5996 L amp R 5996 L amp R 3 4 Stud 5995 3 4 Stud 5995 8 22 5x12 25 15 DC 11 000 70 584 468 120 TR545E 823060A SH ONO L amp R 1 1 8 Stud 5 L amp R 1 1 8 Stud 150 ont 078073 5996 L amp R 5996 L amp R 3 4 Stud 5995 3 4 Stud 5995 9 22 5x13 00 5 DC 12 300 72 3 5 2 38 125 TR543E 883050 SH ONO L amp R 1 1 8 Stud E L amp R 1 1 8 Stud 150 Qon 079073 5996 L amp R 5996 L amp R 3 4 Stud 5995 3 4 Stud 5995 10 22 5x13 00 15 DC 11 000 78 5 3 1
7. Ss ae TIT Seat the second end of the split side ring or lock ring Inflate to 10 psi Check to see that all components with a rubber plastic or leather facet mallet as shown Check carefully to see that the split side ring or side ring and lock ring assembly is in the proper position If not completely remove the components and start over are properly in place If not deflate the tire by removing the valve core and reposition components properly Place in a safety cage or other suitable restraining device refer to OSHA rule 1910 177 paragraph B see Section 7 page 44 Use clip on chuck and stand behind barrier during inflation Do not lean on cage Inflate to recommended pressure Deflate completely to avoid localized over stretching of the tube Reinflate to the tire manufacturer s recommended pressure 41 42 Demounting recommendations for tubed tires 6 4 WARNING An inflated tire contains air under pressure which can be a dangerous explosive force Explosive separation of a tire and wheel can cause serious injury or death WARNING Follow proper service procedures to avoid injury or death WARNING An aluminum wheel can be structurally weakened by uncontrolled excessive heat Tire wheel assemblies using wheels that have been exposed to excessive heat may experience a sudden and unpredictable tire wheel separation causing serious injury or death Immediately and permanently remove any wheel from service
8. The circle defined by the centers of the bolt holes stud holes of a wheel dimensions stated in diameter inches or millimeters BOLT HOLE Hole found in the disc of the wheel through which the bolt stud passes BORE See HUB BORE CENTER BORE See HUB BORE CONE LOCK CAP NUT See 2 PIECE FLANGE NUT DC Abbreviation for drop center DISC AREA The vertical wheel face which supports the rim DISC WHEEL A one piece forged or two piece welded assembly of a disc and a rim DROP CENTER The well or center portion of the wheel rim FLAT BASE WHEEL A multi piece wheel with a removable side ring FOOT POUNDS The measure of the amount of torque applied to a cap nut or other part May be measured with a torque wrench GUTTER FLANGE A groove which supports the removable portion of a multi piece wheel HUB BORE The center hole of a disc wheel dimensions stated in diameter inches or millimeters HUB PILOTED MOUNTING A wheel mounting system which uses the hub to center the wheel and two piece flange nuts to secure it in Abbreviation for inches INNER CAP NUT Cap nut used to mount the inner wheel in a dualed stud located wheel system INSET The distance from the wheel mounting surface to the rim centerline when the centerline is placed inboard of the mounting surface kg Abbreviation for kilogram weight measurement equal to 1000 grams kPa Abbreviation for kilo Pascals pressure measureme
9. and cap nuts with metric and wide base threads Most frequently these are M22x1 5 wheels hub Generally the same diameter stud is used to mount either single or dualed wheels piloted mounting Studs on both sides of the vehicle are right hand threads thereby eliminating the need two piece for flange nuts peculiar to either the right or left side of the vehicle The same flange nut is used to mount dualed or single wheels Proper stud standout for single wheels is 2 flange nuts inch 50 8mm minimum dualed wheels require 2 81 inch 71 4mm minimum and single wide base wheels require 2 32 inch 59mm Some states have laws which dictate full thread engagement or thread engagement past 4 10 the nut body Make sure you know the laws for the states in which you operate and comply DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel NOTICE Do not exceed Spacers are placed between the contact surfaces of the Dura Bright wheel and the maximum wheel load brake drum and between the dual wheels as shown below Customer must compare Note Some stud located ball seat wheels have the same number of holes and bolt OEM vehicle load rating circle diameter as hub piloted wheels They should not be mixed to maximum wheel load rating DiscMate when used DiscMate when used Refer to tire manufacturer s Drum 1 06 27mm l Drum 33mm hex h
10. and wide base wheels hub piloted mounting two piece flange nuts 31 4 11 Tightening hub piloted mounting two piece flange nuts sseenm 32 4 12 Incortect AS SemiPbliBSausnee permit ur eins EE DURUM LO EO RAD ORE RAV PRO Ra 34 5 Proper Torque Wheel Identification Valves and Surface Maintenance 35 gel AVOA ADUSE 35 5 7 Keep wheelnuts Mdh tata ere veh ert datae vira A ERE ra bab ll Bad end 35 Deo bead balakice Welghts tell OI uses doute vet ote losses EEE E EEEE prepa Dind 36 5 4 Dosnotsiraightern Wheels usine pent hon Qnid o E ERE EE aec A 36 5 5 39Wner thsservieeddentieatloP soe odo bMea era EE SAU SU ro DSUR CUR rea IE E OR C ba vs ob CREE e 36 S0 WAVES ES 36 5 7 Maintenance against corrosion non Dura Bright surfaced treated wheels 37 5 8 Dura Bright surface treated wheels cleaning and maintenance ssssssse 37 5x9 CSI ClO sues cars drap a ini DEF FECena ad T MEDIA haan an FE AER Y CIE Q FURM PUR DN ME ea eanumtveuRap Mtoe 38 6 Flat Base Wheel for Tube type Tires eenreeennnrnneee 39 6 1 Tube type wheel part interchangeability eeeeeeeee ee 39 6 2 Mounting recommendations for tubed tires eseeeeeeeeseen mnn 40 6 3 MOUNTING ortubed TES saber eiit Ud dator v HD pi e c D P eoe ecu 41 6 4 Demounting recommendat
11. does not warrant and will not repair or replace or make adjustment with respect to any wheel that has been subjected to misuse or abuse including the following a Using a tire that is oversized according to standards recommended by the Tire and Rim Association Inc or other recognized tire and rim agencies such as ETRTO Europe or others Loading the wheel beyond the applicable maximum wheel load as specified by Alcoa Inflating beyond the applicable maximum as specified by Alcoa Changing the original condition of the wheel by alteration or by subjecting it to any processing such as welding or straightening Accidents abnormal or severe operating conditions including without limitation tire fires brake fires severe brake system drags or seizures or running with a flat tire or Failure to follow maintenance and other instructions and warnings set forth in the Alcoa Heavy Duty Wheel Service Manual Alcoa Technical Bulletins and other Alcoa literature Recommended maintenance includes without limitation using proper torque periodic cleaning polishing valve replacement periodic inspection for damage loose lug nuts and rim flange wear inspections and procedures Nicks scratches and other surface blemishes resulting from improper maintenance cleaning road debris curbing accident or operation are not warrantable Damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alk
12. is available in all polishing finishes Dura Flange is only available in satin finish Inspect thoroughly and frequently 2 1 Safe operation requires thorough examination of wheels and attaching hardware at frequent intervals both on and off the vehicle Wheels that have been in service need to be inspected at regular intervals to assure proper and safe performance Like tires and other vehicle components that work hard wheels will eventually wear out It isn t always possible to predict exactly when the useful life of a wheel will end But generally older wheels and wheels operating in extreme conditions should be examined more frequently for obvious signs that they should be removed from service As an aid to the owner in determining the period of time a wheel has been in service it is recommended the owner stamp an in service date onto the wheel at the time of receipt See 5 5 page 36 for recommended stamping locations Pay particular attention to front end assemblies Examine all exposed areas frequently Clean wheels and look for cracks or other damage Also check the inner dualed wheel when the outer wheel is removed During tire changes thoroughly examine the entire wheel Pay particular attention to the rim contour and the surfaces of the rim On tube type wheels carefully inspect the gutter area normally concealed by the side rings Be sure that the best wheels are on the front of the vehicle Hidden dam
13. manual means a publication containing instructions from the manufacturer or other qualified organization for correct mounting demounting maintenance and safety precautions peculiar to the type of wheel being serviced Rim wheel means an assemblage of tire tube and liner where appropriate and wheel components Service or servicing means the mounting and demounting of rim wheels and related activities such as inflating deflating installing removing and handling Service area means that part of an employer s premises used for the servicing of rim wheels or any other place where an employee services rim wheels 44 OSHA Regulations continued Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components Single piece wheel means a vehicle wheel consisting of one part designed to hold the tire on the wheel when the tire Is inflated Trajectory means any potential path or route that a rim wheel component may travel during an explosive separation or the sudden release of the pressurized air or an area at which an airblast from a single piece rim wheel may be released The trajectory may deviate from paths which are perpendicular to the assembled position of the rim wheel at the time of Separation or explosion See appendix A for examples of trajectories Wheel means that portion of a rim wheel which provides the method of attachment of the assembly to the axle of a vehicle and also
14. manufactured for use with the stud located ball seat mounting system wheel studs on the right side of the vehicle have right hand threads and those on the left have left hand threads The R and L on the studs and nuts indicate right and left hand threads respectively see 4 2 page 24 After mounting a wheel over the studs snug up the cap nuts in the order shown in the illustrations that follow After all the cap nuts have been snugged tighten the cap nuts to the recommended torques following the same tightening sequence 1 1 Q 36 o NN E 40 Os oo O 5 2 2 Five Stud Six Stud 1 6 D 3 i0 8 O O eR fe A In Nos BO O7 uH O o SON 70a 4 O e L C A Eight Stud Ten Stud Continued on the next page Tightening stud After 50 100 miles of operation torque should be rechecked Loosen outer cap nuts on every other stud to check the torque on inner cap nuts then retorque outer cap nuts loc ated ball Repeat steps on remaining studs Check torque frequently from then on If nuts seat cap nuts require frequent tightening studs break frequently or wheel nut seats are pounding out hardware and mounting practices should be reviewed Note whenever the outer cap nut Continued is loosened ALWAYS retorque the inner cap nut before retorquing the outer cap nut j Most U S manufacturers of highway trucks tractors and trailers which incorporate Single dualed the hub piloted wheel mounting system require wheel studs
15. or use bead expander to force tire beads or other mechanical bead seating aid against rim Be sure to stay out of the path of potential exploding parts or air blasts 19 20 Mounting NOTICE Alcoa aluminum 19 5 RW and non symetrical well wide base wheels require tires be 3 mounted and demounted over the disc side of the wheel only For a free instruction wall chart tubeless tires contact Alcoa Inquiry Fulfillment Markinetics Inc P O Box 809 Marietta OH 45750 continued WARNING Use of a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build up in the tire and may result in an explosion WARNING Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire or later on the road Loss of vehicle control can result which can cause serious injury or death Use only approved mechanical or pneumatic bead seating devices NOTICE Not all tire mounting demounting machines work alike Be sure EGET l to read the operating CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause or instruction manual for your extremely rapid corrosion of the wheel rim surface particular machine before attempting to mount ON Severely corroded wheels are unsuitable for service Alcoa wheels corroded by or demount tires the use of liquid tire balancers or sealants will not be
16. out as illustrated Leaving one tool in position work the other around the tire until the bead is completely free Using the same procedures as outlined in Step 1 loosen the bead on the opposite side of the wheel Do not drive tools into rim area Lift wheel from tire 43 J OSHA Regulations OSHA Sec 1910 177 Servicing multi piece and single piece rim wheels Regulations a Scope 1 1 This section applies to the servicing of multi piece and single piece rim wheels used on large vehicles such as trucks tractors trailers buses and off road machines It does not apply to the servicing of rim wheels used on automobiles or on pickup trucks and vans utilizing automobile tires or truck tires designated LT 2 This section does not apply to employers and places of employment regulated under the Construction Safety Standards 29 CFR part 1926 the Agriculture Standards 29 CFR part 1928 the Shipyard Standards 29 CFR part 1915 or the Longshoring Standards 29 CFR part 1918 3 All provisions of this section apply to the servicing of both single piece rim wheels and multi piece rim wheels unless designated otherwise b Definitions Barrier means a fence wall or other structure or object placed between a single piece rim wheel and an employee during tire inflation to contain the rim wheel components in the event of the sudden release of the contained air of the single piece rim wheel Charts means the U S Depart
17. pads or strong chemicals such as acids or lye based products Never Spray cold water on extremely hot wheels Always allow time to cool before cleaning 2 When tires are removed the entire rim must be cleaned and inspected see section 2 page 5 With a brush remove any foreign products from the tire side of the rim portion of the wheel that supports the tire Do not use an abrasive brush to remove dirt corrosion or other foreign products from the Dura Bright wheel surfaces Generously coat the entire air chamber surface with an approved surface protectant and lubricate each time the tire is removed See 3 1 page 18 of the Alcoa Wheel Service Manual J uly 2002 3 To maintain the original appearance of your Alcoa Dura Bright wheels the following procedures are recommended a After installing new wheels and prior to operating your vehicle use a sponge or cloth to wash exposed wheels surfaces with a mild detergent and warm water Do not use abrasives abrasive brushes steel wool scouring pads or strong chemicals Such as acids or lye based products Standard off the shelf car wash and wheel detergents are sufficient Warm water and a mild detergent will speed the cleaning process b Rinse thoroughly with clean water c Wipe dry to avoid water spots 37 38 Dura Bright surface treated wheels cleaning and maintenance continued Identification 9 9 d Clean your Alcoa Dura Bright wheels using the above
18. piece flange nuts t43 22 5x8 25 15 DC i 260 rien ids o 60M S27 885530 013000 39874 39874 181 t44 22 5x9 00 15 DC aa s n nS a 60MS27 894530 013000 39874 39874 181 Hs 22 5x13 00 15 DC noes n 55 a TR543 833570A 013000 39874 39874 181 He 22 5x13 00 15 DC 009 un 65 i825 TR543 833570B 013000 39874 39874 181 47 24 5x8 25 15 DC o dd Mum Tum o TR545D 983500 013000 39874 181 10 hole hub piloted mounting 335mm bolt circle 281 2mm hub bore 32 87mm bolt hole dia use two piece sleeved cap nuts Ds 22 5x8 25 15 DC 7830 55 1 6 60 5 70 138 148 82mm bolt hole 8550 25 0 168 145 952 60MS27 885550 018000 i 430632 430732 TS 22 5x9 00 15 DC 8820 57 1 6 93 6 02 142 149 82mm bolt hole 4000 25 9 176 153 978 60MS27 894550 018000 i 430632 i 430732 i Read carefully all sections of this Service Manual regarding proper inspection installation and maintenance Mishandled tires and wheels can explode causing serious or fatal injury to you and others Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Do not overinflate Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Never use any flammable material on tires or rims to seat beads or for any other purposes Always use safety cages or
19. procedures as frequently as required to maintain their appearance Typical road soils grime and brake dust trap moisture which can cause corrosion over a period of time These must be removed regularly To assist in the removal of excessive dust dirt and road grime the use of warm high pressure water with a mild detergent is recommended The surface of Alcoa Dura Bright wheels will be damaged discolored or removed if abrasives abrasive brushes steel wool scouring pads or strong chemicals such as acids or lye based products are used to clean the wheel DO NOT USE the Alcoa Aluminum Care System on Dura Bright wheels at any time during their service life 4 Once in service Dura Bright wheels can become nicked or scratched by road debris and or mechanical damage If this occurs continue to follow the normal washing and cleaning instructions provided above The surface of an Alcoa Dura Bright wheel is designed to limit cracking and peeling if nicked or scratched while in service 5 Even as durable as Dura Bright wheels are the mounting area can become scratched marred or discolored when mounted against another wheel hub or drum The use of a wheel mounting surface guard such as Alcoa DiscMates is highly recommended The use of the Alcoa Hub Cover System on Alcoa Dura Bright wheels will also assist in limiting such damage and help maintain the appearance of your Alcoa Dura Bright wheels Alcoa wheel identification Sin
20. provides the means to contain the inflat ed portion of the assembly i e the tire and or tube c Employee Training 1 The employer shall provide a program to train all employees who service rim wheels in the hazards involved in servicing those rim wheels and the safety procedures to be followed i The employer shall assure that no employee services any rim wheel unless the employee has been trained and instructed in correct procedures of servicing the type of wheel being serviced and in the safe operating procedures described in paragraphs f and g of this section ii Information to be used in the training program shall include at a minimum the applicable data contained in the charts rim manuals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts or rim manual the employer shall assure that the employee is instructed concerning the contents of the charts and rim manual in a manner which the employee is able to understand 2 The employer shall assure that each employee demonstrates and maintains the ability to service rim wheels safely including performance of the following tasks i Demounting of tires including deflation ii Inspection and identification of the rim wheel components iii Mounting of tires including inflation with a restraining device or other safeguard required by this section
21. replaced under the Alcoa NOTICE Do not exceed limited warranty maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel E fitment check to insure proper F clearance from any P obstructions NOTICE When match mounting tires on Alcoa wheels locate valve stem adjacent to low point mark on the tire NOTICE Alcoa aluminum 19 5 RW and non symmetrical wide base wheels require tires to be mounted and demounted over the disc side of the wheel only NOTICE Refer to tire manufacturer s recommendation for proper tire pressure Heavy duty truck tires have a guide rib molded into the sidewall next to the tire bead When the tire is inflated this ring should be evenly spaced from the wheel rim all the way around the wheel Check the position of the ring before removing the assembly from the inflation cage If the ring and wheel are not concentric deflate the assembly in the cage and remount the tire Rim width to tire matching 3 3 Tire Size for both radial and bias tires 8R 215 75R 9R 10R 245 75R 11R 8 225 70R 245 70R 265 70R 285 70R 305 70R 445 65R 17 5HC 17 5 17 5HC 17 5HC 17 5 17 5HC Approved Rim Widths 6 00HC 6 00 6 75 6 75HC 6 75HC 7 50HC 6 75 7 50 8 25HC 50RW 25RW 25RW 9 00 25RW 9 00 14 0
22. specific instructions on the care and clearing of Alcoa Dura Bright surface treated wheels 1 Clean frequently with high pressure water from a hose The use of a mild detergent will soeed the cleaning process Use no harsh alkaline cleaners 2 When tires are removed the entire wheel must be cleaned and inspected See Section 2 page 5 With a wire brush remove any foreign products from the tire side of the rim Do not use a wire brush to remove dirt and corrosion products from the appearance Surface of the wheel Generously coat the entire air chamber surface with an approved Surface protectant and lubricant each time the tire is removed See 3 1 page 18 3 To maintain the original appearance of your Alcoa wheels the following procedures are recommended a After installing new wheels and prior to operating your vehicle use a sponge cloth or soft fiber brush to wash exposed wheel surfaces with a mild detergent and warm water solution b Rinse thoroughly with clean water c Wipe dry to avoid water spots d Wax the cleaned surface with Alcoa Advanced Aluminum Care System Polish or Simonize Mothers California Gold paste wax No 7 Car Wax or equivalent e Clean your Alcoa truck wheels as frequently as required to maintain their appearance 1 Clean frequently with high pressure water from a hose The use of a mild detergent will soeed the cleaning process Do not clean with abrasives abrasive brushes steel wool scouring
23. studs in use and their design and specifications are not standardized The R and L on cap nut part numbers indicate right and left hand threads respectively Alcoa recommends the following cap nuts for use with Alcoa aluminum truck wheels Cap Nuts 2 piece 33mm hex head flange nut Mounts single and dualed wheels to wheel centering hubs Right hand threads used on both sides of vehicle Single wheels require 2 50 8 mm stud standout Dualed wheels require 2 13 16 71 44 mm stud standout P N 39874 supersedes P Ns 39701 and 39691 M22 1 5 RH threads 2 piece 30mm hex head flange nut Mounts single and dualed wheels to wheel centering hubs Right hand threads used on both sides of vehicle P N 39708 M20x1 5 RH threads 2 piece 33mm hex head flange nut Mounts dualed wheels with 32mm bolt holes to wheel centering hubs Right hand threads used on both Sides of vehicle P N 4307 32 M22x1 5 RH threads 1 1 8 cap nut Mounts Standard single wheels and wide base wheels to 1 1 8 studs Also mounts outer dualed wheel to 1 1 8 inner cap nut P N 5996R 5996L replaces P N 5552R 5552L 3 4 x16 cap nut Mounts Alcoa wide base wheels to 3 4 studs Do not use on steel wheels P N 5995R 5995L replaces P N 5554R 5554L 2 piece 1 1 16 hex head flange nut Mounts single and dualed wheels to wheel centering hubs Right hand threads used in both sides of vehicle P N 39946 5 8 x18 RH threads
24. use two piece flange nuts Front 076018 or 076085 Rear 077018 or 077085 Front 076018 or 076085 Rear 077018 or 077085 Front 076018 or 076085 Rear 077018 or 077085 Front 076018 or 076085 Rear 077018 or 077085 Front 076018 or 076085 Rear 077018 or 077085 0720 22 5x7 50 15 DC 7300 53 6 28 5 44 120 TR545D 873600 011000 2225 39874 39874 181 B21 22 5x8 25 15 DC 7300 47 6 66 5 81 120 TR545D 883620 011000 2227 39874 i 39874 181 3322 22 5x8 25 15 DC 8000 55 6 66 5 69 120 TR543C 885600 011000 2225 39874 i 39874 181 0923 22 5x9 00 15 DC 9000 60 6 94 6 04 130 TR543C 893600 011000 2127 39874 39874 181 24 22 5x9 00 15 DC 10 000 53 3 12 130 TR545E 893630 011000 39874 39874 181 Front 076018 0525 22 5x10 50 15 DC 10 500 68 66 1 5 5 130 TR544 803600 011000 39874 181 or 0760851 Front 076018 26 22 5x12 25 15 DC 11 400 63 56 125 TR543E 823600 011000 39874 39874 181 or 0760851 Reversible Rear 077018 or 077085 Front 076018 TR543E outset or 0760851 DB 2159 27 22 5x12 25 15 DC 11 400 66 3 88 2 75 125 TR545E inset 823650 011000 39874 39874 181 Rear 077018 or 0770851 Front 076018 or 0760851 Rear 077018 or 0770851 Front 076018 29 22 5x12 25 15 DC 10 000 74 6 24 5 12 120 TR545E 823670A 011000 39874 39874 181 or 076085 Rear 077018 or 0770851 Front 076018 o TR543E outset or 0760851 30 22 5x13 00
25. 0 7 8 8 8 Tire Size for both radial and bias tires 8 9 10 245 75R 11 255 70R 265 75R 12 295 75R 305 85R 315 80R 15 385 65R 425 65R 16 5 18 445 50R 445 55R 445 65R 11 275 80R 285 75R 12 305 75R Rim to tire matching chart for medium and heavy trucks Approved Rim Widths O UI UI UIO O C Ui UI C Ul tO tO tO OHO 00 1 1 OY n ud ae a N UIN UI O Ul 0 000000 1 110 OY o un Q NN N UI Ul Ul I 1 CO N IO OO ONN N U1 UI NO UI O O UI UI UI VI 11 75 12 25 11 75 12 25 11 75 12 25 13 00 12 25 13 00 13 00 14 00 14 00 14 00 12 25 13 00 14 00 There may be additional rim to tire matches not shown above Contact the tire manufacturer or your Alcoa wheel representative for additional information Recommendations for demounting tubeless tires 3 4 A WARNING A WARNING WARNING An aluminum wheel can be structurally weakened by uncontrolled excessive heat Tire wheel assemblies using wheels that have been exposed to excessive heat may experience a sudden and unpredictable tire wheel separation causing serious injury or death Immediately and permanently remove any wheel from service that has been subjected to uncontrolled excessive heat such as a tire fire wheel bearing failure or braking system drag seize or a high pressure tire wheel separation WARNING Damaged tires or wheels can lead to an ex
26. 06 20 5375 21 0344 21 4313 21 B281 22 2250 226219 23 0188 23 4158 23 8125 24 2094 24 6063 25 0031 Conversion Inches to Millimeters Factors 9 2 Inches X 25 4 M illimeters Millimeters to Inches Millimeters x 0 03937 Inches PSI to kPa PSI x 6 8948 kPa kPa to PSI kPa x 0 145 PSI Pounds to Kilograms Pounds x 0 4536 kg Kilograms to Pounds kg x 2 2050 Pounds Foot pounds to Kilogram Meters Ft Ibs x 0 13826 kgm Kilogram Meters to Foot pounds kgm X 7 23 Ft Ibs 53 Alcoa Wheel and Forged Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2004 Alcoa Wheel and Forged Products All Rights Reserved Form E37 13584 Printed in USA 02 04 30M
27. 15 DC 12 300 73 3 5 2 38 125 TR545E inset 833650 011000 39874 39874 181 Rear 077018 or 0770851 Front 076018 or 0760851 Rear 077018 or 0770851 Front 076018 x TR543E outset or 0760851 1132 22 5x14 00 15 DC 12 800 71 2 0 0 87 125 TR545E inset 841600 011000 39874 39874 181 Rear 077018 or 0770851 Front 076018 TR543E outset or 0760851 T1933 22 5x14 00 15 DC 12 800 71 1 13 0 125 TR545E inset 841610 011000 39874 39874 181 Rear 077018 or 0770851 28 22 5x12 25 15 DC 11 000 71 5 8 4 68 120 TR545E 823660A 011000 a 39874 39874 181 31 22 5x13 00 15 DC 11 000 74 6 42 5 8 120 TR545E 833660A 011000 39874 39874 181 Front 076018 pr 34 24 5x8 25 15 DC 7300 55 6 6 5 73 120 TR545D 983620 011000 2247 39874 39874 181 Bb or 0770851 Front 076018 or 0760851 Rear 077018 or 0770851 1335 24 5x8 25 15 DC 8000 65 6 6 5 63 120 TR545D 985600 011000 2245 39874 39874 181 10 hole hub piloted bus mounting 11 25 in bolt circle 8 670 in hub bore 1 219 in bolt hole dia use two piece flange nuts 0936 22 5x8 25 15 DC 7300 53 6 66 5 82 120 TR545D 883610 015000 2225 1821 0537 24 5x8 25 15 DC 7300 62 6 6 5 77 120 TR545D 983610 015000 2245 1821 Continued on next page 1 Specifications conta CLASSIC TUBELESS WHEELS ENGLISH UNITS METRIC UNITS Wheel Maximum heel load wt Outset Inset inflation Front Rear Inner R
28. 20 TR545E 8330604 SH 00000 L amp R 1 1 8 Stud 2 s L amp R 1 1 8 Stud 150 ont 079073 5996 L amp R 5996 L amp R TR543E 3 4 Stud 5995 3 4 Stud 5995 H11 22 5x14 00 15 DC 12 800 71 2 0 87 125 outset 841100 Piy OTRO L amp R 1 1 8 Stud B L amp R 1 1 8 Stud 150 ont 079073 TR545E inset 5996 L amp R 5996 L amp R 3 4 Stud 5995 3 4 Stud 5995 12 24 5x8 25 15 DC 7200 59 6 6 5 59 120 TR545D 983120 SH ONO L amp R 1 1 8 Stud S988 L amp R 7896 L amp R L amp R 1 1 8 Stud 150 1075 070013 5996 L amp R 5996 L amp R 13 22 5x13 00 15 DC 11 000 76 e 6 12 120 TR543 833070A B 14 17 5x6 75 15 DC 6050 30 0 130 TR542 661400 i 39946 i 190 15 17 5x6 75 15 DC 6050 29 7 E 0 130 TR542 662400 39946 190 Eight hole hub piloted mounting 275mm bolt circle 221 1mm hub bore 26 75mm bolt hole dia use two piece flange nuts 6 22 5x7 50 15 DC 7300 53 6 28 5 44 120 TR545D 873400 014000 2225 39874 2 39874 181 s 17 22 5x825 15 DC 7300 50 6 66 5 82 120 TR545D 883420 014000 2227 39874 z 39874 181 118 22 5x14 00 15 DC 12 800 71 2 0 0 87 425 TRO43E outset 4441400 014000 39874 2 39874 181 90076 089 TR545E inset 819 24 5x8 25 15 DC 7300 62 6 6 5 77 120 TR509 983400 014000 2245 39874 3 39874 181 B Continued on next page 1 Specifications conta 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hole dia
29. 20X7 5 8 0 DT LB LW 3 R8020LW 20X7 5M FOX 8 ODT LB LW G3 Rgo2oLw LR20X7 5 8 5 10 0M LR20M F20X7 5 8 5M F7520M 20X7 5DA5 20X7 5DA5 20X7 5FLN 20X7 5N5 NONE NONE 20X7 5FLN 20X7 5FLN 20X7 5DA5 20X7 5N5 NONE NONE 20X7 5N5 20X7 5N5 20X7 5FLN 20X7 5DA5 NONE NONE B7520KB R8020KW NONE NONE B7520KW R8020KW NONE NONE B7520KWX R8020KW NONE NONE BW 5 20X7 5 BW 5 20X7 5 BW 5 20X7 5 8 0V 8 5V B 5 20X7 5 20x8 0 20X8 0 5 20X8 00 5 F20800B 2 NONE 20X7 0 7 5 8 0 5 0 20X8 0 5 20X7 5 8 05 7 5FL aes ge B8020LW BOX 6 8 ODT LB LW 3 Rgo2oLw LR20X7 5 8 5 10 0M LR20M F20X7 5 8 5M F7520M B8020KW R7520K NONE NONE BW 5 20X8 0 NONE BW 5 20X7 5 8 0V 8 5V BW 5 20X8 0V 8 5V 22x7 5 1022 22 7 5 T M 22 7 5 8 A3 191 1022 RC22 75 T M 22 7 5 8 A3 191 NONE NONE 22X7 5 5 22X7 50 5 F22750B 2 NONE 22X7 0 7 5 8 0 5 rus eee nee 22X7 5FL B7522FL 22X7 5FL R22X7 5FL R7522FL 22X7 5FL LR22X7 5FL LR7522FL CENE n b 22X7 5LB 22X7 5DT LB 3 R22X7 5 8 0 9 0LB LW NONE NONE B7522LB G22750B 2 22X7 5 8 0DT LB LW 3 RB022LW 22X7 5LW 22X7 50LW B7522LW R22X7 5 8 0 9 0LB LW NONE NONE G22750B 2 22X7 5 8 0DT LB LW 3 RB022LW 22X7 5M R22X7 5 8 0LB LW R8022LW LR22M LR22X7 5 8 5 10 0M F7522M 22X7 5DA5 22X7 5DA5 22X7 5FLN 22X7 5N5 NONE NONE 22X7 5FLN 22X7 5FLN 22X7 5DA5 22X7 5N5 NONE NONE 22X7 5N5 22X7 5N5 22X7 5FLN 22X7 5DA5 NONE NONE B7522KB R8022KW NONE NONE B7522KW R8022KW NONE NONE B7
30. 522KWX R8022KW NONE NONE BW 5 22X7 5 BW 5 22X7 5 BW 5 22X7 5 8 0V 8 5V B 5 22X7 5 22x 8 0 22X8 0 5 22X8 00 5 F22800B 2 NONE 22X7 0 7 5 8 0 5 22X8 0 5 repu an ems o sen utn ren B8022KW R7522KW NONE NONE BW 5 22X8 0 NONE BW 5 22X7 5 8 0V 8 5V BW 5 22X8 0V 8 5V Part numbers listed by Alcoa are followed by one of the characters X T N B or current Alcoa part numbers i e 371010 end in 0 1 2 or 3 indicating a finish condition which does not affect the interchangeability of parts as shown on the chart Matching Chart is represented in the table below 39 Mounting 1 Inspect the wheel for damage Do not use a bent cracked damaged or severely corroded wheel See Section 2 page 5 recommendations for tubed tires 2 Inspect ring s for corrosion bending or other damage and discard if any is apparent 3 Thoroughly clean the wheel and rings Clean the wheel face with a mild detergent Clean the tire bead seat areas and gutter flange with a wire brush 4 Do not gouge or nick the wheel Place wheels on a wooden floor or rubber mat 6 2 Always use a rubber leather faced or plastic mallet mm 5 Inspect and clean the tire tube and flap before mounting replace if damaged badly worn or defective 6 Insert lubricated tube and flap in tire 7 Lubricate the tire beads and rim then mount tire tube and flap assembly onto rim Do not use any lubricant which contains water or a solvent which can inju
31. BLE OR FIT FOR ANY PARTICULAR PURPOSE NOR IS THERE ANY OTHER WARRANTY EXPRESS OR IMPLIED EXCEPT SUCH AS IS EXPRESSLY SET FORTH HEREIN ALCOA SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR ANY BREACH OF WARRANTY ITS LIABILITY AND THE PURCHASER S EXCLUSIVE REMEDY BEING LIMITED TO REPAIR OR REPLACEMENT OF THE WHEEL AS STATED IN THIS LIMITED WARRANTY Alcoa Wheel Service Manual This limited warranty should be used in conjunction with the Alcoa Wheel Service Manual and the Alcoa Dura Bright Wheel Finish Care and Maintenance Manual The Wheel Service Manual contains important safety information and warnings and failure to read and understand this information may result in serious injury or death The limited warranty is included with the Wheel Service Manual but may appear elsewhere If you do not have copies of the Wheel Service Manual you may obtain copies free of charge from Alcoa Wheel and Forged Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 and on the web at www alcoawheels com How to use this manual This manual is written in a style called structured text Throughout the manual you will find numbers which look like this See 3 1 page 18 These numbers are cross references to other sections of the manual The numbers 3 1 refer to section 3 subtopic 1 When you turn to page 18 you will find the section number and subtopic number under the heading in each section as shown below
32. ING or death See chart below for matching components Hu dE meds CEDE er LUE m The following is the Alcoa Aluminum Wheel inter changeability information from the OSHA Multipiece Rim Matching Chart For a complete matching chart write to U S Department of Labor Occupational Health and Safety Administration Publications Department Room N4101 Washington DC 20210 Read across the chart to find interchangeable components for specific size and type of Alcoa wheel The information which is found in the shaded areas of the OSHA Multipiece Rim Multipiece Rim Matching Chart 2 PIECE ASSEMBLIES 3 PIECE ASSEMBLIES RIM SIZE RIM BAST INEN is SIDE RING IDENTIFICATION LOCK RING IDENTIFICATION FLANGE IDENTIFICATION STAMPING STAMPING STAMPING 20X7 5 20x7 5FL B7520FL 20x7 5FL R20X7 5FL R7520FL 20X7 5FL LR20X7 5FL LR7520FL S ME Econ esr simis 1020 20 7 5 T M 20 7 5 8 A3 190 1020 RC20 7 5 T M 207 5 NONE NONE NAA2051 20 75 KH 20X75 135205 F20 7 5 AAA2951 1 NONE NONE 20X7 5 5 20X7 50 5 F20750B 2 NONE 20X7 0 7 5 8 0 5 Bene EECA 3 B03 sS 20X7 5LA 20X7 5MS B7520LA R20X7 5LA 20X7 5MS R7520LA NONE NONE 20X7 5LB 20X7 5DT LB 3 R20X7 5 8 0 9 0LB LW MONE N NE B7520LB G20750B 2 20X7 5 8 0DT LB LW 3 RB020LW 20X7 5LW 20X7 50LW B7520LW 20X7 5 8 0 9 0LW NONE NONE G20750B 2
33. Rim Flange Wear Gauge Instructions Rim Acceptable Rim Acceptable Rim NOT Acceptable Rim Gauge Rim Gauge Rim Gau ge Alcoa P N 000700 Alcoa P N 000700 Alcoa P N 000700 D No daylight Daylight in this Daylight in this area indicates area indicates acceptable rim acceptable rim Wheel rim Wheel rim in this area indicates Wheel rim excessive wear Remove from service immediately To obtain a gauge s at no charge and information on free training on proper installation and maintenance procedures contact Alcoa Wheel and Forged Products at 800 242 9898 option 1 or on the web at www alcoawheels com Determining Rim Flange Wear STEP 1 Remove the wheel tire assembly from the vehicle Remove the valve core to deflate the tire completely Remove the tire from the wheel according to OSHA regulations TMC recommended practices for tire and rim safety procedures and or the Alcoa Wheel Service Manual Photo 1 Acceptable Rim Flange Wear Condition 13 Rim flange wear continued NOTICE Examine the tire for cuts in the bead area and side wall If no damage occurred to these areas return the tire to service Cut tires should be removed from service The tire should be inspected at this time for any other damage and be treated per normal tire procedures recommended by the tire manufacturer NOTICE Check the wheel at every tire change or ONCE PER YEAR for rim flange wear and any sharp edges If you f
34. age Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures listed in Section 1 Specifications of this manual Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Some forms of wheel damage can be hidden beneath the tire so whenever a tire is removed thoroughly examine the complete wheel Remove all grease and road dirt Use a wire brush or steel wool to remove rubber from the bead seats Check mounting holes for the enlargement and elongation which can occur if the cap nuts are not kept tight see 2 5 page 9 Dirt streaks radiating from stud holes may indicate loose cap nuts see 4 9 page 29 Excessive heat damage 2 2 WARNING Excessive heat from fire brake malfunction wheel bearing failure or other sources may weaken the metal and cause the wheel tire assembly to separate explosively WARNING Exploding wheel tire assembly can cause death or serious injury Immediately and permanently remove from service any wheel that has been exposed to excessive heat Inspect for exposure to excessive heat A wheel that has been subjected to excessive heat may appear charred or burned A wheel that has been exposed to excessive heat may appear to be in good condition if it has been cleaned Even if a whe
35. ake drum as shown below DiscMate when used Alcoa Aluminum Wheel Outer Cap Nut P N 5996R or L 4 See 4 2 page 24 Correct single mounting with 1 1 8 inch stud located ball seat mount 1 6 inch gt minimum KF DiscMate when used 4 Alcoa Aluminum Wheel Outer Cap Nut P N 5995R or L 3 4 Stud SN y See 4 2 page 24 Hub Correct single mounting with 3 4 inch stud located ball seat mount 1 6 inch minimum K Rear wheels are most frequently mounted as duals Each inner aluminum wheel is attached by 10 inner cap nuts Alcoa recommends use of inner cap nuts 5978R 5978L or 5988R 5988L see 4 2 page 24 Cap nuts recommended by Alcoa are compatible with Alcoa wheels Hardware of equal dimensions and strength may be used Continued on next page Dualed wheels stud located ball seat mounting continued Drum gt 3 4 Stud y Hub NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Most vehicles have standard length studs 1 31 1 5 16 to 1 44 1 7 16 stud standout Some vehicles use studs longer than standard up to 1 88 1 7 8 standout When changing types of brake drums be sure to check
36. aline Dura Bright Surface Treated Wheels are warranted against a Filiform corrosion worm or hair like lines generally milky in appearance underneath surface protective treatment and emanating from damage to the surface treatment Such as nicks scratches or damage from mounting hardware or wheel weights b Blistering due to loss of adhesion of the surface treatment c Lift off of the surface treatment due to physical damage nicks scratches gouges If nicks dings scratches or other damage does occur to the Dura Bright treatment that exposes the aluminum underneath the metal exposed may naturally oxidize but any corrosion will be confined to the metal exposed and will not extend into or underneath the Dura Bright treatment Normally any washing materials or chemicals including mild acid washes that can safely be used on a vehicle its painted surfaces and components can safely be used on the Dura Bright surface treatment The Dura Bright treatment prevents corrosion of aluminum wheels and protects their shine So long as the treatment remains in place see comments g and h above and is maintained in accordance with the Alcoa Dura Bright Care and Maintenance manual it is warranted against corrosion If corrosion does occur within the treatment warranty period subject to the limitations stated above Alcoa will replace any wheel exhibiting such corrosion THERE IS NO WARRANTY THAT THE WHEEL SHALL BE MERCHANTA
37. allow the employee to stand outside the trajectory 5 Current charts or rim manuals containing instructions for the type of wheels being serviced shall be available in the service area 6 The employer shall furnish and assure that only tools recommended in the rim manual for the type of wheel being serviced are used to service rim wheels e Wheel component acceptability 1 Multi piece wheel components shall not be interchanged except as provided in the charts or in the applicable rim manual 2 Multi piece wheel components and single piece wheels shall be inspected prior to assembly Any wheel or wheel component which is bent out of shape pitted from corrosion broken or cracked shall not be used and shall be marked or tagged unserviceable and removed from the service area Damaged or leaky valves shall be replaced 3 Rim flanges rim gutters rings bead seating surfaces and the bead areas of tires shall be free of any dirt surface rust scale or loose or flaked rubber build up prior to mounting and inflation 4 The size bead diameter and tire wheel widths and type of both the tire and the wheel shall be checked for compatibility prior to assembly of the rim wheel f Safe operating procedure multi piece rim wheels The employer shall establish a safe operating procedure for servicing multi piece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at le
38. amage before removing from vehicle If damage is found the tire must be completely deflated before loosening cap nuts Remove damaged tires or wheels from service WARNING Use of inner tubes in tubeless wheels will hide slow leaks Slow leaks may indicate cracked see section 2 9 page 12 or damaged wheels which lead to wheel failures WARNING Wheel failures can cause accidents which may result in serious injury or death Never use an inner tube on an Alcoa tubeless wheel and always remove cracked or damaged wheels from service 1 Do not gouge or nick the wheel Place aluminum wheels on clean wooden floor or rubber mat when hand mounting tires Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see section 5 8 pages 37 amp 38 for specific cautions care and maintenance procedures DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring 2 Always use a rubber leather faced or plastic mallet 3 Inspect the wheel for damage Do not use a damaged or severely corroded wheel See Section 2 page 5 4 Clean the wheel face with mild detergent and the tire bead seat areas with a wire brush Be sure the wheel is dry before applying tire lubricant 5 Inspect the tire for damage Be sure the inside of the tire is dry before it is mounted 6 Use
39. as illustrated below to trace the bead seats of the wheel Rotate the wheel noting the amount of variation shown on the dial indicator Note Alcoa aluminum wheels should be tested for radial run out only at the bead seat surface A total indicator reading of 045 inches is acceptable rf oe e A Tire wear can also be caused by improperly seated tires Inspect the tire for proper seating on the wheel The tire beads may not be seated properly If so remove the wheel from the vehicle deflate and break the bead seats See 3 5 page 22 for recommendations and instructions for demounting tubeless tires and 6 5 page 43 for recommendations and instructions for demounting tube type tires Adequately lubricate the bead seats and properly reseat the tire beads Reinflate the wheel in a safety cage or other suitable restraint refer to OSHA rule 1910 177 paragraph b see Section 7 page 44 WARNING Cracked or damaged wheels may cause wheels to fail or come off the vehicle while the vehicle is moving Wheels that fail or come off the vehicle while it is moving can cause WARNING serious injury or death Immediately remove cracked or damaged wheels from service Inspect wheels for cracks or damage according to the following sections of Chapter 2 Remove wheels from service with known or suspected damage Mounting area Stud hole cracks are usually caused by improper torquing see 4 9 page 29 and 5 2 page 35 excessive loading or insu
40. ason This does not include normal wheel maintenance as described and approved by Alcoa WARNING An aluminum wheel can be structurally weakened by uncontrolled excessive heat Tire wheel assemblies using wheels that have been exposed to excessive heat may experience a sudden and unpredictable tire wheel separation causing serious injury or death Immediately and permanently remove any wheel from service that has been subjected to uncontrolled excessive heat such as a tire fire wheel bearing failure or braking system drag seize or a high pressure tire wheel separation in H Some fleets wish to specially identify wheels as to OWNERSHIP and IN SERVICE dates Owner in service Alcoa recommends that fleets and owner operators adopt the practice of permanently identification stamping wheels with the date they are first placed into service 1 Use Lo Stress stamps or equivalent 5 5 2 Location of stamped areas on outside disc should be in space outward from a line z between hand hole centers and a minimum of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impression stamp on Dura Bright surface treated wheels can affect the appearance and performance of the Dura Bright surface treatment local to the stamp Alcoa drop center wheels for tubeless tires come from the factory with air valves instal
41. ast the following elements 1 Tires shall be completely deflated before demounting by removal of the valve core 2 Tires shall be completely deflated by removing the valve core before a rim wheel is removed from the axle in either of the following situations OSHA Regulations continued i When the tire has been driven underinflated at 80 or less of its recommended pressure or ii When there is obvious or suspected damage to the tire or wheel components 3 Rubber lubricant shall be applied to bead and rim mating surfaces during assembly of the wheel and inflation of the tire unless the tire or wheel manufacturer recommends against it 4 Ifa tire on a vehicle is underinflated but has more than 80 of the recommended pressure the tire may be inflated while the rim wheel is on the vehicle provided remote control inflation equipment is used and no employees remain in the trajectory during inflation 5 Tires shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead 6 Whenever a rim wheel is in a restraining device the employee shall not rest or lean any part of his body or equipment on or against the restraining device 7 After tire inflation the tire and wheel components shall be inspected while still within the restraining device to make sure that they are properly seated and locked If further adjustm
42. ate the sharp edge This should only be a small amount of metal Perform this work on both flanges if the there is evidence of sharpness Regardless of the method which you choose the objective is to remove the sharp edge photo 9 Remove just enough metal to smooth the edge Take care to make sure the edge removal is as uniform as possible Avoid gouging the wheel Rim flange wear continued STEP 5 After the edge is removed run the sharpness indicator gauge along the area of edge removal to check for any remaining sharpness If the rubber is still cut perform the steps again to remove the sharp edge Always remove the minimum amount of material necessary to eliminate the sharp edge STEP 6 Check the rim flange height with the Alcoa Rim Flange Wear gauge to make sure there is adequate height remaining to safely support the tire The photograph again shows how this gauge is used photo 1 Be sure to move the gauge all around the wheel s circumference and make sure that no area of the flange is below what the gauge indicates is acceptable If the entire wheel flange is within the limits of the rim flange wear gauge the wheel may be returned to service STEP 7 Always inspect the wheel for any other conditions that would warrant removal from service Consult the Alcoa Wheel Service Manual or the TMC User s Guide to Wheels and Rims WARNING Welding or brazing the rim flange or any area of an Alcoa aluminum wheel will weaken t
43. base wheels for tube type tires you must use the proper side ring or side and lock ring required for each wheel The table below lists the Alcoa tube type wheels currently in production and the proper side ring or side and lock ring identification recommended for each wheel See the Multipiece Rim Matching Chart on page 39 for information on older wheels with part numbers not shown here Alcoa Flat Base Wheels for Tube type Tires That Use Goodyear LW or Firestone DT Split Side Rings Only 2 Piece Assemblies Wheel Size Alcoa Part Number Side Ring Identification Stamping Identification Stamping 22x8 00 LW 481010 R8022LW recommended or R22X7 5 8 0 9 0LB LW 22X7 5 8 0DT LB LW 3 22x7 50 LW 471010 R8022LW recommended or R22X7 5 8 0 9 0LB LW 22X7 5 8 0DT LB LW 3 Current Alcoa part numbers i e 481010 end in 0 1 2 or 3 indicating a finish condition which does not affect the compatibility of parts as shown in the table If the wheel requires a lock ring start the leading edge of the lock ring being sure that it is seating in the machined groove Then walk the lock ring onto the wheel as illustrated Lubricate tube flap and wheel Insert tube and flap into tire Place them on the wheel so that the valve is aligned with the valve slot Place side ring on wheel and tire and stand on the ring to position it below the lock ring groove If a split side ring is required start the leading edge and walk the side ring onto the wheel
44. ce 1977 all Alcoa aluminum disc wheels have been identified with a stamp that shows the wheel load rating maximum inflation pressure date of manufacture part number wheel description and DOT marking designation Prior to J une 1996 all Alcoa heavy duty truck wheels had the Alcoa identification symbol x on the outside of the disc neat the hand hole in line with the valve location This marking was phased out on heavy duty truck wheels manufactured after J une 1996 Wheel Load Rating Maximum FMVSS 120 Pounds Inflation Pressure Designation ALCOA amp FORGED MAX LOAD 7300 LB MAX PSI 120 T bor MADE IN U S A 082297 PART NO 883623 22 5X8 25 15 DC Date of Manufacture Wheel Description Month Day Year prior to 2000 some wheels may have only Month Year All Dura Bright surface treated wheels are designated by the letters DB following the part number such as 883620DB Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 with bead seat diameters measured in 0 5 inch increments Not all Alcoa wheels are available with the Dura Bright surface treatment Flat Base Wheel for Tube type Tires Tube type wheel part interchangeability WARNING Mismatched rim wheel components can lead to explosive separation of wheel components Explosive separation of wheel parts can cause serious injury WARN
45. e along the wheel in the area of the wear to determine if the wear is sharp enough to cut or damage the rubber on the sharpness indicator If the flange cuts or appears close to being sharp enough to cut the rubber on the sharpness indicator gauge the edge can be removed per the edge removal procedures below If the rubber is not cut then the wheel can be returned to service without further work for rim flange wear CAUTION Do not run unprotected hands or fingers across worn rim flange areas of used wheels Worn rim flange areas are sharp and can cut hands or fingers CAUTION Cuts can lead to infection Always wear gloves when handling used wheels or when testing for edge sharpness Rim flange wear continued Edge Removal Procedures There are many tools available to remove the sharp edge on the wheel caused by rim flange wear Here are some examples of commonly used tools File A file can be used very effectively to remove the edge photo 4 Photo 4 Removing sharp edge by hand Photo 5 Air or electric power sander with a metal file Air or Electric Powered Sander This provides a very quick and effective method of removing the edge Operators should use all care to keep a uniform edge when using these tools photo 5 Air or Electric Grinder Another quick and effective method of removing the Sharp edge caused by rim flange wear Be careful as grinding pads may gum up from the aluminum that is removed p
46. ead 2 piece flange nut N 39874 a F recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions M22x1 5 M22x1 5 Stud gt lt stud Hub 2 50 8mm minimum 2 32 59mm minimum stud standout single wheels Stud standout wide base single wheels DiscM ates n used IA 2 81 71 4mm minimum stud standout dual wheels m Uu B Drum Stud M22x1 5 33mm hex head 2 piece flange nut P N 39874 1 06 27mm minimum pilot length for dualed aluminum wheels Typical assembly of single and dual wheels of hub piloted type with 33mm hex head two piece flange nut Part No 39874 If hex nuts with greater overall height are used more stud length is required Continued on the next page 31 Single dualed and wide base wheels hub piloted mounting two piece flange nuts continued Tightening hub piloted mounting two piece flange nuts 4 11 32 Hubs designed for steel hub piloted wheels may not have enough pilot length to locate dualed aluminum wheels Pay close attention to pilot length particularly when converting from steel to aluminum duals Measure the hub pilot to make sure the hub has a minimum pilot length of 1 06 inch or 27mm for dualed wheels When mounting painted steel inner dual wheels with outer aluminum wheels be cautious of excessive paint build up on t
47. ear Inner Rear Hub Cover Item Wheel Ibs inches inches PSI cold Valve Part Outer Cap Nuts Cap Nuts Outer Lug Nut System Kits no description kilograms kilograms mm mm KPa stem number DiscMate Stabilizer Cap Nuts AIAI Al Stl Cap Nuts Covers Front Rear Eight hole hub piloted mounting 275mm bolt circle 221 1mm hub bore 24 75mm bolt hole dia use two piece flange nuts 5515 29 5 5 55 4 72 142 38 17 5x6 75 15 DC 2500 13 4 141 120 978 TR543C 663470 014000 2126 39874 39874 181 5515 37 0 5 55 4 72 142 DB o c 39 19 5x6 75RW 15 DC 2500 16 8 141 120 978 TR543C 764480 014000 2126 39874 39874 181 40 19 5x7 50RW 15 DC sa att 6 10 A bs TR543C 773400 014000 2126 39874 39874 181 3000 17 1 155 134 978 10 hole hub piloted mounting 225mm bolt circle 176 1mm hub bore 26 5mm bolt hole dia use two piece flange nuts 5515 28 0 5 24 4 49 142 2500 122 133 114 gro P9430 PEDEM 2125 E i E i i j 41 17 5x6 00 15 DC 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hole dia use two piece flange nuts Front 076018 6615 37 7 6 10 5 28 142 B B or 0760851 42 19 5x7 50RW 15 DC 3000 17 1 155 134 978 TR543C 773600 011000 2126 39874 39874 181 Rear 077018 or 0770851 10 hole hub piloted mounting 335mm bolt circle 281 2mm hub bore 26 75mm bolt hole dia use two
48. ed on Alcoa ball seat wheel Do not use one piece flange nut on ball seat wheels No positional location Proper Torque Wheel Identification Valves and Surface Maintenance Abuse can shorten the life of a wheel Lack of care in changing a tire heavy pounding Avoid abuse of the wheel rim overloading exposure to excessive heat or hitting curbs at high speed or a sharp angle can damage wheels Do not overinflate Use the tire manufacturer s recommended pressure but under 5 1 no circumstances exceed cold tire pressures listed in Section 1 Specifications of this manual Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Keep wheel nuts Wheel cap nuts must be kept tight see 4 9 page 29 When checking the cap nuts on tight dual disc wheels utilizing the stud located ball seat mounting system loosen every other outer cap nut and then check the torque of the inner cap nuts Retorque the loosened outer cap nuts Repeat procedure with the rest of the nuts Check all cap nuts for proper torque after the first use or any removal Inspect wheels and check 5 2 wheel nuts during service stops See Section 2 page 5 Dirt streaks from cap nuts may indicate looseness Flange nuts must be kept tight and
49. el does not appear to be obviously burned check the valve hole and labels for evidence of charring melting blistering or burning A wheel may discolor from excessive heat It can appear a dull grayish color and will not polish to a bright finish as a typical wheel would Any wheel run with a flat tire longer than the time necessary to immediately pull off the road should be checked for excessive heat damage A blistered charred blackened or cracked looking logo decal on an Alcoa wheel may indicate that the wheel has been exposed to excessive heat Dimension checks 2 3 Open side circumference check WARNING Wheels that have been subjected to high pressure tire and rim separation run flat excessive heat or other physical damage may no longer have sufficient dimension and contour to retain tire bead while under pressure WARNING Rims that lack proper dimension and contour can lead to explosive separation of tire and rim causing injury or death Follow dimension check procedures described in this section during each wheel inspection The circumference of the bead seat on the open side of the wheel should be checked with each tire change The open side is the side opposite the disc face In the case of center flange wide base wheels or wheels with insets less than 3 inches both rim flanges should be checked Measure the circumference of the bead seat on the open Side See illustration below with a ball tape Ball tapes
50. ent to the tire or wheel components is necessary the tire shall be deflated by removal of the valve core before the adjustment is made 8 No attempt shall be made to correct the seating of side and lock rings by hammering striking or forcing the components while the tire is pressurized 9 Cracked broken bent or otherwise damaged rim components shall not be reworked welded brazed or otherwise heated 10 Whenever multi piece rim wheels are being handled employees shall stay out of the trajectory unless the employer can demonstrate that performance of the servicing makes the employee s presence in the trajectory necessary 11 No heat shall be applied to a multi piece wheel or wheel component f Safe operating procedure single piece rim wheels The employer shall establish a safe operating procedure for servicing single piece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at least the following elements 1 Tires shall be completely deflated by removal of the valve core before demounting 2 Mounting and demounting of the tire shall be done only from the narrow ledge side of the wheel Care shall be taken to avoid damaging the tire beads while mounting tires on wheels Tires shall be mounted only on compatible wheels of matching bead diameter and width 3 Nonflammable rubber lubricant shall be applied to bead and wheel mating surfaces before assemb
51. fficient mounting flange support by the hub or brake drum Remove wheel from service 2 5 Shown below are stud hole cracks emanating from stud hole to stud hole Causes are undersized diameter of wheel support surface see specifications below support surface not flat incorrect attachment parts see 4 12 page 34 and insufficient torque see 4 9 page 29 and 5 2 page 35 Remove wheel from service Support surface should be flat to the diameter recommended on the chart on the following page Inspect the hub drum contact area thoroughly for cracks or other damage Mounting area Support surface diameters continued Support surface backup diameter should be flat to the diameter recommended on the chart below Number of Bolts Bolt Circle Mounting Type Backup Diameter Thread Size 11 25 inch U S Stud pilot 13 2 13 5 in 750 1 125 in 285 75mm Hub pilot 13 2 13 4 in Hub piot 15 0 15 2 in Corrosion Due to aluminum s natural resistance to corrosion Alcoa aluminum disc wheels do not need to be painted for most operating conditions However certain environments can lead to corrosion Some of these are salt chloride compounds used for snow removal and highly alkaline materials If the air used to fill 2 6 tubeless tires or the tire itself is not dry the areas of the wheel under the tire can corrode severely zi spp rat M CE e Bead seat and valve stem corrosion often are caused by entrapped moisture wh
52. for excessive stud standout greater than 1 88 1 7 8 Excessive stud standout may cause the inner cap nut to bottom out on the longer stud preventing proper seating of the wheel Each outer dual wheel is attached by 10 single cap nuts which thread on the inner cap nuts Use Alcoa outer cap nuts Part Nos 5996R 5996L or equivalents Match mounted dual wheels should be put on the vehicles with the valve stems180 apart DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel Spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the dual aluminum wheels as shown below DiscMate when used Alcoa Aluminum Wheels vov y 4 Outer Cap Nut P N 5996R or L See 4 2 page 24 a FE BN Inner Cap Nut P N 5978R or L or P N 5988R or L See 4 2 page 24 1 31 to 1 88 K Correct mounting for dual aluminum stud located ball seat mount wheels WARNING Incorrect inner cap nuts used with dualed aluminum wheels can bottom out on the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and disengage WARNING from the vehicle which can cause serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 5978R or L 5988R or L or their equivalent when moun
53. he inner steel wheel Excessive paint can reduce the clamping force and allow the wheels to become loose Match mounted dual wheels should be put on the vehicle with the valve stems 180 apart Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of flange nuts should be done in recommended sequences WARNING Undertorqued flange nuts allow wheels to run loose and fatigue studs or lose nuts Overtorquing can stretch studs causing them to fail Both under and overtorquing can lead to wheel disengagement causing injury or death Check all parts including wheels studs and flange nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damaged parts Follow correct tightening sequences and torque levels Two piece flange nuts with a 33mm hex head design see 4 2 page 24 used with hub piloted wheels should be tightened to a torque of 450 to 500 foot pounds Two piece flange nuts with 1 1 2 inch hex head design and other designs have different torque requirements Inquire of the manufacturer for the proper torque values Wheel studs on bo
54. he wheel Weakened or damaged wheels can lead to an explosive separation of tires and wheels or wheel failure on the vehicle WARNING Explosive separations of tires and wheels or wheel failure on the vehicle could cause injuries or death Never attempt to weld or braze any surface of an Alcoa aluminum wheel WARNING Returning wheels to service with inadequate flange height as determined by the Alcoa Rim Flange Wear Gauge can lead to an explosive separation of tires and wheels WARNING Explosive separation can result in serious injury or death Wheels with flange height that falls below the Alcoa gauge have inadequate rim flange height to support the tire on the rim Permanently remove any wheel from service that has inadequate rim flange height Always follow safe mounting procedures as recommended using OSHA approved tire inflation cages See the Alcoa Wheel Service Manual or OSHA safety wall charts and procedures 17 Alcoa 15 Drop Center Wheel for Tubeless Tires Recommendations for mounting tubeless tires 3 1 NOTICE For complete information on tube type wheels contact Alcoa NOTICE Alcoa aluminum 19 5 RW and non symetrical well wide base wheels require special tire mounting techniques See Section 3 2 18 WARNING Damaged tires or wheels can lead to an explosive separation of tires and wheels Explosive separation can result in serious injury or death WARNING Inspect tires and wheels for d
55. hoto 6 Care must be used to avoid gouging the wheel Photo 6 Air or electric grinder Photo 7 Die grinder 15 Rim flange wear 16 continued Die Grinder Used with a sanding wheel cutting stone or grinding tool this is a version of an electric grinder This tool is very quick and effective as well and care must be taken to remove metal as uniformly as possible and not to gouge the wheel photo 7 on page 15 CAUTION Removing sharp edges with hand or power tools produces metal filings and sparks Many power tools have edges that are Sharp or may become hot during use Some power tools produce CAUTION excessive noise when used M etal filings can be sharp and when projected by the action of power tools can cause serious skin or eye damage Excessive noise from power tools can harm hearing Sharp edges can produce cuts and hot surfaces can cause burns Cuts and burns can lead to infection Always wear appropriate safety gear such as protective eye wear gloves protective clothing and hearing protection when using hand or power tools photo 8 s A i a Photo 8 Always use proper safety gear Photo 9 Adequate repair for sharp edge resulting from rim flange wear removes just enough metal to smooth the edge STEP 4 The photographs show the process of removing the edge With whatever tool is selected work the tool around the wheel s circumference removing only enough material to elimin
56. ich contains corrosive elements Mild corrosion should be removed thoroughly by wire brush and the rim protected with a coating of non water based lubricant see 3 1 page 18 Remove any severely corroded wheel from service CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface Severely corroded wheels are unsuitable for service Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced under the Alcoa limited warranty CAUTION 10 Stud holes If wheels are run loose both stud located wheels and hub piloted wheels can be damaged Look for wallowed out or elongated ball seats on stud located wheels On hub piloted wheels look for elongated stud holes Over torquing can lead to damaged ball seats on stud located wheels and can damage 2 7 the disc surface of hub piloted wheels Remove damaged wheels from service wt A SUM TL NF name mm Be D EE J a J LJ i zi af Fail m 7 l P Damaged hub piloted bolt hole Damaged ball seat contact area Elongation from true round dashed Pounding of nut on ball seat contact circle indicated by arrows area identified by arrows Disc area 2 8 Inspect both sides of disc area for hand hole cracks If cracks are found remove the wheel from service 11 Rim area Check the entire rim area for nicks gouges and cracks Loss of air may be caused by cracks in area
57. ified by using the regular numerical part number and the addition of DB at the end Finishes are indicated by changing the last numerical digit of the part number to one of the following For brushed both sides the number is 0 For buffed outside only the number is 1 For buffed inside only the number is 2 For buffed both sides the number is 3 Currently only the wheel item numbers marked with DB are available with the Dura Bright surface treatment Dura Flange wheels are identified by using the regular numerical part number and the addition of DF at the end Only the wheel item numbers marked with DF are available with the Dura Flange option and are only available as satin finish last part number ends in 0 CLASSIC TUBELESS WHEELS round hand holes ENGLISH UNITS Maximum Wheel Maximum Front Rear Inner Rear Inner Rear Hub Cover Item Wheel wheel load wt Outset Inset inflation Valve Part Outer Cap Nuts Cap Nuts Outer Lug Nut System Kits no description in Ibs Ibs inches inches PSI cold stem number DiscMate Stabilizer Cap Nuts AIAI Al Stl Cap Nuts Covers Front Rear 3 4 Stud 5995 1 17 5x6 75 15 DC 5070 32 5 55 4 72 125 TR543C 663170 2125 L amp R 1 1 8 Stud 5988 L amp R 7896 L amp R 5996 L amp R 150 5996 L amp R 3 4 Stud 5995 2 17 5x6 75 15 DC 5070 31 5 55 4 72 125 TR543C 663070 2125 L amp R 1 1 8 Stud 5988 L amp R 7896 L amp R 5996 L amp R 150 5996 L amp R
58. ions for tubed tires eeesssseee menn 42 6 5 Bemouhting or t bed TINGS ass detta e aA A E A bns ub bue L deu 43 7 OSHA RegulabOhs niit iioi a iau o ena a a ER FA OSHA Begulatofisantodkivksrir ca cdd SE ines YE a SU ROREXIBR ESO Fre c DVE SHE odd ea an EODD 44 8 Glossary of Common Terms siiis ceun ui ona sa uev Usus na Fro eroe ag dr Yi o rk Uu Kir FECE Usu or aV a cEeu O Bel glossam ob COMMON TORS irainei E Evi anu tite oa aA Ee onteonstdhstavacane teu tostdutevamaarenss 49 8 2 Wheel tieastlrelTiePIEscssstonssansinugnt uuu statute eased ta Dee RA AANA 51 9 Conversion Tables ERE OE 9 1 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 Inch 52 OZ gt CONNES FG LOIS theca ttaeitefu aset un eom EARE ATOE bri oc ue vu sed osuere idea eeu 53 E 3 E E F3 E65 NE pm n m 1 Specifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J 694 Feburary 2001 Part numbers listed for all sizes are satin finish Polished finishes are indicated by changing the last digit of the part number listed to one of the following For polished outside only part number should end in 1 For polished inside only part number should end in 2 For polished both sides part number should end in 3 Valve hole is on the inside Dura Bright surface treatment wheels are ident
59. is smooth or cover the wheel mounting surface with a protective shield prior to tightening the cap nuts The wrench end will mar the wheel around 4 1 the cap nuts if it is not smooth 4 Keep all component contact surfaces smooth and clean Dirt or projections on mounting surfaces NOTICE Do not exceed may lead to loose wheels Remove all projections resulting from burrs nicks etc Be sure that maximum wheel load loose dirt does not fall onto mounting surface during assembly Customer must pes 5 Check for and replace bent broken cracked or damaged studs When replacing broken studs OEM vehicle load rating to always replace the studs on each side of the broken stud If two or more studs are broken maximum wheel load rating replace all the studs for that wheel position Check with the stud manufacturer for regular i maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric Refer to tire manufacturer s conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs recommendation for proper tire pressure Before mounting 6 Do not introduce any foreign objects such as spacers or high hats into the contact surface areas the tire perform a wheel of the mounting system unless approved by Alcoa Do not paint Alcoa forged aluminum wheels fitment check to insure 7 Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since proper clearance fro
60. iv Use of the restraining device or barrier and other equipment required by this section v Handling of rim wheels vi Inflation of the tire when a single piece rim wheel is mounted on a vehicle vii An understanding of the necessity of standing outside the trajectory both during inflation of the tire and during inspection of the rim wheel following inflation and viii Installation and removal of rim wheels 3 The employer shall evaluate each employee s ability to perform these tasks and to service rim wheels safely and shall provide additional training as necessary to assure that each employee maintains his or her proficiency d Tire servicing equipment 1 The employer shall furnish a restraining device for inflating tires on multi piece wheels 2 The employer shall provide a restraining device or barrier for inflating tires on single piece wheels unless the rim wheel will be bolted onto a vehicle during inflation 3 Restraining devices and barriers shall comply with the following requirements 45 OSHA Regulations continued 46 i Each restraining device or barrier shall have the capacity to withstand the maximum force that would be transferred to it during a rim wheel separation occurring at 150 percent of the maximum tire specification pressure for the type of rim wheel being serviced ii Restraining devices and barriers shall be capable of preventing the rim wheel components from being thro
61. j D stud Stud Standout NN Mounting surface Outboard mounted drum The nut seat for the stud located ball seat mounting system is a seats are precision machined spherical surface Cap nuts must be properly spherical manufactured to assure correct seating Never use one or two piece flange nuts on a wheel designed with ball seats see 4 12 page 34 4 4 Ball seat cap nuts may be obtained from your Alcoa Wheel Distributor L 25 Single wheel stud located ball seat mounting 4 5 NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Dualed wheels stud located ball seat mounting 4 6 26 Front wheels are mounted as singles and require 1 6 1 39 64 minimum stud standout Most vehicles have 1 1 8 inch studs on the front hubs Alcoa single cap nuts Part Nos 5996R and 5996L or equivalents should be used Some front hubs have 3 4 inch studs On these hubs use Alcoa single cap nuts Part Nos 5995R and 5995L or equivalents DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel Spacers are placed between the contact surfaces of the Dura Bright wheel and the br
62. led If it becomes necessary to replace an air valve install it using the following torque values 10 14 foot pounds for Part Nos 7 11 foot pounds for Part Nos TR 542 Series TR 543 Series TR 544 Series TR 545 Series 60MS27N Replacement valves may be obtained from your authorized Alcoa Wheel Distributor Always use silicone o rings not rubber when reinstalling valve stems Metal valve stem caps are recommended instead of plastic When replacing valve stems it is recommended to lubricate the threads and o ring with a non waterbased lubricant 36 Maintenance against corrosion non Dura Bright surface treated wheels 5 7 Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to ensure proper clearance from any obstructions Dura Bright surface treated wheels cleaning and maintenance 9 8 Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to ensure proper clearance from any obstructions The following information is for standard Alcoa forged aluminum wheels without the Dura Bright surface treatment See section 5 8 page 37 for
63. luding wheels studs and cap nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damaged parts Follow correct tightening sequences and torque levels Continued on next page 29 Tightening stud located ball seat cap nuts continued NOTICE In service stud dimensions and condition may change over time due to environmental conditions multiple re installations improper torquing and other factors Consult with your hub and stud manufacturer for maintenance and replacement recommendations 30 Stud located ball seat mounting system It is recommended that stud threads on stud located mounting systems be lubricated with SAE 30W oil and torqued between 350 and 400 foot pounds If threads are not lubricated torque to between 450 and 500 foot pounds Note when dualing steel wheels with Alcoa aluminum wheels follow the steel wheel manufacturer s recommendations regarding the proper torque and use of thread lubricants to mount the wheel WARNING Application of lubricant to the ball seats can cause excessive torque Over torque can stretch studs causing them to fail Overtorquing can lead to wheel disengagement causing injury or death WARNING Do not allow oil to contact ball seats or mounting surfaces of the wheel hub or drum Do not use aerosol cans for lubrication of stud threads On vehicles equipped to accept wheels
64. ly of the rim wheel unless the tire or wheel manufacturer recommends against the use of any rubber lubricant 4 If a tire changing machine is used the tire shall be inflated only to the minimum pressure necessary to force the tire bead onto the rim ledge while on the tire changing machine 5 If a bead expander is used it shall be removed before the valve core is installed and as soon as the rim wheel becomes airtight the tire bead slips onto the bead Seat 6 Tires may be inflated only when contained within a restraining device positioned behind a barrier or bolted on the vehicle with the lug nuts fully tightened 7 Tires shall not be inflated when any flat solid surface is in the trajectory and within one foot of the sidewall 8 Employees shall stay out of the trajectory when inflating a tire 9 Tires shall not be inflated to more than the inflation pressure stamped in the sidewall unless a higher pressure is recommended by the manufacturer 47 OSHA Regulations continued 48 10 Tires shall not be inflated above the maximum pressure recommended by the manufacturer to seat the tire bead firmly against the rim flange 11 No heat shall be applied to a single piece wheel 12 Cracked broken bent or otherwise damaged wheels shall not be reworked welded brazed or otherwise heated GRAPHIC TIFF OMITTED TC270C 91 036 Appendix B Ordering Information for NHTSA Charts OSHA has printed two cha
65. m any minor nicks and scratches cannot be polished out see section 5 8 page 37 38 for specific obstructions cautions care and maintenance procedures 8 DiscMates are a protection gasket designed to be placed between the wheels and also the brake drum wheel contact surfaces See sections 4 5 page 24 4 6 page 25 4 7 page 26 and 4 10 page 31 DiscMates are recommended to be replaced when the tire wheel assemblies are removed and reinstalled WARNING Wheels that are not properly installed or maintained may not work properly Failure to follow proper wheel installation or maintenance practices may WARNING de result in injury or death Follow the proper wheel installation and maintenance practices as contained in this Alcoa Wheel Service Manual For training on proper installation and maintenance available free of charge from Alcoa or for the most recent updates contact Alcoa Wheel and Forged Products at 1 800 242 9898 option 1 or on the web at www alcoawheels com 23 Wheel cap nuts 4 2 24 WARNING Use of chrome plated cap nuts which have chrome plating on the surfaces which contact the wheel can cause reduced and inconsistent wheel clamping This condition can cause wheels to loosen and disengage from the vehicle WARNING causing injury or death Never use cap nuts with chrome plated contact surfaces Use only recommended hardware on Alcoa aluminum wheels There are many types of nuts and
66. ment of Labor Occupational Safety and Health Administration publications entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi piece Rim Matching Chart the National Highway Traffic Safety Administration NHTSA publications entitled Demounting and Mounting Procedures Truck Bus Tires and Multi piece Rim Matching Chart or any other poster which contains at least the same instructions safety precautions and other information contained in the charts that is applicable to the types of wheels being serviced Installing a rim wheel means the transfer and attachment of an assembled rim wheel onto a vehicle axle hub Removing means the opposite of installing Mounting a tire means the assembly or putting together of the wheel and tire components to form a rim wheel including inflation Demounting means the opposite of mounting Multi piece rim wheel means the assemblage of a multi piece wheel with the tire tube and other components Multi piece wheel means a vehicle wheel consisting of two or more parts one of which is a side or locking ring designed to hold the tire on the wheel by interlocking components when the tire is inflated Restraining device means an apparatus such as a cage rack assemblage of bars and other components that will constrain all rim wheel components during an explosive separation of a multi piece rim wheel or during the sudden release of the contained air of a single piece rim wheel Rim
67. nce shown below for your type wheel After 50 100 miles of operation torque should be rechecked Check torque frequently from then on If nuts require frequent tightening studs break frequently or wheel bolt holes are pounding out hardware and mounting practices should be reviewed 1 2 1 f 10 ry B s zT 4 Gu Tor WO 30 77 3 n6 5 be c a G 5 C a A La C2 Lo E F T7 E 3 H 2 Eight Stud Ten Stud 33 34 Inc orrect WARNING Use of two piece flange nuts on ball seat wheels ball seat cap nuts assem blies on hub piloted wheels or single piece flange nuts in place of 2 piece flange i nuts is dangerous Using the wrong wheel nuts can cause loss of torque broken studs WARNING and cracked wheels conditions which can lead to injury or death Use only hardware designed specifically for each wheel type See 4 2 4 1 2 page 24 for proper hardware assemblies The following are examples of incorrect wheel assemblies Stud located ball Va seat aluminum wheel Two piece E A flange nut 4 Incorrect use of two piece flange nut Do not use two piece flange nuts with ball seat wheels Hub piloted Alcoa aluminum wheel Ball seat cap nut Insufficient contact area Incorrect use of ball seat cap nut Do not use ball seat cap nuts with hub piloted wheels Little if any contact area EE e L 1 12 i E f 3 A I EN Incorrect use of one piece flange nut position
68. nt 49 50 Glossary of Common Terms continued LOCK RING The third piece of a three rim assembly which positions and supports the Side ring to the rim base MAXIMUM INFLATION The highest amount of air pressure allowed measured at normal ambient temperatures mm Abbreviation for millimeters MULTI PIECE WHEEL A wheel assembly in which the rim portion of the wheel consists of two or more separate parts OFFSET See OUTSET OPEN SIDE The side of the wheel opposite the disc face OSHA Abbreviation for the U S Department of Labor Occupational Health and Safety Administration OUTER CAP NUT A cap nut used to secure the outer stud located wheel in a dualed wheel pair and thread onto the inner cap nut OUTSET The distance from the mounting surface of the wheel to the rim centerline when the rim centerline is mounted outboard of the hub face This dimension is the same as the 1 2 DUAL SPACING dimension PILOT PAD The raised surfaces on a hub used to center a hub piloted wheel PSI Abbreviation for pounds per square inch REVERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tire centerline RIM CENTERLINE A line to the radial axis of the wheel running through the mid point between the rim flanges RIM FLANGE That portion of the rim which extends above the rim surface which retains the tire bead RIM That portion of the wheel which
69. of a non water based lubricant is recommended as a rim surface protectant and tire mounting lubricant Coat the entire rim surface See 3 2 page 19 7 Lubricate the rim and tire bead immediately before mounting the tire Do not use any lubricant which contains water Water based lubricants can promote corrosion attack on the rim surface The use of non water based lubricants is especially important when mounting tubeless tires as the air in the tire is contained by the seal between the bead and tire rim 8 Never lubricate the rim ortire bead with a flammable solution This can lead to an explosion during airing of the tire or in subsequent operation of the vehicle see Warning below 9 If using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel 10 Use only dry air for tire inflation The use of moisture traps in the air compressor feed line is recommended 11 Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures listed in Section 1 Specifications of this manual see page 2 12 When inflating a tire in an inflation cage or while mounted on a vehicle always use a clip on air chuck or threaded straight chuck and a remote valve with pressure gauge Securely anchor the inflation cage and during inflation or handling of an inflated wheel and tire assembly stay out of the path of potential exploding parts or air blas
70. ollow this practice you will significantly reduce the possibility of a rim flange cutting into the tire 14 STEP 2 After the wheel is separated from the tire use a ball tape to verify the circumference of the bead seat on the open side is acceptable see 2 3 page 7 Check the wheel flange with the Alcoa Rim Flange Wear Gauge to determine if the wheels must be removed from service for excessive rim flange wear photo 1 on page 13 See Rim Flange Wear Gauge Instructions illustrations above to make this determination If you do not have an Alcoa Rim Flange Wear Gauge contact Alcoa Wheel and Forged Products to obtain a gauge s at no charge STEP 3 If the wheel is deemed to be serviceable by the rim flange gauge examine the wheel flange edge for sharpness by using a rubber sharpness gauge These gauges are constructed by having a section of tire side wall or a suitable piece of rubber attached to a block of wood photo 2 By running the sharpness indicator gauge along the wheel in the area of the wear determine if the wear is sharp enough to cut or damage the rubber on the sharpness indicator photo 3 If the rubber is cut then follow the edge removal instructions below fi ia r c m rm a e AU 2 S ni a t l a f p iz p Photo 2 A rubber sharpness gauge constructed from a section of tire side wall or a suitable piece of rubber attached to a block of wood Photo 3 Run the sharpness indicator gaug
71. ong cap nuts can cause loss of torque broken studs and WARNING Cracked wheels conditions which can lead to injury or death Use only hardware designed specifically for each wheel type See 4 2 page 24 for proper hardware assemblies Cap nut thread engagement stud located wheels ball seat mounting 4 8 Tightening stud located ball seat cap nuts 4 9 The actual length of thread engagement present in an assembled wheel can not always be determined by visual inspection or measurement of a tightened assembly The relationship of the wheel cap nut seat to the end of the stud may vary If there is any doubt that enough thread engagement is present the number of engaged threads may be counted Tighten all nuts in the regular manner then loosen one to hand tightness The number of turns to disengage a 1 1 8 inch nut should be at least five full turns At least seven full turns should be required to disengage a 3 4 inch nut Ideally when torqued to the proper load the stud should be flush with the face of the nut The face of the nut may be recessed in nuts that are taller for improved wrenching With most of the nuts in present use a few unengaged threads at the outer end will cause no problem provided at least 5 7 full turns are required to disengage the nut depending on thread size Cap nuts made to Alcoa specification usually give more than the necessary thread engagement on a given stud Some states have laws which dictate f
72. option 1 or on the web at www alcoawheels com To obtain Alcoa rim flange wear gauge s at no charge and information on free training on proper installation and maintenance procedures contact Alcoa Wheel and Forged Products at 800 242 9898 option 1 or on the web at www alcoawheels com Table of Contents V Section Number Page Number V 1 Wheel SpeciliC aliolis aciei inna v ra UN VETE ERR VER CUN R FU VE VAR ATXE E dU EUER VER EIER VEM AD Uu ssggeee 2 1 unspectthoroughlysand Trequehitly vue saputo cinn on ot pe PORE Dave ull es ero Pudd s Peu a CR Rogat prd 5 2 2 EXCESSIVE eat damage bee bat NE txpM DI eaten ne cect tO E d cas od Ocupa Ce 6 BAS Dese Gl Ks vnde end r dut ttekemuri dre b actu dut ode tua bna tb 7 2 4 Cracked or damaged wheel checks ssssssssssrsrrrrrrrrnrnrnrnrnrntrrr trr 111111 rtrt nnn 8 2 5 MOUNTING ANC As ade ui Ue RR co MID DE RM PR emieeimnee inom EP Or Hbpabiv ACA Rei epepbidt e eicere 9 ZO S COITOSIODL noire detec dius e hota clad at Soller tetas lahat Sella ande ciet ean tis ahah ioulinen M at cda 10 Da UU OLS scsi ea dor wien eae ate earl dict yasni d Devine daa ce A ER aa AM EA A 11 EO ISG AE Grancnctiten teas geuteunnanch maa E E E Meareraaanenucemeu ties 11 PISCEM iunc lic TRE AA NEE Irem ntc epeg tnc ume ons 12 Ze OW GUST al NER RE E TE 12 2 11 RIEN alg e WEI oaoa nite dle ort eese PR pde obe aea Ci Vat vd eto a tC rd 13 3 Alcoa 15 Drop Center Wheel for Tubeless Tires
73. other approved restraining devices during inflation Avoid wheel separation tighten nuts in the order and to the torque value specified in this manual Capacity ratings as dual or single in highway service bias ply or radial Load ratings in Ibs for items 38 through 49 rounded to nearest multiple of 5 Some wheels may bear part numbers not shown in this manual Before servicing these wheels contact your Alcoa Wheel Representative for proper load inflation and part compatibility information Outset Positive Inset Negative The distance from the rim centerline to the mounting face of wheel Inset negative places the rim centerline inboard of the wheel mounting face and outset positive places the rim centerline outboard of the wheel mounting face 1 2 dual spacing offset These wheels must be installed only in the inset position because spherical ball seats are on only one side of the disc Indicates lighter weight Alcoa New Generation wheels t Indicates European New Generation Wheels Hub cover system kits P N 076085 front and P N 077085 rear contain screw on Hug a lug nut covers and require a minimum of four threads of the stud to extend above the tightened cap nut for use tt P Ns 841100 841400 841600 and 841610 are recommended for use on drive axle and trailer axle positions tt The minumum stud standout required for P N 833570 is 2 375 inches 60 3mm when using nut P N39874 Taller nuts will require more stud stand
74. out P Ns 885600 and 985600 are Alcoa Severe Service Wheels and are available with either the Dura Flange treatment option or the Dura Bright surface teatment option DB Wheels with the Dura Bright surface treatment option shine without polishing Just wash with soap and water do not polish or clean with abrasives For more information call 800 242 9898 option 6 or visit www dontpolish com Specifications subject to change without notice To request a copy of the current Alcoa Specifications Data brochure for aluminum wheels for trucks trailers and buses call toll free 800 242 9898 option 1 To view online go to www alcoawheels com The Spec Data brochure contains current part number availability and complete specifications such as wheel dimensions load rating wheel weight outset and inset inflation pressure and accessory part numbers Alcoa provides training live or on video on proper wheel installation and maintenance practices free of charge Contact Alcoa Wheel and Forged Products at 1 800 242 9898 option 4 Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 with bead seat diameters measured in 0 5 inch increments Not all Alcoa wheels are available with the Dura Bright surface treatment Note The Dura Bright surface treatment and the Dura Flange options are not currently available together on the same wheel Dura Bright
75. plosive separation of tires and wheels Explosive separation can result in serious injury or death Inspect tires and wheels for damage before removing from vehicle If damage is found tire must be completely deflated before loosening cap nuts Remove damaged tires or wheels from service 21 i 1 When hand demounting tires from wheels placing aluminum wheels on a clean Recommendations wooden floor or rubber mat is recommended Additional care should be used when for demounting demounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches tubeless tires can not be polished out see section 5 8 pages 37 38 for specific cautions care and continued maintenance procedures 2 Always use a rubber leather faced or plastic mallet 3 Keep tire tools smooth Use them with care Rim gouges or nicks may cause cracks 4 If using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel Demounting of tubeless tires 3 5 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction Remove the valve core from the valve stem to ensure Repeat procedure at intervals until bead is totally manual for your particular complete deflation Place wheel on machine and separated from wheel Repeat procedure on other side machine before attempting position tool so flat end can be driven between tire of tire Tire is now
76. que wrenches air wrenches and any other tools should be calibrated periodically to ensure the proper torque is applied 35 Lead balance weights for Alcoa wheels are available from your Alcoa Wheel Distributor Lead balance With radial tires it may be necessary to temporarily reduce the tire pressure when weights c lip on installing clip on weights to allow clearance of the weight clamp over the rim flange Use of coated balance weights is recommended to avoid staining and corrosion of the aluminum wheel surface 5 3 Excessive rim flange wear See section 2 11 pages 13 17 could dictate the use of stick on or adhesive wheel weights if there is inadequate rim to properly hold a clip on Style weight Improperly installed weights could fly off during use and damage the vehicle or cause personal injury Always follow the recommended procedures in this manual or the wheel weight manufacturer Adhesive weights should be applied only to a clean surface on the brake side of the wheel rim These weights should be installed only in a location where they will not contact the brake components during vehicle operation H Do not heat wheels in an attempt to soften them for straightening to repair damage Do not straighten from striking curbs or other causes The special alloy used in these wheels is heat wheels treated and uncontrolled heating will weaken the wheel 9 4 Do not rework weld heat or braze Alcoa aluminum wheels for any re
77. re rubber 8 Select the proper rim components and assemble to rim see 6 3 page 41 Discard bent damaged or corroded side and lock rings Do not use any side or lock ring which is not clearly identifiable WARNING Use of a Firestone 5 side and lock ring assembly with a wheel machined for Firestone DT or Goodyear LW split side ring and vice versa can lead to explosive separation of wheel and tire An explosive separation of miss matched wheel components can lead WARNING to injury or death Alcoa Aluminum Disc Wheels are available to accept 1 Firestone 5 side and lock rings or 2 Goodyear LW and Firestone DT split side rings Select the proper side and lock rings by referring to the Multipiece Rim Wheel Matching Chart on page of this manual Firestone R5 Goodyear LW or Firestone DT Always use the proper side and lock ring assembly or split side rings required for each particular wheel 9 Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures listed in Section 1 Specifications of this manual see page 2 10 When inflating a tire in an inflation cage or while mounted on a vehicle always use a clip on air chuck and a remote valve with pressure gauge During inflation or handling an inflated wheel and tire assembly stay out of the path of potential exploding parts or air blasts 40 Mounting of tubed tires 6 3 When mounting Alcoa flat
78. ready for demounting Lubricate the to mount or demount tires bead and rim flange Straighten tool to a vertical tire bead position until bead is separated from wheel Insert curved end of tire tools between tire and wheel Insert Straight end of tire tool between beads and both approximately 10 inches apart Pull one tool toward rim flanges hooking stop on the tool over second center of wheel then pull second tool in the same flange Position inserted tool at 90 angle to tire manner To free bead leave one tool in position take assembly at top of wheel and lubricate bead areas on out and reinsert the other tool curved end between both sided of tool Lean tire assembly toward tool and bead and flange a short distance from the spanned rock or bounce to pry off the tire area Pry bead free of rim repeating process until entire bead is free from wheel 22 Wheel Installation Recommendations 1 For the same reason the best tires are run on the front axle the best wheels also should be used on the front axle for proper 2 2 Make sure all wheel cap nuts are properly torqued check them often see section 4 9 page 29 installation of If the wheel is loose the holes will pound out deform If some cap nuts are tight and others wheels are loose the wheel may develop cracks or studs may break Dirt streaks radiating from stud holes can indicate loose nuts see Section 2 pages 5 17 3 Be sure the end of the wheel wrench
79. rts entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi piece Rim Matching Chart as part of a continuing Campaign to reduce accidents among employees who service large vehicle rim wheels Reprints of the charts are available through the Occupational Safety and Health Administration OSHA Area and Regional Offices The address and telephone number of the nearest OSHA office can be obtained by looking in the local telephone directory under U S Government U S Department of Labor Occupational Safety and Health Administration Single copies are available without charge Individuals establishments and other organizations desiring single or multiple copies of these charts may order them from the OSHA Publications Office U S Department of Labor Room N 3101 Washington DC 20210 Telephone 202 219 4667 49 FR 4350 Feb 3 1984 as amended at 52 FR 36026 Sept 25 1987 53 FR 34737 Sept 8 1988 61 FR 9239 Mar 7 1996 8 Glossary of Common Terms Glossary of Common Terms 8 1 1 2 DUAL SPACING One half the distance between the two center lines of dualed wheels The dimension is the same as the OUTSET dimension 2 PIECE FLANGE NUT A two piece washer and nut combination used to secure hub piloted wheels AIR CHAMBER The space enclosed by a tire and wheel rim or inner tube BEAD SEAT The area along the outer edges of the rim where the mounted tire and rim are in contact BOLT CIRCLE
80. s around the valve stem hole Remove the wheel from service 2 9 Gutter area Projections on the side of the wheel gutter area on tube type wheels can cause uneven seating of the side and lock ring and chipping of the gutter Such projections must be removed Remove the wheel from service if damaged 2 10 Cracking in bottom of gutter flange Occasionally circumferential cracks may appear in the bottom of the gutter area This area should be thoroughly cleaned and carefully inspected after a tire is removed from the wheel Also check the side underneath gutter flange for circumferential cracks Gutter flange cracks can ultimately lead to the separation of the rim area from the disc Immediately remove from service a wheel that exhibits any cracks 12 Rim flange wear 2 11 Irregular wear on the surface of the rim flange is caused by abrasion from the tire chafer and sidewall Rim flange wear happens most often in applications with heavy or shifting loads If you are experiencing excessive rim flange wear in your operation consider using Alcoa Dura Flange aluminum wheels These wheels have been specially treated to significantly reduce rim flange wear Remove wheels from service when rim flange wear is excessive Excessive wear can be determined using an Alcoa approved wear gauge and procedures detailed below If rim flange wear becomes sharp and or cuts the tire contact Alcoa for recommended maintenance procedures Alcoa
81. studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed For proper nut torque refer to the chart below Nut Torque Level Ft Lb Torque Level Ft Lb Thread Lubricated Dry 11 16 16 300 400 Hub piloted using two piece flange nut ee Li eh Stud piloted double cap nut standard type cu 7 8 radius 350 400 450 500 1 1 8 16 350 400 450 500 Stud piloted double cap 15 16 12 750 900 nut heavy duty type 1 1 8 16 650 800 750 900 1 3 16 radius 1 5 16 12 750 900 For nuts used on hub piloted wheels apply two drops of oil to the point between the nut and flange and two drops to the first two or three threads at the tip of each stud see 4 11 page 32 For nuts used on stud piloted wheels apply two drops of oil to the first two or three threads at the tip of each stud only see 4 9 page 29 NOTE 1 If using specialty fasteners cap nuts consult the manufacturer for recommended torque values 2 Tightening wheel nuts to their specified torque is extremely important Undertightening which results in loose wheels can damage wheels studs and hubs and can result in wheel loss Overtightening can damage studs nuts and wheels and results in loose wheels as well 3 Regardless of the torque method used all tor
82. supports the tire SIDE RING A removable piece of a multi piece wheel assembly which provides lateral support for one tire bead SINGLE CAP NUT A cap nut used to secure single wheels or outer dual wheels STUD A threaded bolt extending from the hub surface to which the wheels are secured by the cap nuts STUD LOCATED BALL SEAT MOUNTING A wheel mounting system which uses the studs and spherical ball seat cap nuts to center and secure the wheel TIRE BEAD That surface of the tire which contacts the angled surface of the wheel rim TORQUE The amount of force used to tighten cap nuts Usually stated in foot pounds or kilograms and measured with a torque wrench WHEEL MOUNTING FACE That portion of the wheel face which contacts the hub or brake drum wt Abbreviation for weight Wheel How to measure minimum dual spacing measurement Minimum dual spacing measurement is determined by the tire manufacturer and may be obtained from the tire manufacturer s handbook To determine if the Alcoa aluminum dual wheel assembly has adequate minimum dual spacing for the selected tires double 8 2 the wheel outset measurement of the Alcoa wheel used If the doubled outset measurement is equal to or greater than the tire manufacturer s recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel on pages 2 and 3 Both inset and outset wheels are measured from the mounting surface of
83. th the right and left side hubs of vehicles utilizing the hub piloted wheel system have right hand threads Prior to mounting hub piloted wheels generously coat the wheel pilot or hub pads with a non water based lubricant to minimize corrosion product build up between the wheel and hub pilot Excessive corrosion build up between the wheel and hub pilots can make wheel removal difficult Do not lubricate the face of the wheel hub or brake drum see illustration on the next page Continued on the next page Tightening hub piloted mounting two piece flange nuts continued NOTICE In service stud dimensions and condition may change over time due to environmental conditions multiple re installations improper torquing and other factors Consult with your hub and stud manufacturer for maintenance and replacement recommendations Lubricate the hub pads or the wheel hub bore generously with a non water based lubricant Before installing two piece flange nuts lightly lubricate the stud threads and the contact Surfaces between the cap nut and the washer as illustrated below with an SAE 30W oll This will minimize corrosion between the mating surfaces Lubrication is not necessary with new hardware Position one of the hub s pilot pads at the twelve o clock position After positioning wheels on the pilot pads hand tighten all two piece flange nuts then tighten to the recommended torque following the proper seque
84. that has been subjected to uncontrolled excessive heat such as a tire fire wheel bearing failure or braking system drag seize or a high pressure tire wheel separation 1 Before removing wheel from vehicle remove the valve core from the valve stem to ensure complete deflation of tire 2 Do not gouge or nick the wheel Place aluminum wheels on a clean wooden floor or rubber mat 3 Always use a rubber leather faced or plastic mallet 4 Keep tire tools smooth Use them with care Rim gouges or nicks near the fixed flange can cause cracks 5 Remove steel side rings carefully If bead is well loosened rings can be removed without gouging the wheel 6 Discard bent damaged or corroded side and lock rings Using bent damaged or corroded rings can shorten service life of wheel and introduce the danger of an explosive separation Demounting of tubed tires 6 5 NOTICE Tire must be completely deflated and valve core removed before demounting If manually breaking the tire beads from the wheel it is important to use the proper tools Tire tools may be inserted next to the tire side wall and the Side ring or locking ring Tools must be smooth and used with care if gouging the rim is to be avoided A stop welded to the tool is recommended Insert the tapered end of the tire tool into the notch on the locking ring Pry up carefully to avoid bending the ring and gouging the wheel Once the tool is inserted pry down and
85. the wheel to the center line of the rim Maintaining proper tire inflation and load ratings are essential to maintaining proper minimum dual spacing S Dual Spacing X Vehicle Tire Clearance clearance Hamas I i Bolt Center hole dia circle dia F 1 I u l mh i EMEN MM NNNM E BENE dns mm l Do E ll he e CHR I M Wheel outset e uu same as offset je i or dual spacing Backspace y a Tire center line Tire center line 51 9 Conversion Tables Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 inch 9 1 52 0 07156 0 0313 0 0468 0 0625 0 0781 0 0938 0 1084 0 1250 0 1406 0 1563 D 1718 0 1875 D 2031 0 2188 D 2344 0 2500 0 2656 0 2813 D 2969 0 3125 0 3281 0 3438 0 3594 0 3750 0 3906 0 4063 0 4219 0 4375 0 4531 0 4688 0 4644 0 5000 Inches Decimals Millimeters 0 3868 0 7938 01 1906 1 5875 1 8844 2 3813 2 7781 3 1750 3 5718 3 9688 4 3856 4 7625 5 1594 5 5563 5 8531 6 3500 6 7469 7 1438 7 5408 7 9375 B 3344 B 7313 9 1281 9 5250 3 8218 10 3188 10 7158 11 1125 11 5084 11 9063 12 3031 12 7000 13 0969 13 4938 13 8906 14 2875 14 6844 15 0813 15 4781 15 8750 16 2719 16 6688 17 0656 17 4625 17 8504 18 2563 18 6531 19 0500 18 4469 19 6435 20 24
86. ting dual aluminum wheels On occasion Alcoa aluminum truck wheels are operated dualed with a steel inner wheel In the event a steel inner wheel is used extreme care must be exercised to properly seat it to the hub or drum prior to mounting the outer aluminum wheel Selection of an inner cap nut capable of fixing the steel inner wheel and providing adequate external thread length to secure the outer aluminum dualed wheel is critical to a safe assembly Alcoa recommends the use of inner cap nuts 7896R and L Grade 8 or equivalent for this purpose 28 Dualed wheels steel inner aluminum outer stud located ball seat mounting 4 7 NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating 3 4 Stud Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions DiscM ate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscM ate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the steel and aluminum wheels as shown below Inner Steel Wheel DiscMate when used y Alcoa Aluminum Wheel Outer Cap Nut P N 5996R or L See 4 2 page 24 Drum 9 NY NN FANN
87. ts Recommendations for mounting tubeless tires continued Mounting tubeless tires 3 2 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tires NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions NOTICE When match mounting tires on Alcoa wheels locate valve stem adjacent to low point mark on the tire NOTICE Alcoa aluminum 19 5 RW and non symmetrical wide base wheels require tires to be mounted and demounted over the disc side of the wheel only NOTICE Refer to tire manufacturer s recommendation for proper tire pressure Use of a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build up in the tire and may result in an explosion Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire on or off the vehicle or later on the road Loss of vehicle control can result which can cause serious injury or death Use only approved mechanical or pneumatic bead seating de
88. ull thread engagement or thread engagement past the nut body Make sure you know the laws for the states in which you operate and comply The number of turns to disengage a 1 1 8 inch nut should be at least five full turns At least seven full turns should be required to disengage a 3 4 inch nut WARNING Lubricants should not be applied to the cap nut seat or to the cap nut to wheel contact surface Oiled seats can lead to over torquing which can stretch studs causing failure of studs Failed studs can cause the wheel to disengage from the vehicle WARNING causing injury or death Lubricants must be completely removed from the cap nut seats and contact surfaces if applied accidentally Cap nuts must be kept tight and studs and nuts should be checked frequently Nuts should be retorqued if necessary At tire changes nuts and studs should be inspected for cracks and stripped or damaged threads After each wheel mounting cap nut torque should be checked with a torque wrench Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of cap nuts should be done in recommended sequences WARNING Undertorqued cap nuts allow wheels to run loose pounding out deforming the ball seats fatiguing studs or losing nuts Overtorquing can stretch studs causing them to fail Both under and overtorquing can lead to wheels coming off causing injury WARNING or death Check all parts inc
89. used for measuring wheel circumference can be purchased from the Tire and Rim Association Inc 175 Montrose West Avenue Copley Ohio 44321 If the circumference of the bead seat does not match the required dimension as indicated by the ball tape remove the wheel from service Be sure to clearly mark the wheel as out of service or otherwise render the wheel unusable Any wheel known to have been run with a flat tire or operated under abnormal conditions Should be checked before continued service If a ball tape is unavailable roll the unmounted wheel without a tire several revolutions over a smooth flat level clean surface Any deviation from rolling in a straight line is an indication of a potential lack of proper dimension and contour Remove the wheel from service until it can be properly checked with a ball tape Continued on the next page Dimension checks continued Cracked or damaged wheel checks 2 4 Tire wear or ride problems If you experience tire wear or ride problems it may be helpful to check radial run out Remove the wheel from the vehicle deflate and remove the tire see 3 5 page 22 for recommendations and instructions for demounting tubeless tires and 6 5 page 43 for recommendations and instructions for demounting tube type tires Remount the wheel on the vehicle without the tire Be sure to follow proper mounting procedures to assure the wheel is well centered on the hub Place a dial indicator
90. vices A pressurized tire wheel assembly can explode and separate violently This violent separation can cause serious injury or death Always contain the tire wheel assembly in an inflation cage during inflation 2 Position wheel on machine Lubricate wheel Insert curved end of tool between bead and entire air chamber surface and tire bead using wheel flange with tool stop against flange In approved lubricant Tire beads should be circular motion use short successive bites to mounted over the rim flange closest to the work the bead over the flange Push down on M ns Push bead over flange as far as tool as bead is worked over flange possible Lubricate the second tire bead Start second Place tire wheel assembly inside safety cage bead into the well holding it in position with or other suitable restraint refer to OSHA rule the clamp to the rim flange Lubricate bead 1910 177 paragraph b see Section 7 page 44 half way around With curved end of tool Refer to tire manufacturer s recommendation between tire bead and flange and the stop for proper tire pressure Using a clip on air towards the wheel push tool outward to work chuck or a self locking straight chuck with remote tire over flange Continue to pry bead over valve and pressure gauge inflate the tire wheel flange using the tool until remaining bead is assembly to proper pressure If air escapes roll over flange Seat the tire bead using an air ring tire
91. wn outside or beyond the device or barrier for any rim wheel positioned within or behind the device iii Restraining devices and barriers shall be visually inspected prior to each day s use and after any separation of the rim wheel components or sudden release of contained air Any restraining device or barrier exhibiting damage such as the following defects shall be immediately removed from service A Cracks at welds Cracked or broken components B C Bent or sprung components caused by mishandling abuse tire explosion or rim wheel separation D Pitting of components due to corrosion or E Other structural damage which would decrease its effectiveness iv Restraining devices or barriers removed from service shall not be returned to service until they are repaired and reinspected Restraining devices or barriers requiring structural repair such as component replacement or rewelding shall not be returned to service until they are certified by either the manufacturer or a Registered Professional Engineer as meeting the strength requirements of paragraph d 3 i of this section 4 The employer shall furnish and assure that an air line assembly consisting of the following components be used for inflating tires i A clip on chuck ii An in line valve with a pressure gauge or a presettable regulator and iii A sufficient length of hose between the clip on chuck and the in line valve if one is used to

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