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2015 Alcoa Wheel Service Manual

1. 4 Clean the wheel disc face and the tire bead seat areas Be sure the wheel is dry before applying tire lubricant 5 Identify the short side of the drop center well Single piece tubeless rims and wheels must be mounted from the short side of the drop center well Aluminum wheels typically have symmetrical drop centers so tires can be mounted from either side however on certain aluminum wheels the short side of the drop center well is located on the disc side See Figure 4 2 Mount Short Side 21 Mounting tubeless tires NOTICE Not all tire changing machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tires NOTICE Do not exceed inflation pressure printed on wheel NOTICE When match mounting tires to Alcoa Aluminum Wheels refer to TMC RP 243 22 oE Figure 4 5 S a 6 Generously lubricate wheel rim flanges drop well and tire beads using non water based lubricant A non water based commercial bead lubricant should be used since water can cause corrosion However thin vegetable oil soap solutions with a water base are approved Tire beads should be mounted over the rim flange closest to the wheel well Push bead over flange as far as possible Never lubricate the rim or tire bead with a flammable solution This can lead to an explosion during tire inflation 7 Push the tire bead onto the
2. ALCOA WHEEL SERVICE MANUAL AUGUST 2015 SUPERSEDES JANUARY 2012 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 HEAVY amp MEDIUM DUTY TRUCK TRAILER BUS MOTOR HOME ALCOA LIMITED WARRANTY FOR MEDIUM DUTY TRUCKS HEAVY DUTY TRUCKS TRUCK TRAILERS BUSES RV and MOTORHOME WHEELS This limited warranty applies to new Alcoa forged aluminum medium duty and heavy duty trucks truck trailers bus RV or motorhome wheels Wheels and the surface or rim flange treatments applied to the Wheels Transit Wheels means Wheels used on transit vehicles such as buses and vans whose primary purpose is to transport people Alcoa warrants to the original purchaser who purchased a Wheel from Alcoa or Alcoa s authorized distributor that the Wheel is free from defects in material and workmanship for the applicable time period set forth below a Except as stated in b of this section Wheels are warranted for 60 months from the date of manufacture as shown on the Wheel b Transit Wheels and RV and motorhome Wheels are warranted
3. E Figure 3 T Before installing the valve apply a thin coat of non water based tire lubricant on the shaft and base of the valve stem where the O ring or grommet is located Do not use any other lubricants that are water based or contain metals Alcoa recommends valve stem torque 9 to 11 ft lbs 12 to 15 Nm Refer to OEM Specifications for TPMS valves Figure 3 22 Valve Extensions Alcoa distributors offer different valve extensions A quality extension of 150 mm 6 inches will enable tire pressure checks and adjustment of the inner tire of a regular dual fitment A valve stem stabilizer must be used if metal valve extensions are used The mass of metal valve extensions and rotation may cause forces that can lead to cracks in the valve hole area of the wheel or the valve stem Only use plastic valve extensions obtained from your authorized Alcoa Wheel Distributor 12 Identification Since 1977 all Alcoa aluminum disc wheels have been identified with a stamping that shows the wheel load rating maximum inflation pressure date of manufacture part number wheel description and DOT marking designation See Chart 3 3 and Figure 3 23 3 1 2 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 Alcoa wheel identification
4. Alcoa aluminum wheels should be tested for radial run out only at the bead seat surface A total indicator reading of 030 inches or less is acceptable j li 7 i in ai i a Figure 3 10 Inspect tire mounting according to instructions Tire wear can also be caused by improperly seated tires Inspect the tire for proper seating on the wheel if the tire beads are not seated properly Remove the wheel from the vehicle deflate and break the bead seats see Section 2 for recommendations and instructions for demounting tubeless tires Adequately lubricate the tire wheel bead seats and properly re seat the tire beads Reinflate the tire in a restraining device Refer to OSHA rule 1910 177 paragraph b See Section 6 WARNING Cracked or damaged wheels may fail and come off the vehicle Wheels that fail or come off the vehicle while it is moving can WARNING Cause serious injury or death 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 Reference Sections 3 7 thru 3 10 Mou nting area Bolt hole cracks are usually caused by improper torquing see Section 5 5 excessive loading or insufficient mounting flange support by the hub or brake drum Remove wheel from service and scrap Figures 3 11and 3 12 are cracks starting from the bolt hole Causes are undersized 3 diameter of
5. M SERIES DATA SHEETS ON WWW ALCOAWHEELS COM How to Measure Stud Standout 0 3 Hub Piloted Mounting System single Dual and Wide Base Wheels Mounting Two Piece Flange Nuts NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating fo 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 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 shoulder First full thread Stud Standout onir surface 7 z gt First full thread Stud Standout aa ounting surface Most U S manufacturers of highway trucks tractors and trailers equipped with the hub piloted wheel mounting system requires whe
6. months from the date of manufacture as shown on the Wheel If the Dura Flange rim flange treatment or Dura Bright surface treatment fail in normal use or service see the qualifications section below to meet the foregoing warranties on any Wheel Alcoa agrees without charge to replace the Wheel Qualifications Alcoa does not warrant and will not repair or replace or make adjustment with respect to any Wheel or surface or rim flange treatment on such Wheel that has been subjected to misuse or abuse including any of the following a Using a tire which is oversized according to standards recommended by the Tire and Rim Association Inc or other recognized tire and rim agencies such as ETRTO Europe b Loading the Wheel beyond the applicable maximum Wheel load as specified by Alcoa c Inflating tires 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 or abnormal or severe operating conditions including without limitation tire fires brake fires severe brake system drags or seizures or running with a flat tire f Failure to follow maintenance instructions or warnings set forth in the Alcoa Wheel Service Manual Service Manual Alcoa Technical Bulletins or other Alcoa literature Recommended maintenance includes without limitation using proper torque periodic cleanin
7. rim as far as possible Using the curved end of the tire iron with the stop resting on the rim flange take small bites to work the remaining section of the bead onto the rim wheel Start the second tire bead into the well holding it in position with foot or self locking pliers clamped to the rim of the flange Insert the curved end of the tire iron with the stop towards the rim and push the iron outwards to work the bead over the flange 8 Take small bites repeat the operation progressively around the rim Keep the tire bead in the well with your foot or with self locking pliers Continue until the second tire bead is full mounted over the flange Inflating Tire Wheel Assembly 4 2 l WARNING Never use a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel The use of these materials lead to an uncontrolled pressure build up in the tire and may result in an explosion with damage to the wheel and cause WARNING personal injury Explosive separation of the tire from the wheel can occur while seating beads in this manner while adding pressure 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 WARNING A pressurized tire wheel assembly can explode and separate violently This violent separation can cause serious injury or death WARNING Always contain the tire wheel a
8. 3 14 UNACCEPTABLE UNACCEPTABLE UNACCEPTABLE For hub piloted wheels visible For hub piloted wheels For stud piloted wheels a thread marks on the inside a wallowed out stud hole damaged ball seat contact area of the stud holes indicate the indicates the wheel ran loose indicates the wheel ran loose wheel ran loose Disc area Inspect both sides of disc area for hand hole cracks Remove damaged wheels from service and scrap 3 9 Hand Hole crack Hand Hole to Nave Exceeding wheel load capacity or damage to the Hand Hole can lead to cracks in the disc area Remove wheel from service and scrap Figure 3 16 Rim Area Drop Center Check the entire rim area for nicks gouges and cracks Loss of air may be caused by cracks in areas throughout the drop Valve Hole and Bead Seat center around the valve hole and in the bead seat area Remove the damaged wheel from service and scrap 3 10 Drop Center crack Drop center cracks are normally caused by exceeding load or inflation capacity or corrosion from excessive air line moisture or improper tire mounting lubricants Alcoa recommends Severe Service wheels if the issue is overload or significant travel on unimproved roads Please see Alcoa Wheels Product Spec Guide for part numbers and wheel descriptions of the Severe Service wheels Permanently remove damaged wheel from service and 3 scrap Valve Hole crack Valve hole cracks are normally caused by exceeding load
9. 4 3 Rim Width to Tire late Mil On cuscernaincninncmint reaaesinatoie moni minapnaamnnasauauawsion 25 4 4 Balance W Clas evens cao tencncsanenternereusncacutenswres es caneroesvaneeauiuecesseesa ranaveanenssantoneanaaved 26 SM VN I NSAR ects ashe tim wc uc N aaa eee se a ecu ano see eset 27 5 1 Recommendations for proper installation of WheeIS ccccecceeeeeeceeeeeeeeeeeens 27 8 o Wheel NULS eee eee eee ne ee ee ee eee eee ee ee eee ee 28 5 3 How to Measure Stud Standout ccccccecccescseeeeeeeeeeeeeeeeeeeeeseeeseeseaeeeeseeeeeeeeas 29 5 4 Hub Piloted Mounting System Single dual and wide base wheels two piece NUNC TS crests nag A E cases a seaceoesexedseemneces cecds N 29 5 5 Tightening Hub Piloted Two Piece Flange Nuts ccccseeceeeeeeeeeeeeeeeeeeeeees 30 5 6 Alcoa Mounting FOO Wa cccntetswionesiaetorcessvicere sey niseerd sasaat 32 5 7 Keep wheel Hub Piloted Nuts Tight c cccccccsseseessssesseesessessesseseesssseeenesenens 33 5 8 Stud Piloted Mounting System Single and Widebase cccccessseeeeeeeeeeeees 33 5 9 Stud Piloted Mounting System Dual Wheels ccccceeeceeeeseeeeeeeeeseeeaaeeeees 35 5 10 Stud Piloted Mounting System Steel Inner Aluminum Outer Dual Wheels 35 5 11 Tightening Stud Piloted Ball Seat Cap Nuts ce cceeeceesseeeeeesseeeeeeeeaeeeees 37 5 12 Keep Stud Piloted Wheel Nuts Tight ccccccccecsseeeeeeeeeeeeeeseeeeeeseeeeeeese
10. Outer Cap Nut Hub gt Correct single mounting with 3 4 inch stud located ball seat mount 1 8 inch minimum stud standout Alcoa Aluminum Wide Base Wheel Orum d Outer Cap Nut J P N 5995R or L Correct wide base wheel mounting with 3 4 inch stud located ball seat mount 1 8 inch hk minimum stud standout Stud Piloted Mounting System Dual Wheels 0 9 NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating fo 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 Stud Piloted Mounting System Steel Inner Aluminum Outer Dual Wheels 0 10 Rear wheels are most frequently mounted as duals Each inner aluminum wheel is attached by 10 inner cap nuts Alcoa recommends use of inner cap nuts 5978R 5978L or 5988R 5988L Cap nuts
11. an approved surface protectant and lubricant each time the tire is removed see Section 4 1 3 To maintain the original appearance of Alcoa wheels the following procedures are recommended a After installing new wheels and prior to operating the 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 Apply polish to the cleaned surface e Clean Alcoa truck wheels as frequently as required to maintain their appearance 19 Dura Brig ht Dura Bright Wheels are the easy maintenance way to bright shiny wheels that stay that way when properly maintained Dura Bright wheels clean easily with mild soap surface treated and water and eliminate the need for harsh cleaning products wheels cleaning and maintenance _ Dura Bright Wheels are maintained best with an off the shelf car wash or a mild near neutral detergent that has a pH between 5 9 or a cleaning solution that has been diluted to a pH between 5 9 3 1 Do not use strong acid or strong alkaline cleaning products on Dura Bright Wheels Step 1 Before cleaning allow the wheels to cool down to a temperature below 95 F 85 Step 4 Clean the wheel e Apply soap or detergent generously on wheel surface with either a spray applicator a clean soft bristled brush or soft sponge Abrasive tools and sco
12. for 120 months from the date of manufacture as shown on the Wheel Alcoa agrees without charge to repair or replace a Wheel that fails in normal use or service see the qualifications section below because of defects in material and workmanship Alcoa warrants to the original purchaser and the end user of the Wheels from Alcoa or its authorized distributor the Dura Flange rim flange treatment against wear which creates a sharp edge that would require maintenance for 24 months from the date of manufacture as shown on the Wheel Alcoa warrants to the original purchaser and the end user of the Wheels from Alcoa or its authorized distributor the Dura Bright surface treatment against i 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 ii blistering due to loss of adhesion of the surface treatment and iii lift off of the surface treatment due to physical damage nicks scratches gouges The foregoing Dura Bright surface treatment warranty is for the applicable period of time set forth below a Except as stated in b of this section Dura Bright surface treatment on Wheels is warranted for 60 months from the date of manufacture as shown on the Wheel b Dura Bright surface treatment for RV and motorhome Wheels is warranted for 120
13. on all wheels Wheels must be taken out of service if this identification is not legible WARNING Welding brazing or otherwise heating 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 injuries or death Never attempt to weld braze or heat any surface of an Alcoa aluminum wheel Heat damage 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 Exploding tire wheel assemblies can cause serious injury or death WARNING Immediately and permanently remove from service any wheel that has been exposed to excessive heat Wheels must be inspected for exposure to excessive heat before being returned to service A wheel that has been subjected to excessive heat may appear charred or burned or may appear to be in good condition 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 inspect the labels tire bead brake drum and high temperature nylon spacer for evidence of charring melting blistering or burning Any wheel run with a flat tire longer than the time necessary to immediately
14. pull off the road should be checked for excessive heat damage A wheel may discolor from excessive heat It can appear a dull grayish color and will not polish to a bright finish as an undamaged Alcoa wheel would k k i Charred sticker prior to 2009 Discoloration of Wheel with charred rubber Figure 3 3 Charred high temperature nylon spacer Starting in January 2009 the new Alcoa ee may not show heat damage Inspect all axle end components for signs of exposure to excessive heat Check the brake drums Disc Pads on discs high temperature nylon spacer and tire beads for heat damage If these components show signs of over heating the entire assembly including the wheel should be replaced 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 Figure 3 1 or discoloration as shown in Figure 3 4 Wheels manufactured starting in January 2009 will have a 1 inch clear round heat indicator located next to the roll stamp on the inside shown in Figures 3 4 3 5 along with the same 1 inch clear round heat indicator located on the tire side drop well as shown in Figure 3 6 If either of these round labels show signs of blistering or have a charred blackened or cracked appearance this may indicate the wheel has been exposed to excessive heat Figure 3 5 py Figure 3 6 Charred Heat Indicator Charred Heat Indicator Charred
15. recommended by Alcoa are compatible with Alcoa wheels Hardware of equal dimensions and strength may be used 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 Most states and provinces have their own standards for fastener engagement Most of these consist of at least 1 to 2 threads 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 Dual wheels should be put on the vehicles with the valve stems 180 apart in order to access the inner wheel valve stem Alcoa Aluminum Wheels f Outer Cap Nut P N 5996R or L Inner Cap Nut P N 5978R or L or P N 5988R or L 1 31 to 1 44 stud standout Correct mounting for dual aluminum stud piloted ball seat mount wheels before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage WARNING and detach from the vehicle which can cause serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 5978R or L 5988R or L or their equival
16. stud length is required 29 Two Piece sleeved Flange Nuts Tightening Hub Piloted Two Piece Flange Nuts 0 9 30 Sleeved flange nuts serve two purposes 1 May increase thread engagement 2 Reduce stud hole misalignment When using sleeved flange nuts e There are two kinds of sleeved flange nuts single mount and dual mount as shown One that aligns outer wheels only One that goes into the inner dual wheel Either sleeve cap nut is acceptable for Alcoa wheels All threads in the sleeve do not need to be engaged with the wheel bolt for proper installation Always use wheels and hardware that are designed for use with sleeved flange nuts Single mounted wheels require Dual mounted wheels require sleeved flange nuts with a short sleeved flange nuts with a sleeve long sleeve Two piece flange nuts must be properly tightened Refer to the chart below for industry standard torque of two piece flange nuts Nut Thread Torque Level Ft Lb Lubricated 11 16 16 300 400 7 8 14 350 400 _M20x 1 5 280 330 M22 x 1 5 450 500 Chart 5 1 Source TMC Refer to truck manufacturer guidelines for specific recommendations Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Nuts should be tightened in recommended criss cross sequences and fatigue studs or lose nuts Overtorquing can yield studs causing th
17. the end of the cap nut Figure 5 5 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 dimensions and condition may change over time due Five Stud to environmental conditions i 1 multiple re installations improper torquing and other 6 O _3 factors Consult your hub and stud manufacturer 2 Six Stud for maintenance 8 O T and replacement recommendations 49 O Og 2 Eight Stud Ten Stud 38 Tightening Stud Piloted Ball Seat Cap Nuts continued Keep Stud Piloted Wheel Nuts Tight 0 12 NOTE After a wheel assembly has been installed and torqued check the fastener torque again within 5 100 miles of operation and retighten the nuts if necessary the recommended torque using the proper sequence Individual fleet conditions will influence the mileage interval Refer to TMC RP 237 Retorquing Guidelines for Disc Wheels which establishes guidelines for determining the fleet torque check interval To check and retorque an inner nut it is necessary to loosened the outer nut first and then tighten the inner nut Finally the outer nuts must be retightened to the proper level Cap nuts must be kept tight and studs and nuts should be checked frequently Nuts should be properly
18. tire sidewall such as in Figure 4 7 Listen for any popping or snapping sounds JE i If ANY of these conditions are present STOP DO NOT approach tire Before removing from restraining device completely deflate tire remotely Remove clip on air chuck Mark tire as damaged and potential zipper rupture Render tire unservicable non repairable and scrap Refer to RMA or TMC 232 Figure 4 7 8 Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures roll stamped on the wheel If none of these zipper conditions are present remove clip on air chuck install the valve core and adjust the inflation pressure to the recommended operating inflation pressure 9 Before removing the tire wheel assembly from the restraining device always visually inspect for proper amp concentric seating of the beads and all parts ORE en EEE 10 Conduct a final inspection Heavy duty O O truck tires have a guide rib or mounting ring molded into the sidewall next to the tire bead When the tire is inflated this molded ring should be evenly spaced from the rim flange all the way around the wheel Check the position of the mounting ring before removing the assembly from the inflation cage If the ring and wheel are not concentric deflate the assembly in the cage re lube and remount the tire Check for air leaks Install a suitable valve
19. wheel assemblies must be trained in OSHA regulations as mentioned in section 6 prior to servicing handling truck tire and wheel assembly 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 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 tires from wheels e Wheel inspections e Inflation of tires e Handling and storing of inflated tire and wheel assemblies 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 Completely deflate any tire by removing the valve core before removing the tire wheel assembly from the axle if there is known or suspected damage to the tire or wheel or if the tire has been operated at 80 or less of its recommended operating pressure Demount inspect and match all tire and rim parts before re inflating in a restraining device NEVER use star
20. without further work to the rim flange T CAUTION Do not run unprotected hands or fingers across worn rim flange areas of used wheels CAUTION Worn rim flange areas are sharp and can cut hands or fingers Always wear gloves when handling used wheels or when testing for edge sharpness 15 Rim flange wear continued 16 metal filings and sparks Many power tools have edges that are sharp or may become hot during use Some power tools produce excessive CAUTION noise when used Metal filings can be sharp and when projected by the action of power tools can cause serious skin or eye damage Excessive noise from power tools can harm hearing Sharp edges can produce cuts and hot surfaces can cause burns 1 CAUTION Removing sharp edges with hand or power tools produces Always wear appropriate safety gear such as protective eye wear gloves protective clothing and hearing protection when using hand or power tools 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 below File A file can be used very effectively to remove the edge Figure 3 30 Removing sharp edge by hand with a metal file Air or electric power sander Air or Electric Powered Sander This tool provides a very quick and effective method of removing the sharpedge Technicians should use care to keep a uniform edge when using t
21. Heat Indicator 2009 and after 2009 and after 2009 and after IF ANY OF THE ABOVE CONDITIONS ARE SEEN REMOVE THE WHEEL FROM SERVICE IMMEDIATELY AND PERFORM DIMENSIONAL CHECKS PER SECTION 3 4 THIS INCLUDES ANY HEAT DAMAGE TO THE TIRE DISCOLORATION TO THE WHEEL AND OR BRAKE DRUM AND ANY BURNT OR CHARRED LABELS Dimensional Dimension Heat Damage and other checks checks OO 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 Exploding tire wheel assembly can cause serious injury or death WARNING Immediately and permanently remove from service any wheel that has been exposed to high pressure tir wheel separation 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 have an explosive separation of the tire WARNING and rim causing serious injury or death Any wheel that has been in service must be inspected prior to ee Follow the procedures for dimensional checks described in this section during each wheel inspection Best Inspection Measure the circumference of the bead seat on the open side Figure 3 7 Method af Ba with a ball tape All wheels should be inspected prior to mounting i
22. The circumference of the bead seat on the open side of the wheel should Figure 3 7 shows B be checked at each tire change The open side is the side opposite the the TRA Ball disc face In the case of center flange wide base wheels or wheels with Tape iis eS insets less than 3 inches both rim flanges should be checked If the cir F cumference of the bead 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 www us tra org For instructions on the proper use of ball tape reference the current Tire and Rim Association yearbook 2nd Best Unacceptable Inspection i If a ball tape is unavailable Photo above shows an undersized wheel that you can easily place a credit card approximately 030 in or 76mm between the square and the wheel THIS INSPECTION TECHNIQUE ONLY APPLIES TO DUAL OR DISC FACED WHEELS 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 is contacting both bead seats The short leg should t
23. When the tire has been driven underinflated at 80 or less of its recommended pressure or ii When there is obvious or suspected damage to the tire or wheel components 3 Rubber lubricant shall be applied to bead and rim mating surfaces during assembly of the wheel and inflation of the tire unless the tire or wheel manufacturer recommends against it 4 If a tire on a vehicle is underinflated but has more than 80 of the recommended pressure the tire may be inflated while the rim wheel is on the vehicle provided remote control inflation equipment is used and no employees remain in the trajectory during inflation 5 Tires shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead 6 Whenever a rim wheel is in a restraining device the employee shall not rest or lean any part of his body or equipment on or against the restraining device 43 44 OSHA Regulations continued 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 w
24. _ or inflation capacity rough finish on the valve hole surface over torquing of the valve nut or corrosion Permanently remove damaged wheel from service and scrap LA I he Figure 3 18 fe ag ot ee oe ee F Bead Seat crack Bead seat cracks may be caused by exceeding load or inflation capacity improper manufacturing tire tool damage damage by hammer impact damage or rim is too narrow for the tire Immediately and permanently remove damaged wheel from service and scrap Figure 3 19 11 Valves It is recommended that valve stems be replaced at every tire change Replacement valves may be obtained from your authorized Alcoa Wheel Distributor Metal valve stem caps are required per DOT instead of plastic DO NOT USE RUBBER GROMMETS OR O RINGS DO NOT USE UNPLATED BRASS VALVES 3 1 1 When replacing valve stems it is recommended that the threads and O ring or grommet be lubricated with a non water based tire lubricant Use silicone viton or EPDM grommets Clean the valve seat and valve hole thoroughly after removal of the valve Remove all dirt grease and oxidation Make sure all contact areas are dry Check for sharp edges or burrs Remove with fine emery cloth if found Figure 3 20 Apply a layer of non water based tire lubricant in the valve hole and the outer and inner side wheel surface up to 1 inch or 2 centimeters in diameter around the valve hole F ag i i E ae gi i 7
25. auge 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 NOTE Always follow safe mounting procedures and inflation procedures using OSHA approved tire restraining device See the Alcoa Wheel Service Manual or OSHA safety wall charts and procedures 17 Corrosion Certain service environments can lead to corrosion Some of the more common corrosive materials are salt magnesium chloride and calcium chloride compounds used for snow removal and highly alkaline materials If the inflation media to fill the tire is not dry the areas of the wheel under the tire can corrode severely 3 14 CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced CAUTION he under the Alcoa limited warranty Severely corroded wheels are unsuitable for service Bead seat and valve stem corrosion often are caused by trapped moisture Mild corrosion as shown in Figure 3 35 should be removed until thoroughly cleaned Remove any severely corroded wheel from service immediately and scrap Figure 3 36 Drop Center Corrosion Valve Hole Corrosion The Alcoa Hub Bore Gauge P N 000701 is made for wheels used in the transit industry The corrosion on the hub bore center hole a
26. by inflating on a mismatched rim wheel the tire bead will break with explosive force and may result in serious injury or death ALWAYS comply with the procedures in the tire wheel manufacturer s catalogs instruction manuals or other industry and government instructional materials Use a non flammable vegetable or soap based rubber lubricant on the beads and rim surfaces Lubricate tire wheel beads to make tire demounting and mounting easier and seat the beads properly Use the proper tools to demount or mount tires and rims refer to Typical Tire Service Tools NEVER strike the tire wheel assembly with a steel duck bill hammer to unseat the beads and do not strike the head of the hammer with another hard faced hammer use a rubber mallet or plastic dead blow hammer Slide impact bead unseating tools are the preferred tools for unseating beads on tubeless tires NEVER reinflate any tire that has been operated in a run flat or underinflated condition i e operated at 80 or less of recommended operating pressure Demount inspect and match all tire and rim components before reinflating in a restraining device with the valve core removed If an emergency puncture repair inflater was used on a tubeless tire deflate and reinflate the tire several times to remove potentially explosive propellant before servicing the tire Statistics show that in most industries at worst only one in 1000 serious accidents results in a fatality but wh
27. cap 24 Rim Width to Tire Matching 4 3 Rim to tire matching chart for medium and heavy trucks a 1 8R17 5 5 25 6 00 9R17 5 6 00 6 75 10R17 5 6 75 7 50 MIE DEA an ire size ITOFr j E E Fi a 5 25 6 00 6 75 6 75 7 50 7 50 8 25 445 65R13 5 pi na 8R22 5 5 25 6 00 6 75 __ 9R22 5 6 00 6 75 7 50 T 235 80R22 5 6 75 7 50 4 25 245 75R22 5 675 750 22 5 10R22 5 J 6 75 7 50 8 25 22 5 255 70R22 5 ___7 50 8 25 22 5 275 80R22 5 _7 50 8 25 22 5 11R225 7 50 8 25 _ 25 7 7 50 8 25 p 22 5 8 25 9 00 22 5 __ 825 900 _ 22 5 295 75R22 5 8 25 9 00 8 25 9 00 22 5 305 85R22 5 8 25 9 00 22 5 315 80R22 5 9 00 9 75 25 335 65R22 5 9 00 9 75 10 5 225 IBR225 a75 22 5 11 75 12 25 22 5 11 75 12 25 13 00 22 5 12 25 13 00 22 5 13 00 14 00 22 5 14 00 225 445 55R22 5 14 00 22 5 13 00 14 00 24 5 7 50 8 25 24 5 7 50 8 25 24 5 8 25 a5 12R24 5_ 8 25 9 00 Chart 4 1 Reference only Refer to tire manufacture documentation for tire fitment information Source 2015 TRA Yearbook and ETRTO 25 26 Balance weights 4 4 Alcoa wheels are fully machined and do not require balancing However the tire wheel combination may need to be balanced Internal balancing compounds are not recommended Use of coated balancing weights is recommended to avo
28. ce Manual STEP 2 After the tire is demounted verify that 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 Figures 3 25 and 3 26 SERVICEABLE NOT SERVICEABLE scrap wheel STEP 3 If the wheel is serviceable by the rim flange gauge examine the wheel flange edge for sharpness by using a rubber sharpness gauge These gauges are constructed with a section of tire or a suitable piece of rubber attached to a block of wood Figure 3 27 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 Figure 3 28 If the rubber is cut then follow the edge removal instructions below Fi 3 28 F ZA Figure 3 20 29 igure 3 z n 3 fo he If LP A rubber sharpness gauge or a suitable piece Run the sharpness indicator gauge along the of rubber attached to a block of wood wheel in the area of the wear to determine if the wear is sharp enough to cut or damage the rubber on the sharpness indicator If the flange cuts or appears close to being sharp enough to cut the rubber on the sharpness indicator gauge the edge can be removed by following the edge removal procedures on the following page If the rubber is not cut then the wheel can be returned to service
29. ct surfaces from marring High temperature nylon spacers can be placed between the contact surfaces of the Dura Bright wheels and the brake drum Single Alcoa Aluminum Wheel Outer Cap Nut Z 5996R or L Correct single mounting with 1 1 8 inch stud located ball seat mount 1 8 inch minimum stud standout 33 Stud Piloted Mounting System Single and Widebase 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 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 34 Alcoa Aluminum Wide Base Wheel Outer Cap Nut J P N 5996R or L Correct wide base wheel mounting with 1 1 8 inch stud located ball seat mount 1 8 inch minimum stud standout Single Alcoa Aluminum Wheel AG en ay
30. d in the Alcoa Wheel Service Manual For additional cop ies of the manual and other useful items available free of charge or for the most recent updates contact Alcoa Wheel Products at 800 242 9898 or on the web at www alcoawheels com The Alcoa Wheel Mounting Tools are designed to 1 Align wheel bolt holes 2 Seat brake drums that have 980 diameter bolt holes Will not seat brake drums that have bolt holes larger than 980 in diameter 3 Prevent thread damage to M22x1 5 studs Assembly Instructions 1 After properly installing the brake drum install 2 wheel mounting tools to seat The brake drum as indicated in figures below Do not torque the wheel mounting tools in excess of 400 foot pounds 2 Install the wheel on the hub aligning it with the wheel mounting tools 3 Install lug nuts according to recommended practice Section 5 5 4 Once flange nut pressure is sufficient to keep the wheel and drum assembly snug against the hub remove wheel mounting tools individually as needed to follow installation pattern 5 After all wheel mounting tools are removed torque flange nuts to required torque levels Section 5 5 32 Keep Wheel Nuts Tight Hub Piloted O Stud Piloted Mounting System Single and Widebase 0 8 Flange nuts must be kept tight the torque studs and nuts should be checked at regular service intervals Nuts and studs should be inspected at tire changes to ensure they are in
31. e Render tire immediately unservicable non repairable and scrap 5 Visually inspect tire rim wheel assemblies throughout the inflation process for improper seating When inflating a tire stay out of the trajectory See Trajectory WARNING in OSHA Regulations Section 6 Appendix A DO NOT stand or lean any part of your body against or reach over the OSHA compliant restraining device during inflation Place tire wheel assembly inside a OSHA compliant restraining device See Section 6 Refer to tire manufacturer s recommendation for proper tire pressure Using a clip on air chuck or a self locking straight chuck with remote valve and pressure gauge inflate the tire wheel assembly to proper pressure Be sure to stay out of the trajectory of potential exploding parts or air blasts 23 Inflating Tire 6 Continue to inflate until the beads are seated on the wheel Inspect both sides of the tire to be sure that the beads are evenly seated NEVER inflate beyond 40 psi to seat Wheel Assembly any tire beads continued If the beads are not seated at 40 psi STOP Completely deflate remove from the restraining device and demount the tire to determine the problem Reposition the tire on the rim relubricate and reinflate 7 fo j a 7 After the tire beads are seated continue to inflate the tire to its recommended inflation pressure IMPORTANT Look for distortions undulations or other irregularities in the
32. e 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 36 Drum 3 4 Stud Inner Steel Wheel Spacer y Alcoa Aluminum Wheel Outer Cap Nut P N 5996R or L w INN Inner Cap Nut P N 7896R or L 1 31 to 1 44 stud standout Correct dual mounting for steel inner aluminum outer stud piloted ball seat mount WARNING WARNING WARNING Incorrect inner cap nuts used with steel wheels can bottom out oe the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and detach from the vehicle which can lead to serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 7896R or L or its equivalent when mounting steel inner duals WARNING Inadequate wheel support surface can lead to stud hole to mare Vee fracture resulting in separation of the outer disc and rim from the vehicle rola of the wheel from the vehicle can cause serious injury or eath Alcoa aluminum wheels with 11 1 4 diameter bolt circle require a support surface at least 13 3 16 in diameter Check the outer support surface of the inner steel wheel for flatness and adequate diameter before installing the outer wheel When the wheels are serviced check the m
33. ed If the doubled outset measurement is equal to or greater than the tire 1 2 manufacturer s recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel in Alcoa s Wheel Product Spec Guide Both inset 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 a Dual Spacing ____ _ _ _ _ _ I I i Vehicle l i Tire Clearance i clearance F l Tire section width _ Bolt a circle dia i l m Wheel outset Wheel Inset o Backspace 7 Tire center line Tire center line J 48 O Conversion Tables Inch Fraction Decimal and an maP Chart Up to 1 inch 0 547 3 1 sez 0504 0 605 0686 45 64 0 703 23 32 0 719 a a 0 750 assa 0 766 1945 9 32 25 32 o731 1984 23 64 o3ss 913 ssvea osso 21 83 Cs 0875 22 23 Cisa oao i191 a 0500 1279 1 1 000 2540 49 Conversion Inches to Millimeters Factors Inches x 25 4 Millimeters 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
34. eeeeeeas 39 5 13 Incorrect assemblies erie ttereittereicnsenicien es sidcarnennieiadapeiadneeamitoaeere tein leeden 40 6 OSHA Regulations sccceccnnctusestessaseczceusGesneapenseeeasieseneceuedunwecsa eed extaneverareesswersseatexeecegnstcctesniecensd 41 EE e E E en E A EE E E E E A T 46 7 1 Glossary of Common TEINS cece ecicustceecensiniacceseiuetssetsceeoseedasdiedehasdccnertedeeetusniteeeiauad 46 7 2 Wheel MEASUrEMENL c ccccceecceseeceeeeceueecseeccuceccacecsacececeseeeeseeesueesueessensnaess 48 8 Conversi n laDl S isrener eE ee doses Sees eens Sania ese ese Re Eas 49 8 1 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 Inch 49 OZ COnveision FAC IONS eies e AA AE R 50 WARNING An inflated tire and wheel assembly contains enough air pressure to cause an explosive separation WARNING Unsafe handling or failure to follow approved mounting and demounting procedures can lead to serious injury or death Study understand and follow the procedures contained in this manual to ensure your safety TIRE AND RIM SERVICING CAN BE DANGEROUS AND MUST ONLY BE PERFORMED BY TRAINED PERSONNEL USING PROPER PROCEDURES AND TOOLS FAILURE TO READ AND COMPLY WITH ALL OF THESE PROCEDURES MAY RESULT IN SERIOUS INJURY OR DEATH TO YOU AND OTHERS Safety is serious business 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
35. el studs and flange nuts with metric threads Most frequently these are M22x1 5 Most states provinces have laws which dictate full thread engagement or thread engagement past the nut body Make sure you know the laws for the states provinces in which you operate and comply with them Note Some stud piloted ball seat wheels have the same number of holes and bolt circle diameter as hub piloted wheels Never mix hub piloted amp stud piloted wheels 5 Hubs designed for steel hub piloted wheels may not have enough pilot length to locate dual aluminum wheels Pay close attention to pilot length particularly when converting from steel to aluminum duals Measure the hub pilot tab length to make sure the hub properly centers the wheels The pilot tab length for sufficient centering must be 5 mm 0 20 or more for mounting single wheel and 1x disc thickness 5mm 0 20 for mounting dual wheels 33mm hex head 2 piece flange nut P N 39874 a S 33mm hex head 2 piece flange nut P N 39874 M22x1 5 Stud Hub When mounting painted steel inner dual wheels with outer aluminum wheels be cautious of excessive paint 3 5 mil build up and flaking on the inner steel wheel Excessive paint can reduce the clamping force and allow the wheels to become loose Typical assembly of hub piloted single and dual wheels use 33mm hex head two piece flanged nuts Part No 39874 If hex nuts with greater overall height are used more
36. em to fail Both under and overtorquing can lead to wheel detachment which WARNING can result in serious Tas pr deat Check all parts including wheels studs and flange nuts Check mounting taces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace pages parts Follow correct tightening sequences and torque levels WARNING Undertorqued flange nuts allow wheels to run loose Tig htening Before installing two piece flange nuts use 1 to 2 drops of motor oil to lightly lubri Hub Piloted cate the first two or three threads at the tip of each stud and the contact surfaces u Oled between the flange nut and the washer as illustrated below This will minimize corro Two Piece sion between the mating surfaces Lubrication is not necessary with new hardware Flange Nuts continued Lubricate here 1 2 drops Lubricate here 1 2 drops Prior to mounting hub piloted wheels coat the wheel hub bore Then push wheels onto the hub so that excess lube will scrape off and not be pushed between the mounting surfaces with a non water based lubricant to minimize corrosion and build up between the wheel and hub pilot Excessive corrosion build up between the wheel and hub pilots can make wheel removal difficult Do not lubricate the face of the wheel hub or brake drum Hub Pilot Hub Pilot Do NOT get lubricant Lubricate the wheel hub bore on the face of the hub hole as shown abo
37. en the accident involves tire and wheels statistically one in every 10 serious accidents is a fatality PES That is 100 times more often than in ES most other industries 1in 1000 1in10 TYPICAL INDUSTRY THE SERVICE INDUSTRY WARNING IF YOU DO NOT KNOW HOW TO USE TIRE SERVICING TOOLS STOP TIRE SERVICING MUST ONLY BE PERFORMED BY TRAINED PERSONNEL FAILURE TO FOLLOW PROPER PROCEDURES CAN RESULT IN SERIOUS INJURY OR DEATH ALWAYS wear adequate protective eyewear or face ALWAYS use soft faced hammers when driving tire irons shield protective footwear and ear protection while or assembling components servicing tires to avoid injury NEVER use a hammer with a loose or cracked handle lt NEVER use a tire tool for anything except demounting NEVER use a bent cracked chipped dented or and mounting tires mushroomed tool Keep tools clean and inspect them NEVER use an extension or cheater bar with tire frequently irons NEVER alter or apply heat to any tire service tool Typical Tire Service Tools metie or wheei manutaciurer a ia in T Rim Mallets Gip on ChuckAn Line e a Gaupe Use suficieni hose f Tubeless S lengit to maintain sate Tire Iran distance during latabien Set l Stay oat of the trajectory ALWAYS WEAA SAFETY GLASSES Source OSHA 3421 10N 2011 NOTICE For information on tube type wheels contact Alcoa at 800 242 9898 Option 1 Deflating and Demounting Tubeless Tr
38. ent when mounting dual aluminum wheels WARNING Incorrect inner cap nuts used with dual aluminum wheels can bottom out on the unthreaded portion of the stud On occasion Alcoa aluminum truck wheels are dualed with a steel inner wheel When this application occurs it is recommended that a high temperature nylon spacer to be used 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 before 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 dual wheel is critical to a safe assembly Alcoa recommends the use of inner cap nuts 7896R and L Grade 8 or equivalent for this purpose Stud Piloted Mounting System Steel Inner Aluminum Outer Dual Wheels continued 0 10 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 th
39. evice or barrier exhibit ing damage such as the following defects shall be immediately removed from service OSHA Regulations continued 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 its effectiveness iv Restraining devices or barriers removed from service shall not be returned to service until they are repaired and reinspected Restraining devices or barriers requiring structural repair such as component replacement or rewelding shall not be returned to service until they are certified by either the manufacturer or a Registered Professional Engineer as meeting the strength requirements of paragraph d 3 i of this section 4 The employer shall furnish and assure that an air line assembly consisting of the following components be used for inflating tires i A clip on chuck ii An in line valve with a pressure gauge or a presettable regulator and iii A sufficient length of hose between the clip on chuck and the in line valve if one is used to allow the employee to stand outside the trajectory 5 Current charts or rim manuals containing instructions for the type of wheels being serviced shall be available in the service area 6 The employer shall furnish and assure that only tools recommended in the rim manual
40. for Tubeless Truck and Bus Tires Demounting and Mounting Procedures for Tube Type Truck and Bus Tires and Multi piece Rim Matching Chart Interested parties can download and print both the manuals and posters from OSHA s Web site at http Awww osha gov publications and type tire chart in the search field However when used by the employer at a work site to provide information to employees the printed posters must be at a minimum 2 feet wide and 3 feet long SD TRAJECTORY Copies of the manual also are available from the Occupational Safety and Health Administration OSHA Office of Publications Room N 3101 U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 telephone 202 693 1888 or fax 202 693 2498 49 FR 4350 Feb 3 1984 as amended at 52 FR 36026 Sept 25 1987 53 FR 34737 Sept 8 1988 61 FR 9227 March 7 1996 76 FR 80739 Dec 27 2011 45 Glossary of Terms Glossary of Common Terms l 1 46 AIR CHAMBER The area in a mounted tire and rim assembly that contains the air BACKUP DIAMETER Hub attachment face diameter that mounts to the wheel BEAD SEAT The tire seating surface of the rim 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 A hole in a disc wheel for attachment fasteners BORE See HUB BORE DISC The center member
41. for the type of wheel being serviced are used to service rim wheels e Wheel component acceptability 1 Multi piece wheel components shall not be interchanged except as provided in the charts or in the 6 applicable rim manual 2 Multi piece wheel components and single piece wheels shall be inspected prior to assembly Any wheel or wheel component which is bent out of shape pitted from corrosion broken or cracked shall not be used and shall be marked or tagged unserviceable and removed from the service area Damaged or leaky valves shall be replaced 3 Rim flanges rim gutters rings bead seating surfaces and the bead areas of tires shall be free of any dirt surface rust scale or loose or flaked rubber build up prior to mounting and inflation 4 The size bead diameter and tire wheel widths and type of both the tire and the wheel shall be checked for compatibility prior to assembly of the rim wheel f Safe operating procedure multi piece rim wheels The employer shall establish a safe operating procedure for servicing multi piece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at least the following elements 1 Tires shall be completely deflated before demounting by removal of the valve core 2 Tires shall be completely deflated by removing the valve core before a rim wheel is removed from the axle in either of the following situations i
42. g polishing valve replacement periodic inspection for damage and loose lug nuts and rim flange wear inspections and procedures g Nicks scratches and other surface blemishes resulting from neglect road salt harsh conditions improper maintenance cleaning road debris curbing accident or operation h Rim flange wear unless the rim flange has been treated with Dura Flange Using a spacer or adaptor of any kind j Damaging the surface during tire mounting and installation due to the use of improper tools or balancing with wheel weights or k Damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline 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 CONSEQUENTIAL INDIRECT OR SPECIAL DAMAGES FOR ANY BREACH OF WARRANTY ALCOA S LIABILITY AND THE PURCHASER S EXCLUSIVE REMEDY IS LIMITED TO REPAIR OR REPLACEMENT OF THE WHEEL AS STATED IN THIS LIMITED WARRANTY This limited warranty should be used in conjunction with the Alcoa Wheel Service Manual and the Alcoa Dura Bright Wheels Cleaning Guide The Service Manual contains important safety information and warnings Failure to read and understand that information may result in serious injury or death If you do not have cop
43. he 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 27 Wheel Nuts 0 2 NOTICE One piece flange nuts are not approved for use on any Alcoa wheel application Flange Nuts 28 WARNING Use of chrome plated wheel nuts which have chrome plating on the surfaces that contact the wheel can cause reduced and inconsistent wheel clamping WARNING This condition can cause wheels to loosen and disengage from the vehicle causing serious injury or death Never use wheel nuts with chrome plated contact surfaces Use only recommended hardware on Alcoa aluminum wheels nuts for use with Alcoa aluminum truck wheels 2 piece 26 25 mm height 33mm hex head flange nut Mounts single and dual wheels to wheel centering hubs Right hand threads used on both sides of vehicle P N 39874 supersedes P Ns 39701 and 39691 M22 1 5 RH threads 2 piece 78 5 mm height 33mm hex head flange nut Mounts dual wheels with 32mm bolt holes to wheel centering hubs Right hand threads used on both sides of vehicle P N 430732 M22x1 5 RH threads Available in Dacromet corrosion resistant coating P N 578732 2 piece 50mm height 33mm hex head flange nut Mounts
44. hese tools Figure 3 31 Air or Electric Grinder This tool is another quick and effective method of removing the sharp edge caused by rim flange wear The grinding pads may gum up from the aluminum that is removed Figure 3 32 3 33 Care must be used to avoid gouging the wheel Figure 3 32 a Figure 3 33 Air or electric power Grinder Die Grinder 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 but care must be taken to remove metal as uniformly as possible and not to gouge the wheel Figure 3 33 Always wear PPE at all times Rim flange wear continued Figure 3 34 Sharp edge removed STEP 4 Figure 3 34 shows the result of removing the sharp edge on the rim flange With 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 Take care to make sure the edge removal is as uniform as possible and avoid gouging the wheel STEP 5 After the edge is removed run the sharpness indicator gauge Figure 3 27 along the flange where the sharp edge was removed to check for any remaining sharpness If the rubber is still cut perform the steps again to remove the sharp edge Always remove the minimum amount of
45. hile the tire is pressurized 9 Cracked broken bent or otherwise damaged rim components shall not be reworked welded brazed or otherwise heated 10 Whenever multi piece rim wheels are being handled employees shall stay out of the trajectory unless the employer can demonstrate that performance of the servicing makes the employee s presence in the trajectory necessary 11 No heat shall be applied to a multi piece wheel or wheel component 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 If a tire changing machine is used the tire shall be inflated only to the minimum pressure necessary to force the tire bead onto the rim ledge while on the
46. hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace camag parts Follow correct tightening sequences and torque levels Note Never get lubricant on the wheel or nut ball seat or mounting faces 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 yield studs causing WARNING failure Failed studs can cause the wheel to detach from the vehicle causing serious injury or death Lubricants must be completely removed from the cap nut seats and contact surfaces if applied accidentally On vehicles equipped with the stud piloted ball seat mounting systems 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 37 Tightening Stud Piloted Ball Seat Cap Nuts continued INNER CAP NUT This should be used for dual wheel NOTE There are two different inner cap nuts for aluminum and steel wheels The inner cap nut in Figure 5 3 is for use with dual aluminum wheels Note INNER CAP NUT LEFT HAND THREADS The letter L should appear on the end of the cap nut The top of the inner cap nut will have thread direction identified on the end of the nut INNER CAP NUT RIGHT HAND THREADS The letter R should appear on
47. id staining and corrosion of wheel surface Always follow the recommended procedures of the balancing weight manufacturer It may be necessary to reduce the tire pressure when installing clip on weights to allow clearance of the weight clamp between the tire and rim flange Adhesive weights should only be applied to a clean surface on the brake side of the rim flange Balance weights should be installed in a location where they will not contact the brake components during vehicle operation Proper pre cleaning is an essential factor for adhesive balance weights It is recommended to review the surface cleaning techniques amp products with the manufacturer or supplier of balancing weights Relocating wheels from a cold place to a warmer place may cause condensation on wheel surfaces which can negatively affect the adhesion Improperly installed weights could come off during use and damage the vehicle and or surrounding objects and cause personal injury Excessive rim flange wear see Alcoa Wheel Service Manual Section 3 13 could dictate the use of stick on or adhesive balancing weights if there is inadequate rim flange to properly hold a clip on knock on style weight Powder Granulate Liquid Balancers or Liquid Sealants Balancing with powder granulates or liquids is not recommended nor is sealing tire punctures with liquid sealants Powder granulates or liquid balancers as well as liquid sealants may harm tubeless tires C
48. ies of the Service Manual you may obtain copies free of charge at www alcoawheels com or by contacting Alcoa Wheel and Transportation Products at 800 242 9898 or the address below Alcoa Wheel and Transportation Products 1616 Harvard Avenue Cleveland OH 44105 WARNING Wheels that are not properly installed or maintained may not be safe Failure to follow proper wheel VARMING installation or maintenance practices may result in injury or death Follow the proper wheel installation and maintenance practices as contained in this Alcoa Service Manual For additional copies of the manual and other useful items listed below available free of charge or for the most recent updates contact Alcoa Wheel and Transportation 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 Publications available free from Alcoa Alcoa Wheel Service Manual Dura Bright Wheels Cleaning Guide Maintaining Alcoa Aluminum Wheels Rim Flange Wear Transit Hub Bore Gage Safety Training Videos available online at www alcoawheels com e Proper Wheel Maintenance e Disc Wheel Inspection TIA e Wheel and Tire Safety Everybody s Job Information available through industry and government organizations TIA Tire Industry Association Info available at www tireindust
49. in servicing those rim wheels and the safety procedures to be followed i The employer shall assure that no employee services any rim wheel unless the employee has been trained and instructed in correct procedures of servicing the type of wheel being serviced and in the safe operating procedures described in paragraphs f and g of this section ii Information to be used in the training program shall include at a minimum the applicable data contained in the charts rim manuals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and un derstand the charts or rim manual the employer shall assure that the employee is instructed concerning the contents of the charts and rim manual in a manner which the employee is able to understand 2 The employer shall assure that each employee demonstrates and maintains the ability to service rim wheels safely including performance of the following tasks i Demounting of tires including deflation ii Inspection and identification of the rim wheel components iii Mounting of tires including inflation with a restraining device or other safeguard required by this section 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 necessit
50. is usually located 180 degrees from the valve stem on the open side of the wheel Wheel identification required by the DOT must be legible Wheels should be taken out of service if this identification is not legible and scrapped Maximum Wheel Load Rating Inflation Pressure m ALCOA FORGED MAXLOAD 3355 kg 7400 LB MAX PRESS 900 kPa 130 PSI accoa USA 042714 PART NO 883673DB 225X825 168 T DOT n Country of Origin Date of Manufacture Wheel Description FMVSS 120 Month Day Year Designation prior to 2000 some wheels may only have Month Year Chart 3 3 Figure 3 23 Alcoa wheels may have markings in the rollstamp to designate certification in other regions as follows e Wheels approved by INMETRO the Instituto Nacional de Metrologia are designated with the symbol e Wheels approved by the Japanese Ministry of Transportation are designated with the symbol SUL eT All Dura Bright surface treated wheels are designated by the letters DB following the part number such as 883671DB 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 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 883677DF All Dura Bright Dura Flange wheels are designated by the letters DD fo
51. lancers of sealants will not be replaced under CAUTION the Alcoa limited warranty CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the Severly corroded wheels are unsuitable for service D Recommendations for proper installation of wheels 5 1 Wheel Installation 1 Make sure all wheel nuts are properly torqued Dirt rust steaks radiating from the bolt stud holes can indicate loose wheel nuts See Section 3 If the wheel becomes loose the wheels bolt stud holes can become elongated egg shaped or damaged as shown in Section 3 8 If wheel nuts are loose you may break studs and or develop cracks at the wheel bolt stud holes This condition may cause the wheel to loosen and disengage from the vehicle 2 On ball seat wheels be sure the end of the socket is smooth or cover the wheel mounting surface with a protective shield prior to tightening the cap nuts The end of the socket 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 aluminu
52. ll 39 Incorrect assemblies 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 WARNING racked wheels conditions which can lead to serious injury or death 5 1 3 Use only hardware designed specifically for each wheel type See Section 5 2 for proper hardware assemblies The following are examples of incorrect wheel assemblies Stud piloted ball seat P wheel Two piece flange nut Incorrect use of stud piloted wheels on hub piloted system Do not use ball seat wheels as inner and outer duals with a hub piloted wheel system Insufficient contact area Hub piloted Alcoa 4 aluminum wheel Ball seat cap nut ai Incorrect use of stud piloted Insufficient contact area wheel on hub piloted system Do not use ball seat wheels as outer duals with a hub piloted mounting system Incorrect use of a ball seat cap nut on a hub piloted system Do not use ball seat cap nuts with hub piloted wheels NOTE Notice all the different variations of mounting wheels incorrectly on hubs Incorrect use of a hub Incorrect use of ball seat piloted wheel as an inner wheel on hub piloted system Do not use hub piloted Do not use ball seat wheels wheels with stud piloted as inner dua
53. llowing the part number such as 883673DD Alcoa introduced a new logo label in January 2009 13 Owner in service identification Figure 3 24 Rim flange wear 3 13 14 Some fleets mark their names and or in service date When marking wheels use the following guide lines 1 Use Lo Stress stamps or equivalent 2 Stamp on outside disc should be placed near the center bore 3 Stamps on rim should be as close to the roll stamp as possible Note Use of an impression stamp on Dura Bright surface treated wheels may affect the appearance and performance of the Dura Bright surface treatment in the area around the stamp Rim flange wear is not a warrantable condition Only Dura Flange wheels have a 24 month warranty on rim flange wear mre hai TA For 3 25 Irregular wear on the surface of the rim flange is caused by abrasion from the tire and or debris Rim flange wear occurs most often in applications with heavy or shifting loads If your wheels are experiencing excessive rim flange wear consider using an Alcoa Sebe SL aluminum wheel 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 the procedures detailed below If rim flange wear becomes sharp and or cuts the tire contact Alcoa for recommended maintenance procedures at 800 242 9898 or a
54. ls with a hub mounting systems Note lack piloted wheel system of contact between duals on a stud piloted system 40 OSHA Regulations OSHA 29 C F R Section 1910 177 Regulations 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 utilizing automobile tires or truck tires designated LT 2 This section does not apply to employers and places of employment regulated under the Longshoring Standards 29 CFR part 1918 Construction Safety Standards 29 CFR part 1926 or Agriculture Standards 29 CFR part 1928 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 publications entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi Piece Rim Wheel Matching Chart the National Highway Traffic Safety Administration NHTSA publication
55. m wheels 5 Additional care should be used when mounting Alcoa Dura Bright surface 5 treated wheels since minor nicks and scratches cannot be polished out Section 3 17 for specific cautions care and maintenance procedures 6 High temperature nylon spacers are a protection gasket designed to be placed between the wheels and also the brake drum wheel contact surfaces High temperature nylon spacers can be used when the tire wheel assemblies are removed and reinstalled be safe Failure to follow proper wheel installation or maintenance practices may WARNING Wheels that are not properly installed or maintained may not 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 and Transportation Products at 1 800 242 9898 or on the web at www alcoawheels com 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 t
56. material necessary to eliminate the sharp edge STEP 6 Check the rim flange height with the Alcoa Rim Flange Wear gauge to make sure there is adequate height remaining to safely support the tire Figure 3 25 shows how this gauge is used Be sure to move the gauge all around the wheel s circumference and make sure that no area of the flange is below what the gauge indicates is acceptable If the entire wheel flange is within the limits of the rim flange wear gauge the wheel may be returned to service STEP 7 Always inspect the wheel for any other conditions that would warrant removal from service Consult the Alcoa Wheel Service Manual or the TMC User s Guide to Wheels and Rims for informa tion on Out of Service Conditions WARNING Welding or brazin aluminum wheel will weaken the rim flange or any area of an Alcoa e wheel Weakened or damaged wheels can result to an explosive separation of tire from wheels WARNING Explosive separations of tires from 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 Soe wheels to service with inadequate HEL height as AA determined by the A l coa Rim Flange Wear Gauge can lead separation of tires and wheels o an explosive WARNING Explosive separations of tires and wheels on the vehicle could cause serious injury or death Wheels with flange height that falls below the Alcoa g
57. n 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 41 42 OS HA Regulations Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components continued Single piece wheel means a vehicle wheel consisting of one part designed to hold the tire on the wheel when the tire is inflated Trajectory means any potential path or route that a rim wheel component may travel during an explosive separation or the sudden release of the pressurized air or an area at which an airblast from a single piece rim wheel may be released The trajectory may deviate from paths which are perpendicular to the assembled position of the rim wheel at the time of separation or explosion See Appendix A for examples of trajectories Wheel means that portion of a rim wheel which provides the method of attachment of the assembly to the axle of a vehicle and also provides the means to contain the inflated portion of the assembly i e the tire and or tube c Employee training 1 The employer shall provide a program to train all employees who service rim wheels in the hazards in volved
58. of a disc wheel DISC FACE The flat central portion of a disc wheel in which the bolt holes are located and which contacts the drum hub or mating wheel DISC WHEEL A rim combined with a center disc which has bolt holes for attaching to a vehicle DOUBLE CAP NUTS Two wheel nuts used in stud piloted wheel systems They include inner cap nuts used to fasten inner wheels to a vehicle and outer cap nuts used to fasten single wheels and outer wheels to a vehicle These nuts have both right and left hand threads and have ball seats that fit into the wheel ball and ball seat bolt holes to center and clamp the wheels on the hub DROP CENTER The well or center portion of the wheel rim DUAL WHEEL DUALABLE Any wheel that can be mated disc side to disc side with another wheel resulting in an inner and outer dual wheel assembly FLANGE NUT A nut with a flat face or flange that bears against the wheel can be one piece or multi piece construction Use on hub piloted wheels FOOT POUNDS The measure of the amount of torque applied to a cap nut or other part May be measured with a torque wrench HUB BORE Bore The large hole in the middle of a disc wheel HALF DUAL SPACING The distance from the outside disc face surface between the wheels as a dual assembly to the center of the rim HUB PILOTED MOUNTING A wheel mounting system in which location of the wheel is accomplished by positioning the wheel center hole on a machined pilo
59. onsult the tire manufacturer s recommendation for information about tire compatibility Alcoa Wheel Products Policies do not endorse any specific brand or type of balancing powder or granulates The use of these balancers in Alcoa wheels may clog valves A filtered valve core is recommended when using balancing powder or granules The use of these materials will not void the limited warranty see Section 3 11 of the Alcoa Wheel Service Manual unless inspection of the wheel shows anomalies related to its use Caution The use of liquid tire balancers or sealants in Alcoa wheels may cause galvanic corrosion at the valve hole area as well as corrosion to the valve itself and or may cause extremely rapid corrosion of the wheel rim surface Corrosion at the bead seat areas can allow loss of inflation pressure Corrosion at the valve hole will also result in a loss of inflation pressure Severely corroded wheels are unsuitable and should be permanently removed from service and scrap Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced under the Alcoa limited warranty CAUTION Clip on balance weights are not recommended T for Dura Flange wheels The usage of clip on style balance weights will not CAUTION adequately engage the hardened Dura Flange coating Alcoa recommends adhesive style balance weights for this application wheel rim surface Alcoa wheels corroded by the use of liquid tire ba
60. ouch both rim flanges at each point If a space greater than the thickness of a credit card or 030 in or 6mm feeler gauge appears between the short leg and the rim flange opposite the disc the wheel should be removed from service and scrapped 3rd Best If a ball tape or carpenters square is unavailable roll the unmounted wheel a minimum of 10 feet over Inspection Method 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 deformed rim contour Remove the wheel from service until it Rolling wheel as can be properly checked with a ball tape PA DR ORS IF YOU DO NOT FULLY UNDERSTAND ANY OF THESE INSPECTION METHODS AS DESCRIBED page IN THIS SECTION CONTACT ALCOA AT 800 242 9898 FOR CLARIFICATION TMC RP 247 Tire Wear or Ride Problems 3 5 Cracked or damaged wheel checks 3 6 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 2 for recommendations and instructions for demounting tubeless tires Remount the wheel on the vehicle or balance without the tire Be sure to follow proper installation procedures to assure the wheel is properly centered on the hub Place a dial indicator as illustrated in Figure 3 10 to trace the bead seats of the wheel Rotate the wheel noting the amount of variation shown on the dial indicator Note
61. ounting surfaces of both wheels for stud hole to stud hole cracks If cracks are found immediately and permanently remove the wheel from service and scrap For the support surface diameter required by other bolt circle sizes ask your Alcoa representative WARNING Use of two piece flange nuts on stud piloted 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 WARNING cracked wheels wheel loss which can lead to serious injury or death Use only hardware designed specifically for each wheel type See Section 5 2 for proper hardware assemblies Tig htening Stud Wheel cap nuts must be properly tightened Piloted Ball Seat Refer to the chart below for the proper nut torque of stud piloted double cap nuts Cap Nuts Ball Seat Radius NutThread Torque Level Ft Lb Dry 7 8 450 500 5 11 7 38 3 18 36 450 500 E 1 3 16 750 900 1 3 16 1 18 16 750 900 1 3 16 1 5 16 12 750 900 Chart 5 2 Source TMC Refer to truck manufacturer guidelines for specific recommendations 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 WARNING BOth under and overtorquing can lead to wheels coming off causing serious injury or death Check all parts including wheels studs and cap nuts Check mounting faces of wheels
62. plosive separations of tires from wheels can cause serious injury or WARNING death Inspect tires and wheels for damage before Lure from vehicle lf damage is found the tire must be completely deflated before loosening cap nuts Immediately and permanently remove damaged tires or wheels from service Slow leaks may indicate cracked or damaged wheels which lead to wheel WARNING Use of inner tubes in tubeless wheels will hide slow leaks A failures See Section 3 10 WARNING oe failures can cause accidents which may result in serious injury or eath Never use an inner tube on an Alcoa tubeless wheel Immediately and permanently remove cracked or damaged wheels from service and scrap Only properly trained technicians should service tire wheel assemblies Before mounting be sure that the tire is properly matched to the rim 1 Do not gouge or nick the wheel If changing by hand place aluminum wheels on a clean floor and use a protective mat when 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 17 page 20 for specific cautions care and maintenance procedures If using a tire changing machine care should be taken to prevent gouging the aluminum wheel 2 Always use a rubber leather faced or plastic mallet 3 Inspect the tire wheel for damage Do not use a damaged or severely corroded wheel Section 3 14
63. pounds to Newton Meters Ft lbs x 1 3558 N m Newton Meters to Foot pounds N m x 3756 Ft Ibs 50 Alcoa Wheel Products 1616 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2015 Alcoa Wheel Products All Rights Reserved Form E37 13584 Printed in USA
64. pposite the tire irons in the drop center well Figure 2 6 Remove one tire iron and insert the curved end between the bead and rim Pry the rest of the top bead over the rim flange Repeat this process until the first bead is entirely free from the rim Figure 2 7 Stand the tire on its tread Slide the flat end of the tire iron between the bead and the rim flange make sure the tip is completely over the rim flange Figure 2 8 Pry the tire iron and allow the rim wheel to drop IMPORTANT Make sure your feet are clear of the rim If necessary rock or bounce the assembly to remove the tire from the tire wheel Inspection and Maintenance Inspect thoroughly and frequently 3 1 Wheel alteration 3 2 Safe operation requires thorough examination of wheels and attaching hardware at frequent intervals both on and off the vehicle Wheels that are in service need to be inspected at regular intervals to ensure proper and safe performance It is not always possible to predict the useful life of a wheel Wheels eventually wear out but generally older wheels and wheels operating in extreme conditions should be examined more frequently for obvious signs they should be removed from service Examine all exposed areas frequently Clean wheels and look for cracks corrosion wear or other damage Also check the inner dualed wheel when the outer wheel is removed During tire changes thoroughly examine the entire wheel Pay particula
65. r attention to the rim contour and the surfaces of the rim Hidden Damage Do not exceed maximum wheel load Users must compare OEM vehicle load ratings to maximum wheel load ratings and inflation pressures which are roll stamped onto the wheel See Section 3 12 Do not overinflate a tire wheel assembly Use the tire wheel manufacturer s recommended pressure and under no circumstances exceed the cold tire wheel pressures as listed by the tire wheel manufacturer which is moulded stamped on the tire and wheel Before mounting the tire perform a wheel fitment check to ensure proper clearance from any obstructions 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 Alcoa does not approve of any form of alteration to wheels except minor cosmetic buffing for appearance purposes Sanding and or grinding is permitted to properly maintain the rim flange area of the wheel Welding brazing or other heat application must never be used to repair or straighten a wheel Use of adapter plates or bead locks are not approved on Alcoa wheels Alcoa wheels should not be painted or otherwise coated in any way that may interfere with the mounting surfaces Any wheels that show signs of alteration should be removed from service and scrapped The wheel identification required by DOT is stamped
66. 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 properly calibrated torque wrench Impact wrenches if used should be carefully adjusted to apply torque within the limits recommended Torquing of cap nuts should be tightened in recommended sequences Some states provinces have laws which dictate full thread engagement or thread engagement past the nut body Make sure you know the laws for the states provinces in which you operate and comply with them When checking the cap nuts on dual disc wheels utilizing the stud piloted ball seat mounting system loosen every other other cap nut and then check the torque of the inner cap nuts Retorque the loosened outer cap nuts Repeat procedure with the rest of the nuts Check all cap nuts for the proper torque after the first use or any removal Inspect wheels see Section 3 and check wheel nuts during service stops Dirt and rust streaks from cap nuts may indicate looseness 1 If using specialty fasteners cap nuts or any hardware not noted above consult the manufacturer for recommended torque values 2 Tightening wheel nuts to their specified torque is extremely important Undertightening results in loose wheels which can damage wheels studs and hubs and can result in wheel loss Overtightening can damage studs nuts and wheels and result in wheel loss as we
67. ry org or 301 430 7280 RMA Rubber Manufacturers Association Info available at www rma org tire safety or 202 682 4800 OSHA Occupational Safety and Health Administration of US government Info available at www osha gov or 800 321 OSHA TMC Technology amp Maintenance Council Info available at tmc trucking org or 703 838 1763 DOT U S Department of Transportation Info available at www transportation gov or 855 368 4200 Table of Contents How to use O Section Number Page Number O this manual Oae eane a a E eee eee 2 1 This manual is written in a 2 Deflating and Demounting Tubeless Truck amp BUS Tir S cceccceceeeeeeeeeeeeeeeeeeeeeneeessnnereaes 4 style called structured text Throughout the manual you 3 Inspection and Maintenance sicocsncocernsconvnrentgsedaniencenanesdeniabetetheiindotaeesesbensedeninncsansdceeed aeeeedieds 5 2 will find numbers which look 3 1 Inspect thoroughly and freg enty isesi nhie 5 like this See Section 3 1 3 2 Wheel alteration scx cccscs cx cas ocecesececdccavcscsecieeseleniedesccduncasdeuceseaatbcceuvelascceepecesdccneoiewdiases 5 These numbers are cross 3 3 Heat damage E I E E ete E veneers Coeds sate ee vende sdeeap ude EE E sense 6 references to other sections 3 4 Dimensional checks NTP O I EE E E E EEA T 3 of the manual The numbers 3 5 Tire Wear or Ride Problems sacaconiicc cd sctecwntnccecs sends baedsaeniuands trasesedentedpanecnanetenadianestes 8 3 1 refer to
68. s entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi Piece Rim Wheel Matching Chart or any other poster which contains at least the same instructions safety precautions and other information contained in the charts that is applicable to the types of wheels being serviced Installing a rim wheel means the transfer and attachment of an assembled rim wheel onto a vehicle axle hub Removing means the opposite of installing Mounting a tire means the assembly or putting together of the wheel and tire components to form a rim wheel including inflation Demounting means the opposite of mounting Multi piece rim wheel means the assemblage of a multi piece wheel with the tire tube and other components Multi piece wheel means a vehicle wheel consisting of two or more parts one of which is a side or locking ring designed to hold the tire on the wheel by interlocking components when the tire is inflated Restraining device means an apparatus such as a cage rack assemblage of bars and other components that will constrain all rim wheel components during an explosive separation of a multi piece rim wheel or during the sudden release of the contained air of a single piece rim wheel Rim 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 a
69. s shown here are from wheel end systems using a full hub Figure 3 37 ACCEPTABLE UNACCEPTABLE Hub Bore Gauge does not fit This wheel is Hub Bore Gauge fits indicating severe hub acceptable for use bore corrosion Remove any severely corroded wheel from service immediately and scrap 18 Dura Flange maintenance 3 15 Corrosion Prevention non Dura Bright surface treated wheels 3 16 Dura Flange has a 24 month warranty against wear which creates a sharp edge that requires maintenance per Section 3 13 Minor wear or minor pitting is not a warrantable condition Edge re conditioning of any kind cannot be performed on Dura Flange wheels including those methods as described in Section 3 13 Figure 3 39 ACCEPTABLE PITTING The following information is for standard Alcoa forged aluminum wheels without the Dura Bright surface treatment See Section 3 17 for specific instructions on the care and cleaning of Alcoa Dura Bright surface treated wheels 1 Clean frequently with high pressure water The use of a mild detergent will speed the cleaning process Do not use harsh alkaline cleaners 2 When tires are removed the entire wheel must be cleaned and inspected see Section 3 With a wire brush remove any foreign materials from the tire side of the rim Do not use a wire brush to remove dirt and corrosion materials from the appearance surface of the wheel Generously coat the entire air chamber surface with
70. section 3 3 6 Cracked or damaged wheel CNECKG cccccccssseeeceeeesecceeeeecseeseeeseseeessegeeseees 8 subtopic 1 You will find the 3 Mou n ng NC ea iiss sates presse tease etree tows a A R EEEN rN n Rne ainiin onii 9 section number and subtopic BO RO E a cin edad occa 10 4 number under the heading in 3 9 Disc FN re 10 each section 3 10 Rim Area Drop Center Valve Hole and Bead Seat ccccccececeeseeeeeeeeeeeees 11 SR E oe E A A A E E EA E eee ene ee A E emcee ne eee 12 3 12 NSTI CIN MU Nes sencticso cores eeesdeg sesso es esc ne eE Ea EEn EEEE EE eects eee 13 3 13 Rim Flange Wear ss enzgisnireaatatananaarasunivalnieaimiance dunadn rca nsiushaatersenltaneerhsvand eaedustighae 14 5 3 14 CONOS IOI asses ses eg ceased i rooie teiaa ce cheneaonenegeniecaadseeseaeceeanceronies ceteoasceeeie 18 3 15 Dura Flange maintenance cccccccccecseseeseeeeeeceeeeeseaeeeeesceeeeeeeeeseeeeaeeeeseeeeeenes 19 3 16 Corrosion Prevention non Dura Bright surface treated wheels 066 19 3 17 Dura Bright surface treated wheels cleaning and maintenance 606 20 6 4 Mounting Alcoa Wheels with Tubeless TiresS ccccseeceeeeeeeeeeeeeseeeeeseeeeeseeeeeseeeeesaesessaes 21 4 1 Mounting Tubeless Tires on Alcoa Wheels ccccccccssseeeseseeeeeseeenseeseneeeeeneas 21 4 2 Inflating Tire Wheel ASSEMDIY ccccceseeeeeceeeeeeeeseeeeeeeeeeeeeeeeaeeeesseeeeeeessaeeeeeeas 23
71. serviceable working condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed NOTE 1 Tightening wheel nuts to their specified torque is extremely important Undertightening results in loose wheels which 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 2 All torque wrenches impact wrenches and any other tools used for tighten ing flange nuts should be calibrated periodically to ensure the proper torque is applied 3 Refer to OEM for torque ranges of hardware that is not noted in this manual The cap nut seat for the stud piloted system is a precision machined spherical surface Cap nuts must be properly manufactured to assure correct seating Never use one or two piece flange nuts on a wheel designed with ball seats Section 5 11 D 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 vehicles have 1 1 8 inch studs on the front hubs Alcoa single cap nuts Part Nos 5996R and 5996L or equivalents should be used Some front hubs have 3 4 inch studs On these hubs use Alcoa single cap nuts Part Nos 5995R and 5995L or equivalents High temperature nylon wheel spacers can be used with Alcoa Dura Bright surface treated wheels to protect the wheel conta
72. single wheels to wheel centering hubs with 32mm bolt holes Right hand threads used on both sides of vehicle P N 430632 M22x1 5 RH threads Available in Dacromet corrosion resistant coating P N 578632 Cap Nuts There are many types of nuts and studs in use and their design and specifica tions are not standardized The R and L on cap nut part numbers indicate right and left hand threads respectively Alcoa recommends the following wheel 1 1 8 X 16 cap nut Mounts standard single wheels and wide base wheels to 1 1 8 studs Also mounts outer dual wheel to 1 1 8 inner cap nut P N 5996R 5996L replaces P N 5552R 5552L 3 4 x16 cap nut Mounts standard single wheels and wide base wheels to 3 4 studs Do not use on steel wheels P N 5995R 5995L replaces P N 5554R 5554 L Inner cap nut inner thread 3 4 x16 outer thread 1 1 8 x16 For use with steel inner dual wheel and aluminum outer dual wheel with 1 31 1 5 16 to 1 44 1 7 16 stud standout P N 7896R 7896L Grade 8 Inner cap nut for use with 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 dual wheel FOR MEDIUM DUTY MOUNTING HARDWARE SEE THE
73. ssembly in an OSHA compliant restraining device during inflation 1 Before inflating any tire rim wheel assembly be sure to read understand and comply with ALL WARNINGS Use only dry air for tire inflation Be sure that in line air dryer is maintained properly 2 After mounting the tire on the rim if needed use a compressed air tank with a quick 4 release valve to seal the beads Do not exceed 5 psi before placing the assembly in a OSHA compliant restraining device 3 Place the assembly in an OSHA compliant restraining device such as a tire safety cage Figure 4 6 is an example of one type of a restraining device Manufacturers recommend that OSHA compliant restraining devices be freestanding and located at least one foot away from any flat or solid surface 4 Inflate the tire with the valve core removed using a clip on air chuck with an in line valve or pressure regulator and a sufficent length of hose Inflate to 20 psi in OSHA y NS N compliant restraining device IMPORTANT Look for distortions undulations or other irregularities in the tire sidewall Listen for any popping or snapping sounds See Figure 4 7 The OSHA compliant restraining device should not be bolted to the floor If ANY of these conditions are present STOP DO NOT approach tire Before removing from OSHA compliant restraining device completely deflate tire remotely Remove clip on air chuck Mark tire as damaged for a potential Zipper ruptur
74. t continuous or interrupted on the hub Fastening is accomplished by flange nuts bearing against the flat face of the wheel disc HUB PILOTS Pads on the hub to locate the center hole of a hub piloted wheel in Abbreviation for inches INNER CAP NUT The ball seat nut used to install the inner stud piloted dual wheel to a vehicle see Double cap nut 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 MAXIMUM INFLATION The highest amount of air pressure allowed measured at normal ambient temperatures mm Abbreviation for millimeters NAVE See DISC FACE N m Abbreviation for Newton meters OFFSET See OUTSET Glossary of Common Terms continued OPEN SIDE The side of the wheel opposite the disc face OSHA Abbreviation for the U S Department of Labor Occupational Safety and Health Administration OUTER CAP NUT The ball seat nut used to install the outer wheel of a stud piloted dual assembly or a single stud piloted wheel to a vehicle The outer nut screws onto the inner cap is a dual assembly see Double 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
75. t www alcoawheels com 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 Chart 3 4 Rim Acceptable Rim NOT Acceptable Rim Gauge Rim Gauge Alcoa P N 000700 Alcoa P N 000700 b No daylight in Daylight in this this area area indicates indicates acceptable rim Wheel rim excessive Wheel rim wear Remove from service immediately To obtain a gauge s P N 000700 at no charge and information about free training on installation and maintenance procedures contact Alcoa Wheel and Transportation Products at 800 242 9898 or on the web at www alcoawheels com 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 NOTICE Check the wheel at every tire change for rim flange wear and any sharp edges Following this practice will significantly reduce the possibility of a rim flange cutting into the tire Determining Rim Flange Wear STEP 1 Remove the wheel tire assembly from the vehicle Remove the valve core per section 2 1 to deflate the tire completely demount the tire from the wheel according to OSHA regulations TMC Recommended Practices RP 209 for tire and rim safety procedures and or the Alcoa Wheel Servi
76. ter fluid propane ether gasoline or other flammable materials and or accelerants to lubricate the beads and or seat of a tire This practice can cause the explosive separation of the tire wheel during servicing or during highway use which may result in serious injury or death NEVER inflate beyond 40 psi to seat any tire beads NEVER stand lean or reach over the tire rim wheel assembly in the restraining device during inflation Even if a tire is in a restraining device inflating beyond 40 psi when trying to seat the beads is a DANGEROUS PRACTICE that may break a tire bead or the rim wheel with explosive force and possibly result in serious injury or death Any inflated tire mounted on a wheel contains explosive energy The use of damaged mismatched or improperly assembled tire and wheel components can cause the assembly to separate with explosive force If struck by an exploding tire wheel component or the air blast you or someone else may be seriously injured or killed Mismatching tire and rim diameters is dangerous A mismatched tire and rim assembly may separate and can result in serious injury or death This warning applies to 15 and 15 5 16 and 16 5 17 and 17 5 22 and 22 5 24 and 24 5 tire and rim assemblies as well as other sized assemblies NEVER assemble a tire and rim unless you have positively identified and correctly matched the tire and rim diameter If an attempt is made to seat the tire bead
77. the same as the 1 2 DUAL SPACING dimension PILOT PAD See HUB PILOTS 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 That portion of the wheel which supports the tire RIM CENTERLINE A line to the radial axis of the wheel running through the mid point between the rim flanges RIM FLANGE The edge of a rim that has a larger diameter that the tire bead designed to support the tire SINGLE CAP NUT A cap nut used to secure single wheels or outer dual wheels STUD A threaded bolt that is used with wheel nuts to fasten wheels or rims to a vehicle STUD PILOTED MOUNTING A wheel mounting system in which location and fastening of the wheel are both accomplished by nuts which fit corresponding studs at each wheel bolt hole TIRE BEAD That surface of the tire which contacts the angled surface of the wheel rim TORQUE Rotational force to measure nut tightness WHEEL MOUNTING FACE See DISC FACE wt Abbreviation for weight 47 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 us
78. tire changing machine 5 If a bead expander is used it shall be removed before the valve core is installed and as soon as the rim wheel becomes airtight the tire bead slips onto the bead seat 6 Tires may be inflated only when contained within a restraining device positioned behind a barrier or bolted on the vehicle with the lug nuts fully tightened 7 Tires shall not be inflated when any flat solid surface is in the trajectory and within one foot of the sidewall 8 Employees shall stay out of the trajectory when inflating a tire 9 Tires shall not be inflated to more than the inflation pressure stamped in the sidewall unless a higher pressure is recommended by the manufacturer 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 OSHA Regulations Appendix A Trajectory continued WARNING Stay out of trajectory as indicated by shaded area NOTE Under some circumstances the trajectory may deviate from its expected path ee SF Appendix B Ordering Information for OSHA Charts The information on the OSHA charts is available on three posters or in a manual contain ing the three charts entitled Demounting and Mounting Procedures
79. uck amp Bus Tires ALWAYS completely deflate the tire assembly before attempting to demount a tire from a tire wheel assembly Remove the valve core and insert a wire down the valve stem to ensure complete deflation NEVER demount a tire from a rim unless it is completely deflated Lubricate the beads of the tire and bead seat of the wheel Then use a slide impact bead unseating tool duck bill hammer with a rubber mallet or other bead unseating tools Both beads must be loosened before demounting a tire For aluminum wheels a mat should be placed on the floor to prevent damage to the mounting surface of the wheel Figures 2 1 through 2 3 Identify the short side of the drop center wheel well Single piece tubeless rims and wheels must be demounted from the short side of the drop center well On steel disc wheels the short side is typically located opposite the disc Aluminum wheels typically have symmetrical drop centers so tires can be demounted from either side However on certain non symmetrical aluminum wheels the short side of the drop center well is located on the disc side Figure 2 4 Lubricate and unseat both beads in the bead seat area of the tire and wheel Position the assembly with the short side of the drop center well facing up a Figure 2 9 Figure 2 5 Insert tire irons on either side of the valve stem approximately 6 inches 152 mm apart Pry the top bead over the rim flange and force the bead o
80. uring pads e g 3M Scotch Brite should not be used Step 2 Rinse wheels thoroughly to remove any loose and visible dirt debris e Rinsing the wheel with water helps to prevent scratching and abrasion Step 5 Rinse the wheel e Use a water hose or power washer e Rinse the wheel thoroughly to remove soil sand etc with clean water to remove all remaining soap and dirt e f you intend to dry your wheels be sure to use a soft cloth free of debris Look for the black Alcoa sticker to identify E ALCOA 7 a i z Step 3 Prepare cleaning solution to a pH 5 9 e Add a mild detergent e g common i dish soap liquid to the water at the specified dilution ratio before applying to vehicle e The pH level should be 5 9 in diluted ready to use state e f using multiple solutions each solution must fall within the pH range of 5 9 Do not use strong acid pH lt 5 on Dura Bright Dura Bright Surface Treatment Wheels e Never use cleaning products containing This is an example Hydrofluoric acid on Dura Bright Wheels of how to test pH If soils attached to the surface do not come off with cold water try warm water and wipe with a soft towel or chamois cloth Use warm water and a mild detergent with assistance of a commercial high pressure power washer if available Always dilute the detergent according to the manufacturer s recommendation never use the detergent straight without dil
81. uting with water Once in service Dura Bright wheels can become nicked or scratched by road debris and or mechanical damage If this occurs continue to follow the normal washing and cleaning instructions provided above The mounting area on Dura Bright wheels can become scratched marred or discolored when mounted against another wheel hub or drum Components such as high temperature nylon spacers can prevent scratches Contact Alcoa Field Service team if you have any questions Note pH value can be found in chemical MSDS Material Safety Data Sheet from the product manufacturer If the cleaner is in concentrated form contact your cleaning chemical supplier to determine pH levels The full Dura Bright cleaning procedure can be reviewed in the Dura Bright Cleaning Guide available in print and online at www alcoawheels com Only Alcoa s Warranty Center can authorize warranty claims and justify warranty returns Dura Bright and Dura Flange claims can only be authorized and determined by Alcoa s Warranty Center 20 4 Mounting tubeless tires on Alcoa Wheels 4 1 NOTICE For information on tube type wheels contact Alcoa at 800 242 9898 Option 1 NOTICE Alcoa Aluminum non symmetrical wheels require special tire mounting techniques Mount Either Side Mounting Alcoa Wheels with Tubeless lires WARNING Mounting damaged tires or wheels can lead to an explosive separation of tires and wheels Ex
82. ve wheel face or brake drum 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 a wheel assembly has been installed and torqued check the fastener torque again within 5 100 miles Individual fleet conditions will influence the mileage interval Refer to TMC RP 237 Retorquing Guidelines for Disc Wheels which establishes guidelines for determining the fleet torque check interval NOTICE In service stud 4 1 dimensions and condition O 10 o 8 may change over time due 6 3 O to environmental conditions O rai N O Jm 6 multiple re installations Q 40 improper torquing and other 1 j factors Consult your hub A Af C 50 KS O4 and stud manufacturer 4 om 5 Oz O for maintenance and p 7 Os replacement 2 recommendations Six Stud Eight Stud Ten Stud 31 Alcoa Mounting WARNING All wheel mounting tools must be removed before Tool P N vehicle operation Wheels that are not properly installed or main 000426 tained may not be safe WARNING Failure to follow proper wheel installation or maintenance practices may result in injury or death Alcoa Mounting Tool will not seat brake drums that have bolt holes larger than 980 in diameter 5 6 Follow the proper wheel installation and maintenance practices as containe
83. wheel support surface see specifications on next page support surface not flat incorrect attachment parts and insufficient torque see Section 5 11 Remove wheel from service and scrap Figure 3 11 Figure 3 12 Inspect the hub drum contact area thoroughly for cracks or other damage Support surface diameters Support surface should be flat and match the diameter recommended in Chart 3 1 or 3 2 Chart 3 1 ISO 4107 STUDS BOLT CIRCLE MOUNTING TYPE MIN DISC FLAT CLEARANCE DIAMETER STUD SIZE 8 HUB 8 27mm HUB 85mm O 10 285 75mm HUB 845mm 10 335mm HUB Chart 3 2 SAE J694 STUDS BOLT CIRCLE MOUNTING TYPE MIN DISC FLAT CLEARANCE DIAMETER STUD SIZE s C ar 5 s smm m smm 2mm WE 1 w n wus sse o 10 STUD 13 56 750 1 125 10 335 mm HUB 390 mm 22mm Bolt holes Check bolt holes for enlargement and elongation and any damage which can occur if the wheel nuts are not kept tight Dirt streaks or rust radiating from stud holes may indicate loose wheel nuts 3 8 If wheels are run loose both stud piloted wheels and hub piloted wheels can be damaged Look for wallowed out or elongated ball seats on stud piloted wheels On hub piloted wheels look for elongated stud holes Over torquing can lead to damaged ball seats on stud piloted wheels and can damage the disc surface of hub piloted wheels Remove damaged wheels from service and scrap Figure 3 13 Figure
84. y of standing outside the trajectory both during inflation of the tire and during inspection of the rim wheel following inflation and viii Installation and removal of rim wheels 3 The employer shall evaluate each employee s ability to perform these tasks and to service rim wheels safely and shall provide additional training as necessary to assure that each employee maintains his or her proficiency d Tire servicing equipment 1 The employer shall furnish a restraining device for inflating tires on multi piece wheels 2 The employer shall provide a restraining device or barrier for inflating tires on single piece wheels unless the rim wheel will be bolted onto a vehicle during inflation 3 Restraining devices and barriers shall comply with the following requirements i Each restraining device or barrier shall have the capacity to withstand the maximum force that would be transferred to it during a rim wheel separation occurring at 150 percent of the maximum tire specification pressure for the type of rim wheel being serviced ii Restraining devices and barriers shall be capable of preventing the rim wheel components from being thrown outside or beyond the device or barrier for any rim wheel positioned within or behind the device iii Restraining devices and barriers shall be visually inspected prior to each day s use and after any separa tion of the rim wheel components or sudden release of contained air Any restraining d

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