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Alcoa Wheel Service Manual

1. Hidden damage 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 2 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 Section 3 8 Dirt streaks radiating from stud holes may indicate loose cap nuts Wheel alteration Alcoa does not approve any form of alteration to wheels except minor cosmetic buffing for appearance purposes or sanding in the rim flange area see Section 3 12 Wheels should not be altered by welding brazing or other heat application in an attempt to repair or straighten a wheel Use of adapter plates or bead locks are not approved on Alcoa wheels 3 2 Wheels should not be painted or otherwise coated in any way that may interfere with the mounting surfaces Any wheels that shows signs of alteration should be removed from service and scrapped WARNING Welding brazing or otherwise heating any ar
2. 23 24 Wess 126 27 28 10 hole hub piloted bus mounting 11 25 in bolt circle 8 670 in hub bore 1 219 in bolt hole diameter use two piece flange nuts Lug nut cover 182 Hub covers N A Specifications are 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 To view online go to www alcoawheels com The Spec Data brochure con tains current part number availability and complete specifications such as wheel dimensions load rating wheel weight outset and inset 22 5x7 50 15 DC 22 5x8 25 15 DC 22 5x8 25 15 DC 22 5x9 00 15 DC 22 5x9 00 15 DC 22 5x10 50 15 DC 22 5x12 25 15 DC 22 5x12 25 15 DC 22 5x12 25 15 DC 22 5x13 00 15 DC 22 5x13 00 15 DC 22 5x14 00 15 DC 22 5x14 00 15 DC 24 5x8 25 15 DC 24 5x8 25 15 DC 22 5x8 25 15 DC 24 5x8 25 15 DC 7300 7400 8000 9000 10 000 10 500 12 300 11 400 11 000 12 300 11 000 12 800 12 800 7400 8000 7300 7300 53 47 55 59 53 68 63 66 68 70 74 68 71 56 65 53 62 6 66 6 94 6 61 56 Revers ible 5 8 33 2 0 1 13 6 6 6 6 6 6 5 81 5 69 6 04 3 12 5 5 4 68 5 3 5 63 inflation pressure and accessory part numbers Alcoa provides tra
3. Inner cap nut inner thread faa 3 4 x16 outer thread i 1 1 8 x16 For use with standardlengthstuds 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 4 standard length 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 5 3 Stud located ball seats are spherical 5 4 Single and wide base wheel stud located ball seat mounting J J Stud standout is measured from the axle end mounting surface the hub for inboard mounted drums and the drum for outboard mounted drums to the first complete thread at the outside end of the stud Exposed SS First full thread Stud Standout a First full a thread 4 Stud Standout Mounting surface Mounting surface Inboard mounted drum Outboard mounted drum The nut seat for the stud located ball seat mounting system is a precision machined spherical surface Cap nuts must be properly manufa
4. 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 with a Photo 5 Air or electric power sander metal file Air or Electric Powered Sander This provides a very quick and effective method of remov ing 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 photo 6 Care must be used to avoid gouging the wheel Photo 6 Air or electric grinder Photo 7 Die grinder Rim flange wear 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 previous page A CAUTION 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 excessive noise when used Metal filings can be sharp and when p
5. 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 10 Mounting area Support surface diameters continued Support surface should be flat to the diameter recommended per SAE J694 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 10 10 ooo asm mepe nanan po sm mopo soisin oe e Corrosion Certain environments can lead to corrosion Some of the more common corrosives are salt magnesium chloride and calcium chloride compounds used for snow removal and highly alkaline materials If the air used to fill tubeless tires or the tire itself is not dry the areas of the wheel under the tire can corrode severely Bead seat and valve stem corrosion often are caused by entrapped moisture Mild corrosion should be removed thoroughly by wire brush and the rim protected with non water based tire lubricant see Section 4 1 Remove any severely corroded wheel from service 3 Hub bore gauge does not fit Hub bore gauge with severe corrosion 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 o
6. WHEEL SERVICE ma ANU AG Ss IMPORTANT SAREI PRECAUTIONS FOR TRUCK RIMS ANID WHEELS JANUARY 2009 SUPERSEDES JANUARY 2007 IMPORTANT Federal OSHA Regulations require all employers to make sure their employees who service rims wheels understand the safety information contained in this manual Do not let your employees service rims wheels unless they are thoroughly trained and completely understand this safety information If you are a service technician do not service rims wheels unless you are thoroughly trained and completely understand this safety information 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 bo
7. 45 46 Glossary of Common Terms continued LOCK RING The third piece of a three piece 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 N m Abbreviation for Newton meters OFFSET See OUTSET OPEN SIDE The side of the wheel opposite the disc face OSHA Abbreviation for the U S Department of Labor Occupational Saftey and Health Administration OUTER CAP NUT A cap nut used to secure the outer stud located wheel in a dualed wheel pair and threaded 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 retain
8. Pounds Inflation Pressure Designation ALCOA FORGED MAX a 7300 MAX PSI 120 TvoT MADE IN U S A ALCOA 082205 PART NO 883640 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 MEALEU WIICELS ALC UCSIYIALCU DY the letters DB following the part number such as 883640DB 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 All Dura Flange wheels are designated by the letters DF following the part number such as 883640DF All Dura Bright Dura Flange wheels are designated by the letters DD following the part number such as 883640DD If you cannot identify the size or load rating of the wheel it should not be used As of January 2009 Alcoa introduced a new logo label 39 J OSHA Regulations OSHA Regulations Sec 1910 177 Servicing multi piece and single piece rim wheels a Scope 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 uti
9. as well as some other wheel designs feature an increased underwell diameter and also have a non symmeterical sloping rim profile which provides additional brake clearance In order to minimize the possibility of tire bead damage all mounting and dismounting of the tire should be performed only from the narrow ledge side of the wheel in accordance with OSHA regula tion Tires should be mounted demounted only across the disc side of the wheel Do not mount from this side Mount from this side Do not mount from this side Rim width to tire matching 4 4 Recommendations for demounting tubeless Tire Size for both radial and bias tires 8R17 5 9R17 5 10R17 5 11R17 5 8R19 5 225 70R19 5 245 70R19 5 265 70R19 5 445 65R19 5 for additional information Approved Rim Widths 5 25 6 00 6 75 6 00 6 75 6 7 5 7 50 7 50 8 25 13 00 14 00 Tire Size for both radial and bias tires 8R22 5 9R22 5 235 80R22 5 245 75R22 5 10R22 5 255 70R22 5 255 80R22 5 275 80R22 5 11R22 5 265 75R22 5 12R22 5 295 60R22 5 295 75R22 5 305 75R22 5 305 85R22 5 315 80R22 5 335 65R22 5 15R22 5 385 65R22 5 425 65R22 5 16 5R22 5 18R22 5 445 50R22 5 445 55R22 5 445 65R22 5 1124 5 275 80R24 5 285 75R24 5 12R24 5 Rim to tire matching chart for medium and heavy trucks Approved Rim Widths 5 25 6 00 6 75 6 00 6 75 7 50 6 75 7 50 6 75 7 50 6 75 7 50 8 25 7 50 8 25 7 50 8 25 7 50 8 25
10. d Tire servicing equipment The employer shall furnish a restraining device for inflating tires on multi piece wheels 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 Restraining devices and barriers shall comply with the following requirements 41 OSHA Regulations continued 42 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 compo nents from being thrown outside or beyond the device or barrier for any rim wheel posi tioned 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 follow ing defects shall be immediately removed from service A Cracks at welds B Cracked or broken components 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 i
11. 0813 15 4761 15 8750 16 2718 18 6065 17 0656 7 4625 17 2554 Umre 18 6531 19 0500 13 4469 13 8438 20 2406 e063 ho 21 0344 21 Asis 21_E2E1 0 8750 22 2250 0 8306 0 8065 0 82148 0 9375 0 9531 0 9944 1 000 er 6215 23 0188 24 1155 23 6125 24 2054 24 E0ES 25 C031 25 4000 Conversion Inches to Millimeters Factors Inches x 25 4 Millimeters 9 2 Millimeters to Inches Millimeters x 0 03937 Inches PSI to kPa PSI x 6 8948 kPa kPa to PSI kPa xX 0 145 PSI Pounds to Kilograms Pounds x 0 4536 kg Kilograms to Pounds kg x 2 2046 Pounds Foot pounds to Newton Meters Ft lbs x 1 35582 N m Newton Meters to Foot pounds N m x 737561 Ft Ibs 49 Alcoa Wheel Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2009 Alcoa Wheel Products All Rights Reserved Form E37 13584 Printed in USA 05 06 30M
12. 8 Stud 5996 L amp R 5988 L amp R 7896 L amp R 1 1 8 Stud 5996 L amp R Eight hole hub piloted mounting 275mm bolt circle 221 1mm hub bore 26 75mm bolt hole diameter use two piece flange nuts Lug nut covers 181 Hub covers N A Hub Cover Kits 082122 Front 33mm 082133 Rear 33mm 082012 30mm 140233A Stainless Front 33mm 109176A Stainless Rear 33mm TR555D 10 22 5x7 50 15 DC 7300 53 6 28 5 44 120 je 7 SA00 o 1 2 2225 39874 39874 TR5554D 0 1 2 ODE 11 22 5x8 25 15 D 7400 0 82 1 44 4 9874 9874 5x8 25 15 DC 5 6 66 5 8 30 ao ee 398 398 412 22 5x14 00 15 DC 12 800 71 2 0 130 cance 841400 ox 2 39874 F 39874 This Specifications guide is not inclusive of all applicable Alcoa part numbers If a part number is not on this list call 1 800 242 9898 for further information TUBELESS WHEELS round hand holes ENGLISH UNITS continued Item no 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hole diameter use two piece flange nuts Wheel description Maximum wheel load Wheel wt in Ibs Approx Ibs Outset inches Inset inch es Maxi mum inflation PSI cold Valve stem Alcoa Part No Part number2 Stabi lizer Available finishes Lug nut covers 181 Hub covers Front 076018 or 076085 Rear 077018 or 0770854 One Piece hub cover system Front 086100S Rear 087100S 15 16 20 21 22
13. 9 Follow the 4 hardware manufacturer s recommendations when replacing studs Alcoa Grooved Bore Hub 2 36 60mm minimum stud standout wide base single wheels 3 346 85mm minimum stud standout dual wheels q M22x1 5 Stud 33mm hex head 2 piece flange nut P N 39874 Alcoa Grooved Bore 1 38 35mm 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 33 Single dualed and wide base wheels hub piloted mounting two piece flange nuts continued Tightening hubpilotedmounting two piece flange nuts 5 10 34 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 38 inch or 35mm for dualed wheels When mounting painted steel inner dual wheels with outer aluminum wheels be cautious of excessive paint build up on the inner steel wheel Excessive paint can reduce the clamping force and allow the wheels to become loose Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should
14. 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 9227 Mar 7 1996 a Glossary of Common Terms Glossa ry of 1 2 DUAL SPACING One half the distance between the two center lines Common Terms of dualed wheels The dimension is the same as the OUTSET dimension 1 PIECE FLANGE NUT A one piece washer and nut combination not recommended for use on any Alcoa wheel application 2 PIECE FLANGE NUT A two piece washer and nut combination used to secure Q 1 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 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
15. mounted over the rim motion use short successive bites to work the bead er demount tires flange closest to the wheel well Push bead over flange over the flange Push down on tool as bead is worked as far as possible over flange 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 non symmetrical wheels require tires to Lubricate the second tire bead Start second bead into Place tire wheel assembly inside safety cage or other Fe re tiarael ain eane aei the well holding it in position with the clamp to the suitable restraint refer to OSHA rule 1910 177 aig rim flange Lubricate bead half way around With paragraph b see Section 7 Refer to tire manufacturer s the disc side of the wheel only curved end of tool between tire bead and flange and recommendation for proper tire pressure Using a clip the stop towards the wheel push tool outward to work on air chuck or a self locking straight chuck with remote NOTICE Refer to ure tire over flange Continue to pry bead over flange valve and pressure gauge inflate the tire wheel assembly manufacturer s recomm
16. 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 serious 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 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 Section 5 2 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 NOTICE In service stud 1 dimensions and condition 6 O 3 may change over time due to m O RL environmental conditions _ D multiple re installations improper torquing and other 4 O Os factors Consult with your hub 7 O and stud manufacturer for 2 z maintenance and replacement Five Stud Six Stud recommendations 1 6 3 3 10 8 D 2 a 9 S 35 6 BO ye 4 Q 5 C4 gt ET 0 gt gt F oe Wo 2 Eight Stud Ten Stud Continued on the next page 32 After 5 50 miles of operation torque should be rechecked unle
17. piece wheel or wheel component g 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 assembly of the rim wheel unless the tire or wheel manufacturer recommends against the use of any rubber lubricant 4 Ifa 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 Ifa 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 sur
18. 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 circum ference and make sure that no area of the flange is below what the gauge indicates is accept able 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 the 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 serious injury 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 cause 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 Immediately and permanently remove any wheel from service that has inadequate rim flange height WARNING Excessive heat from fire brake malf
19. sion 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 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 infla tion 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 least the following elements 1 2 Tires shall be completely deflated before demounting by removal of the valve core 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 i When the tire has been driven underinflated at 80 or less of its recommended pressure OSHA Regulations continued 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 Ifatire on
20. the opposite of installing Mounting a tire means the assembly or putting together of the wheel and tire components to forma 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 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 40 OSHA Regulations conti
21. tires it may be necessary to temporarily reduce the tire pressure when 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 Excessive rim flange wear see Section 3 12 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 Some fleets wish to specially identify wheels as to OWNERSHIP and IN SERVICE dates Alcoa rec ommends that fleets and owner operators adopt the practice of permanently stamping wheels with the date they are first placed into service 1 Use Lo Stress stamps or equivalent 2 Location of stamped areas on outside disc should be in space outward from a line 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
22. 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 lubri cate 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 oil This will minimize cor rosion 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 sequence shown below for your type wheel After 5 50 miles of operation torque should be rechecked unless your documented fleet practices determine otherwise Check torque frequently from then on If nuts require frequent tigh
23. 0 242 9898 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 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 follow this practice you will significantly reduce the possibility of a rim flange cutting into the tire STEP 2 After the wheel is separated from the tire verify the circumference of the bead seat on the open side is acceptable see Section 3 4 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 previous page See Rim Flange Wear Gauge Instructions on the illustrations on previous page to make this determination If you do not have an Alcoa Rim Flange Wear Gauge contact Alcoa Wheel Products to obtain a gauge s at no ch
24. 5RW 4 72 TR553C 2 5515 2500 36 4 16 5 5 55 141 142 978 764490 Oi 2 39874 39874 i 15 DC oka lee a 120 ee 005533 19 5x7 50RW 5 28 TR553C 15 3000 37 7 17 1 6 10 155 142 978 773400 OF lee 39874 39874 of 15 DC aaia Atai a 134 K 005533 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hole diameter use two piece flange nuts Lug nut covers 181 Hub covers Front 076018 or 076085 Rear 077018 or 0770854 One Piece hub cover system Front 086100S Rear 087100 19 5x7 50RW 5 28 TR553C 34 6615 3000 37 7 17 1 6 10 155 142 978 773600 OMe 39874 15 DC t tal 134 P 005533 10 hole hub piloted mounting 335mm bolt circle 281 2mm hub bore 26 75mm bolt hole diameter use two piece flange nuts Lug nut covers 181 Hub covers 5811 polished with view port for P N 833580 only all others N A 0 3 ODB 3DB 5 70 70MS7 ODF 22 5x8 25 15 DC 8047 3650 50 6 23 0 6 57 167 138 952 886520 39874 y 39874 i on A 3650 5061230 1637116 iis eee 007007 3DF ODD 3DD 6 02 70MS7 0 3 ODB 3DB 5x9 00 15 1 5 23 4 6 89 17 142 97 2 9874 9874 F386 22 5x9 00 15 DC 9094 4125 51 5 234 689 175 153 978 Me 896520 Bae 398 398 22 5x13 00 6 12 437 se lt 12 800 5806 76 0 34 5 ss 130 896 TR553 005530 833580 0 1 39874 39874 6 79 5 81 TR554D 24 5x8 25 15 D 4 0 29 120 827 9874 p 9874 38 5x8 25 15 DC
25. 7 50 8 25 7 50 8 25 8 25 9 00 8 25 9 00 8 25 9 00 8 25 9 00 8 25 9 00 9 00 9 75 9 00 9 75 10 5 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 13 00 14 00 7 50 8 25 7 50 8 25 8 25 8 25 9 00 There may be additional rim to tire matches not shown above Contact the tire manufacturer or your Alcoa wheel representative WARNING An aluminum wheel can be structurally weakened by excessive heat Tire wheel assemblies using wheels that have been exposed to excessive heat may tires experience a sudden and unpredictable tire wheel separation causing serious injury or WARNING death Immediately and permanently remove any wheel from service that has been subjected to excessive heat such as a tire fire wheel bearing failure or braking system drag seize or a high pressure tire wheel separation 4 5 WARNING Damaged tires or wheels can lead to an explosive separation of tires and wheels Explosive separation can cause serious injury or death WARNING Inspect tires and wheels for damage before removing from vehicle If damage is found tire must be completely deflated before loosening cap nuts Immediately and permanently remove damaged tires or wheels from service 23 Recommendations for demounting tubeless tires continued Demounting of tubeless tires 4 6 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating 1
26. 8500 3855 64 0 29 0 ya qays 120 827 oa 983500 0 3 398 398 Ten hole hub piloted mounting 335mm bolt circle 281 2mm hub bore 32 87mm bolt hole diameter use two piece flange nuts Lug nut covers N A Hub covers N A 0 3 ODB 3DB D 2 bol 047 3650 0 3 22 8 57 167 138 952 886510 4306 32 4307 32 t39 Da olt 8047 3650 50 3 22 8 6 57 167 145 952 007007 3DF ODD 3DD 22 5x9 00 15 6 02 70MS7 0 3 ODB 3DB 4 D 2 bol 9094 4125 1 2 23 2 6 89 175 142 978 896510 4306 32 4307 32 t40 T olt 51 2 23 2 175 153 978 007007 ODE 3DF Six hole hub piloted mounting 205mm bolt circle 160 2mm hub bore 21 5mm bolt hole diameter use two piece flange nuts Lug nut covers N A Hub covers N A 27 0 4 25 41 17 5x6 00 15 DC 4000 1814 12 2 5 0 127 108 130 896 TR554C 664800 0 1 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 ensure proper clearance from any obstructions 1 Capacity ratings as dual or single in highway service bias ply or radial Load ratings in Ibs for items 31 through 41 rounded to nearest multiple of 5 2 Part numbers listed for all sizes are brushed finish the last digit of the six digit numerical part number is 0 Polished f
27. CAP NUT See 2 PIECE FLANGE NUT DC Abbreviation for drop center DISC AREA The vertical wheel face which supports the rim DISC MATE wheel gasket A nylon 6 6 gasket that goes between the brake drum and wheel and or between two wheels to protect against corrosion 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 DUAL WHEEL Any wheel that can be mated disc side to disc side with another wheel resuliting in an inner and outer dual wheel assembly 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 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 measurement
28. E For complete information on tube type wheels contact Alcoa at 800 242 9898 NOTICE Alcoa aluminum non symetrical wheels require special tire mounting techniques see Section 4 3 20 WARNING Damaged tires or wheels can lead to an explosive separation of tires and wheels Explosive separation can cause serious injury or death WARNING Inspect tires and wheels for damage before removing from vehicle If damage is found the tire must be completely deflated before loosening cap nuts Immediately and permanently 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 3 10 3 11 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 Immediately and permanently 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 3 15 pages 19 for specific cautions care and maintenance procedures Disc Mate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marrin
29. IDE 2DF 8864 0 3 ODB 3DB ODF 3DF ODD 3DD OF Bie 224 ODE DBH i Front outer cap nuts 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 numbers ending in a 4 or 7 Not all Alcoa wheels are available with the Dura Bright surface treatment Rear inner cap nuts AIAI Rear in ner cap Rear outer cap nuts Al Stl nuts 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 39874 TUBELESS WHEELS round hand holes ENGLISH UNITS METRIC UNITS Approx Maxi Maximum Wheel Duce dest kaaa Valve Rear Rear in ltem Wheel descrip wheel load tibs qnchaee inches inflation stem Part Available Stabi Front outer cap inner nercap Rear outer cap no tion in Ibs elo ary tama l Psi cold Alcoa Part mumber finishes lizer nuts capnuts nuts nuts kilograms grams KPa No AI Al Al Stl Eight hole hub piloted mounting 275mm bolt circle 221 1mm hub bore 24 75mm bolt hole diameter use two piece flange nuts Lug nut covers 181 Hub covers N A Hub Cover Kits 082122 Front 33mm 082133 Rear 33mm 082012 30mm 140233A Stainless Front 33mm 109176A Stainless Rear 33mm 4 72 TR553C 1 17 5x6 75 15 D 15 250 29 5 13 4 5 55 141 142 978 663470 0 2 39874 39874 3 5x6 5 DC 5515 2500 5 13 4 141 120 978 005533 19 5x6 7
30. When hand demounting tires from wheels placing aluminum wheels on a clean wooden floor or rubber mat is recommended Remove valve core air from tire wheel assembly prior to removal from vehicle Additional care should be used when demounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches can not be polished out see Section 3 15 for specific cautions care and 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 pre vent gouging the wheel or instruction manual for your particular machine before attempting to mount or Repeat procedure at intervals until bead is totally separated from wheel Repeat procedure on other side of tire Tire is now ready for demounting Lubricate the tire bead Remove the valve core from the valve stem to ensure complete deflation Place wheel on machine and position tool so flat end can be driven between tire bead and rim flange Straighten tool 24 demount tires to a vertical position until bead is separated from wheel Insert curved end of tire tools between tire and wheel approxi mately 10 inches apart Pull one tool toward center of wheel then pull second tool in the same manner To free bead leave one tool in position take out and reinsert the other too
31. 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 adjustment 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
32. 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 installed If it becomes necessary to replace an air valve install it using 9 to 11 foot pounds of torque Replacement valves may be obtained from your authorized Alcoa Wheel Distributor Always use sili cone or EPDM O rings or grommets not rubber when reinstalling valve stems Metal valve stem caps are recommended instead of plastic It is recommended that valve stems with O rings or grom mets be replaced at every tire change When replacing valve stems it is recommended to lubricate the threads and O ring with a non water based tire lubricant When valve stem extensions are used it is recommended that valve stem stabilizers be used Identification 6 6 Alcoa wheel identification Since 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 June 1996 all Alcoa heavy duty truck wheels had the Alcoa identification symbol on the outside of the disc near the hand hole in line with the valve location This marking was phased out on heavy duty truck wheels manufactured after June 1996 Wheel Load Rating Maximum FMVSS 120
33. arge by calling 800 242 9898 or on the web at www alcoawheels com 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 Photo 3 Run the sharpness indicator gauge 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 Photo 2 A rubber sharpness gauge or a suitable piece of rubber attached to a block of wood 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 rub ber 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 Cuts can lead to infection CAUTION Always wear gloves when handling used wheels or when testing for edge sharpness 16
34. art number and the addition of DF at the end Only the wheel part numbers with available surface finishes having the DF suffix are available with the Dura Flange option The Dura Bright with XBR Technology surface treatment and the Dura Flange Wear Protection options are currently available together on the same wheel indicated by the DD suffix TUBELESS WHEELS round hand holes ENGLISH UNITS Ap Maxi Maximum Valve Rear Rear in prox Inset mum Pe Item wheel Outset stem Part Available Stabi Front outer cap inner nercap Rear outer cap Wheel description 1 Wheel 3 inch inflation 2 PSZ i load in inches Alcoa Part mumber finishes lizer nuts capnuts nuts nuts es PSI Ibs ike d No AI Al Al Stl Six hole stud located ball seat mounting 8 750 in bolt circle 6 495 in hub bore 1 219 in bolt hole diameter Lug nut covers 150 Hub covers N A TR553C 3 4 Stud 5995 L amp R 1 17 5x6 75 15 DC 5070 32 5 55 4 72 125 663170 0 2 5988 L amp R 7896 L amp R 5996 L amp R 005533 1 1 8 Stud 5996 L amp R 10 hole stud located ball seat mounting 8 750 in bolt circle 6 495 in hub bore 1 219 in bolt hole diameter Lug nut covers 150 Hub covers N A TR553C 3 4 Stud 5995 L amp R 2 17 5x6 75 15 DC 5070 31 5 55 4 72 125 663070 0 2 a 5988 L amp R 7896 L amp R 5996 L amp R i 005533 1 1 8 Stud 5996 L amp R 10 hole stud located ball seat mounting 11 25 in b
35. 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 recommend ed Torquing of flange nuts should be done in recommended sequences WARNING Under or Over torqued flange nuts allow wheels to run loose and fatigue studs or lose nuts Overtorquing can stretch studs causing them to fail with loss to torque and may cause pre mature fatigue Both under and overtorquing can lead to wheel disengagement causing serious injury WARNING 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 Section5 2 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 See section 6 2 Wheel studs on both 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
36. ccasion Alcoa aluminum truck wheels are operated dualed with a steel inner wheel When this application occurs it is recommended to use a Disc Mate because of corrosion issues 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 equiva lent for this purpose 29 30 Dualed wheels steel inner aluminum outer stud located ball seat mounting continued rr 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 ob structions NOTICE Check for and replace bent broken cracked or damaged studs When replacing broken studs always replace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manu
37. ctured to assure correct seat ing Never use one or two piece flange nuts on a wheel designed with ball seats see Section 5 11 Ball seat cap nuts may be obtained from your Alcoa Wheel Distributor Front wheels are mounted as singles and require 1 8 45 7mm minimum stud standout Most vehi cles 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 Disc Mate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring Disc Mate wheel spacers are placed between the con tact surfaces of the Dura Bright wheel and the brake drum as shown below and on the next page Disc Mate when used Single Alcoa Aluminum Wheel Y Outer Cap Nut P N 5996R or L See 5 2 page 26 Correct single mounting with 1 1 8 inch stud located ball seat mount 1 8 inch minimum stud standout Continued on the next page 27 Single and wide base wheel stud located ball seat mounting continued 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 i
38. de at a minimum the appli cable 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 manualin a manner which the employee is able to understand The employer shall assure that each employee demonstrates and maintains the ability to ser vice 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 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 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
39. 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 immediately and permanently 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 wrong cap nuts can cause loss of torque broken studs and cracked wheels WARNING Conditions which can lead to serious injury or death Use only hardware designed specifically for each wheel type See Section 5 2 pg 26 for proper hardware assemblies Tightening stud located ball seat cap nuts 5 8 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 recommend ed Torquing of cap nuts should be done in recommended sequences Some states have laws which dictate full thread engagement or thread engagement past the nut body Make sure you know the laws for the states in
40. ea of an Alcoa aluminum wheel will weaken the 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 serious injuries or death Never attempt to weld braze or heat any surface of an Alcoa aluminum wheel Heat damage 3 3 IF ANY OF THE ABOVE CONDITIONS ARE SEEN REMOVE THE WHEEL FROM SERVICE IMMEDIATELY THIS INCLUDES ANY HEAT DAMAGE TO WARNING Excessive heat from fire brake malfunction wheel bearing failure tire failure or other sources may weaken the metal and cause the wheel tire assembly to separate explosively WARNING Exploding wheel tire assembly can cause serious injury or death 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 condi tion if it has been cleaned Do not use any wheel that has been overheated regardless of appearance Even if a wheel does not appear to be obviously burned labels tire bead brake drum and Disc Mate 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
41. ead seat does not match the required dimension as indicated by the TRA certified ball tape immediately and permanently remove the wheel from service Ball tapes used for measuring wheel circumference can be purchased from the Tire and Rim Association Inc 175 Montrose West Avenue Copley Ohio 44321 330 666 8121 or at www rma org For instructions on proper use of ball tape reference the current Tire and Rim Association yearbook 2nd Best Inspection Method If a ball tape is unavailable Tey Pe ra TTT HE PET TTT 2 3135 A r i sald agis s s3fge o s syfgs s ju r je S a sj o s lt c 53 a aie A 5 ST s eerie te MAA WO l i ej tl villa Photo above shows carpenter square even on both bead seats Photo above shows and undersized wheel that you can clearly place a credit card approximately 030 in or 76mm between the square and the wheel Z THIS INSPECTION TECHNIQUE ONLY APPLIES TO DUAL OR DISC FACED WHEELS Non Dual wheel Check all wheels at each tire change for proper contour of the open side of the rim Place the long leg of a carpenters square across the center of the disc side of the wheel Extend the short leg across both rim flanges of the wheel as shown above Repeat this process at four equidistant points around the wheel The short leg should touch both rim flanges at each point If a distance greater than the thickness of a credit card or 030 in or 76mm feeler gau
42. eads past full thread engagement 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 stems 180 apart Disc Mate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring Disc Mate wheel spacers are placed between the 9 contact surfaces of the Dura Bright wheel and the brake drum and between the dual aluminum Disc Mate when used Y Y Alcoa Aluminum Wheels Outer Cap Nut P N 5996R or L See 5 2 page 26 Inner Cap Nut P N 5978R or L or P N 5988R or L See 5 2 page 26 Correct mounting for dual aluminum stud located ball seat mount wheels 1 31 to 1 44 k stud standout 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 from the vehicle which can cause serious injury or death Loose running wheels can lead to stud WARNING breakage Use only cap nut 5978R or L 5988R or L or their equivalent when mounting dual alumi num wheels On o
43. ee 5 2 page 26 located ball seat mounting Cap nuts recommended by Alcoa are compatible with Alcoa wheels Hardware of equal dimensions and strength may be used Continued on next page 5 6 28 Dualed wheels stud located ball seat mounting contin ued 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 ob structions NOTICE Check for and replace bent broken cracked or damaged studs When replacing broken studs always replace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs 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 for excessive stud standout greater than 1 88 1 7 8 All states and provinces have their own standards for fastener engagement Most of these consist of at least 1 to 2 thr
44. endation using the tool until remaining bead is over flange Seat to proper pressure If air escapes roll tire or use bead for proper tire pressure the tire bead using an air ring or other mechanical expander to force tire beads against rim Be sure to bead seating aid stay out of the path of potential exploding parts or air blasts 21 22 Mounting tubeless tires continued Mounting tires on non symmetrical drop well wheels 4 3 Mount from this side CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface CAUTION 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 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 Alcoa wheels often contain a symmetrical drop well with a narrow ledge on both sides of the rim This feature allows mounting of the tire from either side of the wheel However some Alcoa wheels are non symmetrical and contain a narrow ledge on only one side of the wheel Reduced well wheels
45. escssenseseees 19 4 Mounting Alcoa Wheels with Tubeless Tires ccsccescssssssssessssssesssessssssssssesssessssssessssssssssssssssessssssssees 20 6 4 1 Recommendations for MOUNTING tubeless tires eessesssssessecscsecsessssssscsessssessscsecscencsssassessucseeassassesseeseenss 20 4 2 Mounting tubeless TINGS sesnesiieenmnieninsnnninnnninannann aa anaes 21 4 3 Moounting tires on non symmetricial drop well wheels ssssessssesssseessseessseessseessseessseessseessssessseessseessseessse 22 AA FIP WIA to tire matchiNGsasisennenansnnamnnnnnnnnnn aia 23 4 5 Recommendations for demounting tubeless tires ssssessssseesssssersssssessssseesssseerssseerossssresssseorssseeenssserossseesrsss 23 4 6 Demounting of tubeless tires ssssessssseeesssesessssseesssseeessseeesssseesssssesssseeresssseenssstrossseerosseeeossssressssterosseerossseressseesrsss 24 5 Wheel Installation ss sesesssesssesssesssesssessseosseosseosseosseosseosseesseesseesseesseesseesseesseesseesseeoseesseroseeoseroseroseeoseeoseee 25 5 1 Recommendations for proper installation of wheels ss ssseessseeesseeesseeesseeesseeesseeesseersseeesseeroseresseersseresseersss 25 5 2 Wheel cap NnUtsS ssessseesseessesseesssesssessecesecessesssessseesecesscessesoseesseessseoseeoserosetosstosstoseeessresstosseossteseeesetesstosseesseesssesseeoseeesee 26 5 3 How to measure stud standout eseseessssseesessseeesssseesssscesssseesssseerosseerosssstosssseorssneeeossseeosssero
46. f liquid tire balancers or sealants will not be replaced under the Alcoa limited warranty CAUTION 11 Bolt 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 the disc surface of hub piloted wheels Remove damaged wheels from service 3 8 For hub piloted normally if you see thread For hub piloted normally if you see a wal Damaged ball seat contact area Pounding marks on the inside diameter of the bolt lowed out bolt hole this would indicate the of nut on ball seat contact area identified by holes this would indicate the wheel ran loose wheel ran loose arrows Disc area 3 9 Inspect both sides of disc area for hand hole cracks If cracks are found remove the wheel from service 12 Rim area Check the entire rim area for nicks gouges and cracks Loss of air may be caused by cracks in areas around the valve stem hole Remove the wheel from service 3 10 Valve hole crack Drop center crack Be ad Se at area Loss of air may be caused by cracks in the bead seat areas around the rim Remove the wheel from service if damaged 3 11 Bead seat cracks are normally caused by overloading of the wheels If you have this type of wheel breakage it would be recommended to u
47. face 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 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 39 FR 23502 June 27 1974 as amended at 52 FR 36026 Sept 25 1987 53 FR 34736 Sept 8 1988 43 OSHA Regulations continued 44 Appendix A Trajectory APPENCHX A TRAJECTORY WAANIKG STAT OUT OF THE TRAJECTORY A3 INDICATED BY SHADED AREA Ppa Lah cee el Garr re i iperinn may deria kym Ha upei ph Appendix B Ordering Information for NHTSA Charts OSHA has printed two charts 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
48. facturer s recommendations when replacing studs Disc Mate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring Disc Mate wheel spacers are placed between the e e contact surfaces of the Dura Bright wheel and the brake drum and between the steel and aluminum wheels as shown below Inner Steel Wheel Disc Mate when used z Alcoa Aluminum Wheel Outer Cap Nut P N 5996R or L See 5 2 page 26 3 4 Stud meee eee eee Hub Inner Cap Nut P N 7896R or L See 5 2 page 26 stud standout 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 lead to serious injury or death Loose running wheels can lead to stud WARNING 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 serious injury or death WARNING Alcoa aluminum wheels with 11 1 4 diameter bolt circle require a support surface at least 13 3 16 in
49. for the states in which you operate and comply 5 9 NOTICE Do not exceed maximum wheel load Cus tomer must compare OEM vehicle load rating to maximum wheel load rating Disc Mate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring Disc Mate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the dual wheels as shown below Note Some stud located ball seat wheels have the same number of holes and bolt circle diameter as hub piloted wheels They should not be mixed Disc Mate when used Disc Mate when used 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 ob structions NOTICE Check for and replace bent broken cracked or damaged studs When replacing broken studs always replace the studs on each 1 06 27mm 33mm hex head gt 2 piece flange nut P N 39874 M22x1 5 Stud side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with A the stud manufacturer for regular maintenance and stud replacement practices 1 2 36 60mm minimum stud standout single wheels Disc Mates when used All wheel fastener hardware should be grade 8 or metric Drum conversion 10
50. g 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 3 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 of a non water based lubricant is recommended as a rim surface protectant and tire mounting lubricant Coat the entire rim surface see Section 4 2 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 or tire 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 on next page 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 rec ommended 11 Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold
51. ge appears between the short leg and the rim flange the wheel should be removed from service and scrapped 3rd Best Inspection Method If a ball tape or carpenters square is unavailable roll the unmounted wheel without a tire a minimum of 10 feet Rolling wheel as described on this page over a smooth flat level clean surface such as asphalt or concrete pavement 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 IF YOU DO NOT FULLY UNDERSTAND ANY OF THESE INSPECTION METHODS AS DESCRIBED IN THIS SECTION CONTACT ALCOA AT 800 242 9898 FOR CLARIFICATION Dimension checks continued Cracked or damaged wheel checks 3 5 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 Section 4 5 for recommendations and instructions for demounting tubeless 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 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 t
52. ide circumference check checks WARNING Wheels that have been subjected to high pressure tire and rim separation or excessive heat damage may no longer have sufficient dimension and contour to retain the tire bead while under pressure 3 4 WARNING Exploding wheel tire assembly can cause serious injury or death Immediately and permanently remove from service any wheel that has been exposed to high pressure tire and rim seperation or excessive heat WARNING Wheels that have been run flat or have other physical damage may no longer have sufficient dimension and contour to retain the tire bead while under pressure Rims that lack proper dimension and contour can lead to explosive separation of the tire and rim causing serious injury or death WARNING Any wheel that has been in service must be inspected prior to mounting Follow dimension check procedures described in this section during each wheel inspection Best Inspection Method Measure the circumference of the bead seat on the open side see illustration to left with a ball tape The circumference of the bead seat on the open side of the wheel should Photo to the right be checked at each tire change The open side is the side opposite the disc shows the TRA Ball face In the case of center flange wide base wheels or wheels with insets less Tape than 3 inches both rim flanges should be checked Any wheel should be inspected prior to mounting If the circumference of the b
53. ill find numbers which look 39 Hea CAI CS sarene A E case etek eset 7 like this See Section 3 1 These 2A Dimension CSC eects eat ii aa a menos se 8 3 numbers are cross references to 3 5 Cracked OF damaged wheel CHECKS sscrssnecssascasesaesnetezsnnssntesssesorntensnecgandedensnevuedednenstttedcasnarteesdvexsshseuensentsatanunavanterenotanie 9 other sections of the manual The 3 6 Mounting afea Qu csssssesssssssssssssssssssssssssssessssusossssssssssossssssssosessssssssosssssssossosssssusssssussssnsesssssasssssssssssssoseessssessseessseesesssonssses 10 numbers 3 1 refer to section T O O a E A AE N A A A E 11 3 subtopic 1 You will find the S PROE or EA TE E E E 12 section number and subtopic o DE N o TEE E E TAE N ENNE IAE OE ETATE 12 4 number under the heading O PN care e e NTNU Tay rere vTictr rere renr amen rireer vier sneee Tra were reve 13 in each section 3 11 Bead Seat area ccccccscssssssssssssssssssessssssssssssssssssssssssssssssssessscssssssssscssssssssssssssessssssssssssscsscssssecsscssesascsssssesssssssssesaseesssaessses 13 s Rimang WC AN eri ssvsccecssseeeoieacivcrtsciesquccsatas soos dees unesteneceiviasestars asa restos eases eet ednid desea andes 14 3 13 Dura Flange RAE TY re NCE sissien tisadi tO PT AE a 19 3 14 Maintenance against corrosion non Dura Bright surfaced treated Wheels sssssssscsssssececsenserees 19 5 3 15 Dura Bright surface treated wheels cleaning and MAINTENANCE cssessscesseesessssessecsssscsssseesc
54. ining live or on video on proper wheel installation and maintenance practices free of charge Contact Alcoa Wheel and Forged Products at 800 242 9898 Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part 120 130 130 130 130 130 130 130 130 130 130 130 130 130 130 120 120 TR555D 005554 TR554D 005544 TR553C 005533 TR554D 005544 TR555E 005555 TR553 005530 TR553E 005535 TR553E outset 005535 TR555E inset 005555 TR552 005520 TR553E outset 005535 TR555E inset 005555 TR552 005520 TR553E outset 005535 TR555E outset 005555 TR553E inset 005535 TR555D 005554 TR555D 005554 TR555D 005554 TR555D 005554 873600 883640 885600 893640 893630 803600 823600 823650 823640 833650 833640 841600 841610 983640 985600 883610 983610 0 1 ODE 1BB 2DB a OW 27333 ODB 1DB 2DB 3DB ODF 1DF 2DF ODD 1DD 2DD OF 2 ODE 1DF 2DF O12 3 0BB 1DB 2DB 3DB ODF 1DF 2DF 3DF ODD 1DD 2DD 3DD 0 1 0DB 1DB 8864 8964 UDBK 0 2 O71 279 OBB 1DB 2DB 9DB ODF 1DF 2DF 9DF 0 1 ODB 1DB ODF 1DF 0 1 2 9 0 1 0 2 ODB 2DB Onl 2 9 ODB 1DB 2DB 9DB 0 1 2 3 ODB 1DB 2DB 3DB ODF 1DF 2DF 3DF o 1 2 ODE
55. inishes are indicated by changing the 0 with any of the suffixes in the adjacent column Available Finishes 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 3 Outset positive inset negative The distance from the rim centerline to the mounting face of the 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 dual spacing offset 4 The Dura Bright surface treatment and the Dura Flange options are currently available together on the same wheel indicated by the DD suffix Part numbers should end in 1 or 9 when used in an inset position and 0 or 2 when used in an outset position This finish is only available under the non stock policy TR55XX Valve stems are the standard rim valves with a rubber grommet TR54XX are an acceptable option with O rings t Indicates European New Generation Wheels tt Check with vehicle manufacturer or axle manufacturer before retrofitting to outset wide base wheels to ensure compatibility with axle and wheel end components P Ns 841100 841400 and 841600 are not recommended for use on N spindle trailer axles Hub cover system kits P N 076085 front and P N 077085 rear contain screw on Hug a
56. l curved end between bead and flange a short distance from the spanned area Pry bead free of rim repeating process until entire bead is free from wheel Insert straight end of tire tool between beads and both rim flanges hooking stop on the tool over second flange Position inserted tool at 90 angle to tire assembly at top of wheel and lubricate bead areas on both sided of tool Lean tire assembly toward tool and rock or bounce to pry off the tire 5 Wheel Installation Recommendations for proper installation of wheels 5 1 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 Check for and replace bent broken cracked or damaged studs When replacing broken studs always replace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs 1 Make sure all wheel cap nuts are properly torqued check them often see Section 5 8 If the wheel is loose the oles wil
57. l pound out deform If some cap nuts are tight and others are loose the wheel may develop cracks or studs may break This condition may cause wheel to loosen and disengage from the vehicle Dirt streaks or rust radiating from stud holes can indicate loose nuts see Section 3 2 Be sure the end of the wheel wrench is smooth or cover the wheel mounting surface with a protective shield g p prior to tightening the cap nuts The wrench end will mar the wheel around the cap nuts if it is not smooth 3 Keep all component contact surfaces smooth and clean Dirt or projections on mounting surfaces may lead to loose wheels Remove all projections resulting from burrs nicks etc Be sure that loose dirt does not fall onto mounting surface during assembly 4 Do not introduce any foreign objects such as spacers or top hats into the contact surface areas of the mounting system unless approved by Alcoa Do not paint Alcoa forged aluminum wheels 5 Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 3 15 for specific cautions care and maintenance procedures 6 Disc Mates are a protection gasket designed to be placed between the wheels and also the brake drum wheel contact surfaces see Sections 5 2 5 6 5 7 5 9 Disc Mates are recommended to be replaced when the tire wheel assemblies are removed and reinstalled WARNING Wheels that are not p
58. le 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 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 Innercap nut inner 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
59. lizing automo bile 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 Department of Labor Occupational Safety and Health Administration pub lications 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
60. lt 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 E warranted for 24 months against sharp edges 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 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 b Loading the wheel beyond the applicable maximum wheel load as specified by Alcoa c Inflating beyond the applicable maximum as specified by Alcoa d Changing the original condition of the wheel by alteration or by subjecting it to any processing such as welding or straightening e 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 f Failure to follow maintenance and other instructions and war
61. lug nut covers and require a minimum of four threads of the stud to extend above the tightened cap nut for use The minimum stud standout required for P N 833580 is 2 375 inches 60 3mm when using wheel nut P N 39874 Taller nuts will require more stud standout P Ns 885600 and 985600 are Alcoa Severe Service Wheels Dura Bright wheels with XBR Technology 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 or visit www alcoawheels com durabrightxbr Inspection and Maintenance Inspect thoroug h ly Safe operation requires thorough examination of wheels and attaching hardware at frequent intervals both d off the vehicle and frequently oth on and off the vehicle Wheels that have been in service need to be inspected at regular intervals to assure proper and safe perfor mance 3 1 It is not always possible to predict the useful life of a wheel Wheels will eventually wear out Generally older wheels and wheels operating in extreme conditions should be examined more frequently for obvious signs that they should be removed from service 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
62. nings set forth in the Alcoa 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 g Nicks scratches and other surface blemishes resulting from improper maintenance cleaning road debris curbing accident or operation are not warrantable h Rim flange wear other than Dura Flange is not warrantable i Damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline 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 o
63. nsure proper clearance from any ob structions NOTICE Check for and replace bent broken cracked or damaged studs When replacing broken studs always replace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs Disc Mate when used Alcoa Aluminum Wide Base Wheel Drum Outer Cap Nut P N 5996R or L V4 See 5 2 page 26 1 1 8 Stud Correct wide base wheel mount ing with 1 1 8 inch stud located ball seat mount 1 8 inch k minimum stud standout Disc Mate when used Single Alcoa Aluminum Wheel Outer Cap Nut P N 5995R or L See 5 2 page 26 Correct single mounting with 3 4 inch stud located ball seat mount 1 8 inch minimum stud standout Disc Mate when used Alcoa Aluminum Wide Base Wheel Outer Cap Nut P N 5995R or L See 5 2 page 26 Correct wide base wheel mount ing with 3 4 inch stud located ball seat mount FA asinch minimum stud standout Rear wheels are most frequently mounted as duals Each inner aluminum wheel is attached by 10 inner Dualed wheels stud cap nuts Alcoa recommends use of inner cap nuts 5978R 5978L or 5988R 5988L s
64. nued 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 assem bly to the axle of a vehicle and also provides the means to contain the inflated portion of the assembly i e the tire and or tube c Employee Training 1 2 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 inclu
65. offen ihan in most mi 1 In 1000 o other Industries i 1 in 10 TYPECAL INDUSTRY TIRE SERVICE INDUSTRY 2 Wheel Specifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J694 June 2007 Part numbers listed for all sizes are brushed finish the last digit of the six digit numerical part number is 0 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 Only for item numbers marked with a single asterisk part numbers ending in 9 are inset posi tion wheels brushed finished see footnote Dura Bright Wheels with XBR Technology are identified 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 polished outside only the number is 1 For polished inside only the number is 2 For polished both sides the number is 3 Only the wheel part numbers with available surface finishes having the DB suffix are available with the Dura Bright with XBR Technology option Dura Flange Wear Protection wheels are identified by using the regular numerical p
66. olt circle 8 73 in hub bore 1 219 in bolt hole diameter Lug nut covers 150 Hub covers Front 076015 Rear 077015 3 4 Stud 5995 0 1 2 0DB TR555D SRN 3 4 Stud 5995 L amp R L amp R 22 5x8 25 15 D 72 2 12 11 IDB 222 988 L amp R 7896 L amp R eee 09 3 ee nee i 005554 ote 3 1 1 8 Stud 5996 L amp R PREL PROLA 1 1 8 Stud 5996 AID L amp R 3 4 Stud 5995 TR553C 3 4 Stud 5995 L amp R L amp R 4 22 5x9 00 15 DC 9000 60 6 94 5 94 130 893000 OM 5988 L amp R 7896 L amp R 005533 1 1 8 Stud 5996 L amp R 1 1 8 Stud 5996 L amp R 56 3 4 Stud 5995 5 22 5x12 25 15 DC 11 400 62 Tan 130 1a 823000 0 ee LER i j 005535 1 1 8 Stud 5996 L amp R 1 1 8 Stud 5996 ible L amp R TR553E outset 3 4 Stud 5995 005535 3 4 Stud 5995 L amp R L amp R ce 22 5x12 25 15 D 11 4 2 7 1 2 APPa b a PDE uv 96 388 i 30 TR555E inset 823030 0 3 1 1 8 Stud 5996 L amp R 1 1 8 Stud 5996 005555 L amp R 3 4 Stud 5995 TR555E 3 4 Stud 5995 L amp R L amp R 7 22 5x12 25 15 DC 11 000 71 5 84 4 68 130 823060A 0 1 005555 1 1 8 Stud 5996 L amp R 1 1 8 Stud 5996 L amp R 3 4 Stud 5995 TR553E outset 3 4 Stud 5995 L amp R L amp R 8 22 5x14 00 15 DC 12 800 71 2 0 130 841100 0 277 tt 005535 1 1 8 Stud 5996 L amp R 1 1 8 Stud 5996 L amp R 3 4 Stud 5995 P TR555D 3 4 Stud 5995 L amp R L amp R 9 24 5x8 25 15 DC 7200 59 6 6 5 59 120 005554 983120 Ola 1 1
67. on 3 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 Section 4 1 3 To maintain the original appearance of your Alcoa wheels the following procedures are recom mended 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 any automotive polish equivalent e Clean your Alcoa truck wheels as frequently as required to maintain their appearance 1 The Dura Bright surface treatment is designed to be easy to clean and generally only requires water If soils attached to the surface do not come off with cold water try warm water and wipe with a soft towel or chamois material If soils remain use warm water and a mild detergent with assistance of a commerical high pressure power washer if available Always dilute the detergent according to the manufacturer s recommendation never use the detergent straight without diluting with water In the mixed diluted state the cleaner acidity should be at pH equal
68. or greater than 5 avoid cleaners that contain any hydroflouric acid In the mixed diluted state the cleaner alkalinity basicity should be at pH equal or lower than 9 2 When tires are removed the entire rim must be cleaned and inspected see Section 3 With a soft brush remove any foreign products from the rim portion of the wheel that supports the tire Generously coat the entire air chamber surface with an approved surface protectant and lubricate each time the tire is removed see Section 4 1 3 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 4 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 Disc Mates are highly recommended e Note pH value can be found in chemical MSDS Material Safety Data Sheet If the cleaner is in concentrated form contact your cleaning chemical supplier to determine pH Only Alcoa s Warranty Center can authorize warranty claims and determine justified warranty returns Dura Bright and Dura Flange claims can only be authorized and determined by Alcoa s Warranty Center 4 Mounting Alcoa wheels with Tubeless Tires Recommendations for mounting tubeless tires 4 1 NOTIC
69. otal indi cator reading of 040 inches or less is acceptable 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 Section4 5 for recommendations and instructions for demounting tubeless 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 WARNING Cracked or damaged wheels may fail or come off the vehicle Wheels that fail or come off the vehicle while it is moving can cause serious injury or death WARNING Immediately and permanently remove cracked or damaged wheels from service Visually inspect wheels for cracks or damage Remove wheels from service with known or suspected damage Mounti Ng area Stud hole cracks are usually caused by improper torquing see Sections 5 8 and 6 2 excessive load ing or insufficient mounting flange support by the hub or brake drum Remove wheel from service 3 6 Shown below are stud hole cracks emanating from bolt hole to bolt hole Causes are undersized diameter of wheel support surface see specifications on next page support surface not flat incorrect attachment parts see Section 5 2 and insufficient torque see Sections 5 8 5 11 6 2 Remove wheel from service
70. pear elsewhere If you do not have copies of the Wheel Service Manual you may obtain copies free of charge from Alcoa Wheel Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 and on the web at www alcoawheels com WARNING Wheels that are not properly installed or maintained may not be safe Failure to follow proper wheel installation or maintenance practices may result in injury or WARNING death Follow the proper wheel installation and maintenance practices as contained in this Alcoa Wheel Service Manual For additional copies of the manual and other useful items listed below available free of charge or for the most recent updates contact Alcoa Wheel Products at 1 800 242 9898 or on the web at www alcoawheels com To obtain information on free training on proper installation and maintenance procedures contact Alcoa Wheel Products at 800 242 9898 or on the web at www alcoawheels com Important information available free from Alcoa Alcoa Wheel Service Manual Videos CD e Safe Wheel and Tire Changing Practices for Heavy Duty Trucks and Buses e Maintaining Your Edge Rim Flange Maintenance e Simple Facts about Hub Piloted Wheel System Maintenance e Disc Wheel Inspection CD published by the TIA Maintenance Charts Zipper Rupture Published by RMA e Tire Information Service Bulletin Published by RMA e Heavy amp Medium Truck amp Trailer Torque Specifications Published by WRIS e Demounting amp Moun
71. que refer to the chart below Torque Level Ft Lb Torque Level Ft Lb Lubricated Dry 11 16 16 300 400 7 8 14 350 400 M20 x 1 5 280 330 M22 x 1 5 450 500 Hub piloted using two piece flange nut Stud piloted double cap nut standard type 7 8 radius 3 4 16 450 500 1 1 8 16 450 500 Stud piloted double cap 15 16 12 nut heavy duty type 1 1 8 16 1 3 16 radius 1 5 16 12 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 Section 5 10 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 Sections 5 8 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 All torque wrenches air wrenches and any other tools should be calibrated periodically to ensure the proper torque is applied 37 Balance weights clip on 6 3 Owner in service identification 6 4 Valves 6 5 38 Balance weights for Alcoa wheels are available from your Alcoa Wheel Distributor With radial
72. r chemicals including mild acid washes that can safely be used ona 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 merchantable 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 ap
73. rojected 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 Severe rim Photo 9 Sharp edge flange wear removed STEP 4 These photographs show the process of removing the edge Using whatever tool is selected work the tool around the wheel s circumference removing only enough material to eliminate the sharp edge This should only be a small amount of metal Perform this work on both flanges if there is evidence of sharpness Regardless of the method which you choose the objective is to remove only 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 17 Rim fla nge 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 Weal co nti nued 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
74. roperly installed or maintained may not be safe Failure to follow proper wheel installation or maintenance practices may result in serious injury or death WARNING 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 Products at 1 800 242 9898 or on the web at www alcoawheels com 25 Wheel Cap n uts 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 causing serious injury or death WARNING 5 2 Never use cap nuts with chrome plated contact surfaces Use only recommended hardware on Alcoa aluminum wheels There are many types of nuts and studs in use and their design and specifications are not standard 26 NOTICE One piece flange nuts are not approved for use on any Alcoa wheel application ized 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 Sing
75. rsseerossesresssseesssseessseeees 27 5 4 Stud located ball seats are sph heriCal ss sssesseessscessesssessseessecsseessessseesnsessscoseceserescosseosscoseersscesscosseesseesssesseesseeesee 27 8 5 5 Single and wide base wheel stud located ball seat mounting essesessseessseessseessseessseessserssseesseeessseessseesss 27 5 6 Dualed wheels stud located ball seat Mounting ssseessseessseessserssseessseessseessserssseessserssseessseessseeosserssseesseersss 28 5 7 Dualed wheels steel inner aluminum outer stud located ball seat mounting sssssssssessssessseessssess 30 5 8 Tightening stud located ball seat cap nuts ses essseessserssseessseessseessserssseessseessseessseessseeosserssseeosserosseeosserssseesseeress 31 9 5 9 Single dualed and wide base wheels hub piloted mounting two piece flange NUS 33 5 10 Tightening hub piloted MOUNTING two piece flange NUTS cecessesssssessssecscsscsscsssssscseesssncsesseeseescsseneeseees 34 5 11 Incorrect ASSIS sec scsscszscsezesessestecsencescececcentatedsacceceebacecssuesosscescossscededestboscckeassenducissucdetdondsticazsteosetsdoscderdiebioecsaistaides 36 6 Proper Torque Wheel Identification and Valves ou essesssssssesesesessssesssesscsesessesescseesesesesseseecseeees 37 Gl Avoid aD Epa nan EE N EEEO NEO AE EEE ere 37 6 2 Keep wheel nuts tight esseessesesseeesseeessseesseerssseeoseersseeeoseeessseesseerosseeoseerosseeoseerssserosserossreosserosserosserosserosse
76. rssseroseeress 37 039 Pakne WEJM acoro an n A A 38 6 4 Owner in service identification s sesssssseesesssssseessssseseesssssseeeessssseereesssssterensssseeeressssseeerssseseeesrssseseeesssseereesssssreeees 38 Oa oe oeae E A R ee se ee rere 38 SR mmm TOMICA O ener ene eee ener re ero tie rrner ial eran a tae See eres eee 39 7 OSTA GANS sameina E E A EEA 40 7 1 OSHA SACI ING ass cetexatacecacesesncsbucesavsscatsegtexsasactesicscuacasetvesinceisvcseaactannssdeqamcauacerenst baa ap onan eg anense eran 40 8 Glossary of Common TEMMS wicispcssaseninnniasoninninawaisiandadnimiuiananinnrundiansiu 45 8 amp 1 Glossary of Common TEMIS cepini aa er vere ae renee eee eer ee eevee 45 8 6p ele Mager a ap f 9 ener ere ee ee eer ene a a ni Dan ee neon ye 47 SF OM VU SHON UN CS E EN E ses E N ea ose gaat desea eee 48 9 1 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 INCH sss sssesseesseesseesssesssesseeesseessessses 48 9 2 SSON ISLS MO Wl CON Scrinis e aa eia orea ana i N EEE E carn caa cedieu eee eto eateelanee 49 Safety Safe service practices are a matter of life and death 1 1 WARNING An inflated wheel and tire assembly contains enough air pressure to cause an explosive separation Unsafe handling or failure to follow approved mounting and demounting procedures can WARNING lead to serious injury or death Study understand and follow the procedures contained in this manual Safety is serious b
77. s the tire bead RIM That portion of the wheel which 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 kilo grams 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 the wheel outset measurement of the Alcoa wheel used If the doubled outset measurement is equal to or greater than the tire manufacturer s Q 2 recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel on pages 2 and 3 Both inse
78. se SEVERE SERVICE WHEELS 13 14 Rim flange wear 3 12 Rim Flange wear is not a warrantable issue Only Dura Flange wheels have a warranty on rim flange wear against sharp edges for the 24 month warranty period 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 Rim Flange Wear Gauge Instructions THESE GAUGES ARE TO BE USED FOR RIM FLANGE WEAR ONLY THEY ARE NOT A BEAD SEAT ANGLE OR DIAMETER TOOL Rim Acceptable Rim Acceptable Rim Gauge Alcoa P N 000700 Rim NOT Acceptable Rim Gauge Alcoa P N 000700 Rim Gauge Alcoa P N 000700 AS No daylight in Daylight in this Daylight in this this oe area indicates area indicates f j indicates acceptable rim acceptable rim Wheel rim SCENE Wheel rim Wheel rim 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 Products at 80
79. ss your documented fleet practices determine otherwise Loosen outer cap nuts on every other stud to check the torque on inner cap nuts then retorque outer cap nuts Repeat steps on remaining studs Check torque frequently from then on If nuts require frequent tightening studs break frequently or wheel nut seats are pounding out hardware and mounting prac tices should be reviewed Note whenever the outer cap nut is loosened ALWAYS retorque the inner cap nut before retorquing the outer cap nut Tightening stud located ball seat cap nuts continued Most U S manufacturers of highway trucks tractors and trailers which incorporate the hub piloted wheel mounting system require wheel studs and cap nuts with metric threads Most frequently these are M22x1 5 Single dualed and wide base wheels hub piloted mounting two piece flange nuts Generally the same diameter stud is used to mount either single or dualed wheels Studs on both sides of the vehicle are right hand threads thereby eliminating the need 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 36 inch 60mm minimum dualed wheels require 3 346 inch 85mm minimum and single wide base wheels require 2 36 inch 60mm Some states have laws which dictate full thread engagement or thread engagement past the nut body Make sure you know the laws
80. t and outset wheels are measured from the mounting surface of 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 Vehicle clearance l Tire Clearance l y Tire section width Bolt hole dia circle dia Center i Wheel outset Wheel same as offset Inset or half dual spacing a TE j l i Tire center line Tire center line 47 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 inch 9 1 48 Q Conversion Tables aE A 11 64 a 16 19 32 31 64 0 0756 0 0813 0 0468 0 0625 0 1719 0 1875 0 2031 W218 0 2344 0 2500 0 2060 0 2813 0 2568 0 91725 0 3261 03A 0 35e4 0 5000 Decimals Millimeters 0 2965 0 7938 01 1806 1 5875 ia Et 4 3656 Ti 0 104 offal 4 7625 5 15 Jaa 5 853 6 3300 G 7469 r 1435 r 40i Foor Baap AF 9 1281 10 3186 10 7156 I 1 1125 11 5094 11 9063 12 3031 12 7000 agad 41 64 21 52 43 64 11 16 4564 rete e AF 64 3 4 45o4 25 32 51 84 1316 5484 STA 5564 7 8 57 G4 29 52 5S 64 S16 61 84 Je EJ54 0 6094 0 6250 0 6406 0 6563 0 6719 0 6575 0 7031 U7 188 0 7344 0 7500 0 7556 0 7613 0 7369 0 8125 0 6281 0 8438 0 8554 Decimals WMillimeters 13 0965 13 4938 13 2806 14 2875 14 6844 15
81. tening studs break frequently or wheel bolt holes are pounding out hardware and mounting practices should be reviewed Six Stud 1 Z D a Ei 2 y J Eight Stud O 36 o8 gO O4 one 2 Ten Stud 35 Incorrect assemblies 5 11 WARNING Use of two piece flange nuts on ball seat wheels ball seat cap nuts on hub piloted wheels or single piece flange nuts in place of 2 piece flange nuts is dangerous Using the wrong wheel nuts can cause loss of torque broken studs and cracked wheels conditions which can lead to serious injury or death WARNING Use only hardware designed specifically for each wheel type See Section 5 2 pg 26 for proper hardware assemblies The following are examples of incorrect wheel assemblies 36 Stud located ball seat aluminum wheel Two piece flange nut Insufficient contact area Do not use two piece flange nuts with stud located ball seat wheels Hub piloted Alcoa aluminum wheel Ball seat cap nut Insufficient contact area Incorrect use of ball seat cap nut on hub piloted system Do not use ball seat cap nuts with hub piloted wheels 1 ieee eg Little if any contact area No positional location Incorrect use of flange nut positioned on Alcoa ball seat wheel Do not use any flange nut on Alcoa aluminum ball seat wheels Proper Torque Wheel Identification and Valves Avoid abuse Abuse can shorten the life of a wheel Lack of care in changing a
82. ting Procedures for Truck Bus Tires Published by RMA e Multipiece Rim Matching Chart Published by OSHA e Mounting Demounting Instructions for Alcoa Aluminum 19 5 RW Published by Alcoa Wheel Products e Wheels and Steel Disc 19 5 Wheels Published by Alcoa Wheel Products Alcoa Rim Flange Safety Material e Maintaining Alcoa Aluminum Wheels Rim Flange Wear Instructions e Rim Flange Wear Gauge Technical Bulletins available on Alcoa web at www alcoawheels com e Welding Rim Flange or otherwise heating Alcoa Aluminum Wheels e Altering Alcoa Wheels from original design and use of adaptor plates e Tire Balancers Sealants e Wheel balancing weights e Mounting demounting tires on Alcoa 22 5 non symmetrical wide base wheels e Rim Flange Wear Table of Contents How to use X Section Number Page Number X this manual E E EN E E ENEA S str 2 oe 2 Wheel Specifications atsscricccaseteesersnassian ena snasameanatiinnsareniemnnaunmumseneioniaits 3 2 This manual is written in a style eee ee 3 Inspection and Maintenance s esseessessssssessscsseeseessceseesseessesseossesseesscoseesscoseesseoseesseoseessceseesseoseesseossessess 6 2 3 1 Inspect thoroughly and frequently ssesseeesssesseceesssssseoeosssssecorssssseeosossseseeossssseecosssssereeosssssrorossssserorssseserososssesseesss 6 Throughout the manual you 3 2 WheelakterdtiOiissisienisie ioiei aiaa ou costs easascecsasccs ened ceas aoa taustoteocesa enna cubctea ni tasted 6 w
83. tire heavy pounding 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 no cir 6 1 cumstances exceed cold inflation pressures listed in Section 2 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 tig ht Wheel cap nuts must be kept tight see Section 5 8 When checking the cap nuts on 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 proce dure with the rest of the nuts Check all cap nuts for proper torque after the first use or any removal 6 2 Inspect wheels and check wheel nuts during service stops see Section 3 Dirt streaks from cap nuts may indicate looseness 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 For proper nut tor
84. tire pressures listed in Section 2 Specifications of this manual see page 3 12 When inflating a tire always use a clip on air chuck or threaded straight chuck and a remote valve with pressure gauge Recommendations for i WARNING Never use a volatile or flammable material such as ether or gasoline as an pe nti ng tu beless aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build tires up in the tire and may result in an explosion co ntin ued WARNING 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 Only use approved mechanical or pneumatic bead seating devices WARNING 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 WARNING Mounting tubeless tires 4 2 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your Position wheel on machine Lubricate wheel entire Insert curved end of tool between bead and wheel particular machine before air chamber surface and tire bead using approved flange with tool stop against flange In circular attempting to mount lubricant Tire beads should be
85. ts 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 require ments of paragraph d 3 i of this section 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 allow the employee to stand outside the trajectory Current charts or rim manuals containing instructions for the type of wheels being serviced shall be available in the service area 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 2 Multi piece wheel components shall not be interchanged except as provided in the charts or in the applicable rim manual 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 corro
86. unction wheel bearing failure tire failure or other sources may weaken the metal and cause the wheel tire assembly to separate explosively Exploding wheel tire assembly can cause serious injury or death WARNING Immediately and permanently remove from service any wheel that has been exposed to excessive heat 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 18 Dura Flange maintenance 3 13 Maintenance against corrosion non Dura Bright surface treated wheels 3 14 Dura Bright surface treated wheels cleaning and maintenance 3 15 1 Dura Flange has a 24 month warranty against wear which creates a sharp edge that would require maintenance per section 3 12 2 Minor wear or minor pitting is not a warrantable condition 3 Edge re conditioning cannot be performed on Dura Flange wheels including those described in Section 3 12 The following information is for standard Alcoa forged aluminum wheels without the Dura Bright surface treatment See Section 3 15 for specific instructions on the care and cleaning of Alcoa Dura Bright surface treated wheels 1 Clean frequently with high pressure water from a hose The use of a mild detergent will speed the cleaning process Use no strong cleaners 2 When tires are removed the entire wheel must be cleaned and inspected See Secti
87. usiness All tire shops must know and follow OSHA work regulations no matter how small the shop Under U S federal law any individual handling tire wheel assemblies must be trained in OSHA regulations as mentioned in section 7 Safety is everybody s business Do not attempt to service any wheel assembly without proper training Proper equipment is important Be sure you have the recommended tools and equipment on hand and use them according to manufacturer s instructions Tubeless wheels and tires require the same equal care Even though tubeless assemblies have fewer parts than multi piece wheels they still require respect and proper handling Pay particular attention during crucial steps e Removal of tire and wheel assemblies from vehicles e Demounting tire from wheel e Wheel inspections e Inflation of tire e Handling and storing of inflated assembly Safety and service information is readily available Wheel tire and service equipment manufacturers offer service manuals and other training materials Stay up to date on proper procedures and keep current instructional materials handy in the shop Study safety and service information and use it on the job Sfaiisiics show thal in most indveteies af worst only one In 1000 s rfous aecidents results in a fatality Bui when fhe accident involves tires and wheels sfafisiically one in every 10 serious accidents is 2 fatality Thats 100 frmes i i ol J i T A pei more
88. 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 After January 2009 the new Alcoa Logo may not show 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 as shown in picture to the left or discoloration of the wheel as shown in pic ture to the right Inspect all axle end components for signs of exposure to excessive heat Pay particular attention to brake drums or discs Disc Mate wheel liners and tire beads If these components show signs of over heating the entire assembly including the wheel should be replaced Charred Rubber Charred Heat Indicator Drop Center 2009 and after Wheels manfactured starting in January 2009 will have a 1 inch clear round heat indicator located next to the roll stamp on the inside shown on the left and right along with the same 1 inch clear round heat indicator located on the tire side drop well as shown in the photo above Charred Heat Indicator If either of these round labels show signs of blistering Charred Heat Indicator 2009 and after charred blackened or cracked look this may indicate 2009 and after that the wheel has been exposed to excessive heat THE TIRE DISCOLORATION TO THE WHEEL AND OR BRAKE DRUM AND ANY BURNT OR CHARRED LABELS Dimension Open s
89. which you operate and comply 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 causing serious injury WARNING or death Lubricants must be completely removed from the cap nut seats and contact surfaces if applied accidentally 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 serious injury or WARNING death Check all parts including 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 31 Tightening stud Stud located ball seat mounting system located ball seat capn uts conti nued It is recommended to torque to between 450 and 500 foot pounds If lubricated with SAE 30W oil torque should be between 350 and 400 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

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