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Alcoa Wheel Service Manual Jan. 99 US English

1. o Hub gt Inner Cap Nut P N 7896R or L 1 31 a 1 44 4 Correct dual mounting for inner and outer aluminum stud located ball seat mount WARNING Incorrect inner cap nuts used with steel wheels can bottom out on the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running WARNING wheels can lead to stud breakage Use only cap nut 7896R or L or its equivalent when mounting steel inner duals WARNING Inadequate wheel support surface can lead to stud hole to stud hole fracture resulting in separation of the outer disc and rim from the vehicle Separation of the wheel from the vehicle can cause injury or death WARNING Alcoa aluminum wheels with 11 1 4 diameter bolt circle require a support sur face 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 wheels are serviced check both mounting surfaces of both wheels for stud hole to stud hole cracks If found remove the wheel from ser vice For the support surface diameter required by other bolt circle sizes ask your Alcoa representative WARNING Use of two piece flange nuts on ball seat wheels or ball seat cap nuts on hub piloted wheels is dangerous Using the wrong cap nuts can
2. ee Pi LE Y onn Aud rk t T tU IDA a s 5 2 AY ho lal F auda hy od r nons non sum una un mas uuu anus auus clus TS 4 2 S OMA AO uss ID Aran oe re Sree a oe m a 55 P aam mre T Foun eee a m B aT I bohas sl I Us Xue WP M ree 2e gd D a FP gt be I fL ha 1 s 1I DUM 1 uam apud uc ee 2 Vu Mua r E a 1 14 mu EE TET asl boa 4 1 odd uam k JI I k 4i s2r kro ofl w y ctn ni tor gp malis mM 56 t as VE L pies ae jE afte JL oct I de e Tb Pee d uoa on sl e tao mE gn m s m m m s m m m m Mounting 1 Inspect the wheel for damage Do not use a bent cracked damaged or severely cor recommendations roded wheel See Section 2 page 3 for tubed tires 2 Inspect ring s for corrosion bending or other damage and discard if any is apparent 3 Thoroughly clean the wheel and rings Clean the wheel face with a mild det
3. 2 nm 425 SENS Shee 4 000 74 S ion 4 it See oe dete 7250 5 54 ion TR e4eD perna 44 cm Edd epe 4 000 ur 6 42 ion TREET cones 4 5 m ETGDASTE TODD gu 5 28 5 44 ion TR e4eD 575400 CAES Shee eet en 5 55 E ion TR e4eD i See Oe Der 8550 en E 4 E 0 icm TR 24907 8 2254222460 44 400 425 4 9 Sede oe ere 44 400 er cree 276 125 555450 20 22 64600 46 425 TR c40E SCO 24 She oe eben T 577 i TREKS Serco hole hub piked mounting 285 75 mm bolt orobe 220 4 hub bore use 2 pene tange nut ESR TR al ol a IE _2 2288046 Im Ine Pene 5 E n 22642 25 4809 44 400 A 425 Somer BSR SMES MOG _ 4 SR 05 4 11 000 Li PER ABE i TREE SESE BRED 0 44 000 71 got 5 12 ize TRACE 0000 67 pbe Boo 2a 45 Inc _ amp SOE OD O TE 642 AT 0 _ __ RRR SHED 5 45D oO _ 10 IwHe hub piloted bus mounting 1 1 29 In circle 8 870 In hub bore use 2 plece flange nuts in 38 13TC zu So Tec 24 5825 1600 MM BUUU 7800 6 BG bel GE S
4. Wheel Service Manual E ku Ww H v Ww yf Ww i ul Tha VO MVC ECOSSE OVE MOVE T OECD TOV NEWER V CAPE CC NCC VW VC NC MEM n Jn h Fal n n na p n P P n A at p JH h 1 LIMITED WARRANTY FOR HEAVY DUTY TRUCKS TRUCK TRAILERS AND BUSES Wheels with bead seat diameters measured in 5 inch increments and Alcoa tube type wheels Alcoa warrants to the original purchaser from Alcoa or its authorized distributor that a new Alcoa aluminum disc heavy duty truck truck trailer or bus wheel is free from defects in material and workmanship Alcoa agrees without charge to repair or replace a wheel which fails in normal use and ser vice because of defects in material or workmanship Wheels are warranted for 60 months from date of manufacture as shown on the wheel Alcoa bus mount wheels 10 hole 11 25 inch bolt circle 8 670 inch hub bore with 1 22 inch diameter bolt holes used in transit service are warranted for 120 months from date of manufacture Alcoa does not war rant and will not repair or replace or make adjustment with respect to normal wear or for any wheel which has been damaged or subjected to misuse or abuse including without limitation the following a Using a tire which is improperly sized according to standards recommended by Alcoa or the Tire and Rim Association
5. Stud o e c u um c Inner Cap Nut P N 5978R or P N 5988R or L 1 31 a 1 88 4 Correct dual mounting with stud located ball seat mount WARNING Incorrect inner cap nuts used with dualed aluminum wheels can bottom out on the unthreaded portion of the stud before the wheels are prop erly seated Improperly seated wheels can run loose cause stud breakage and disengage WARNING from the vehicle which can cause serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 5978R or L 5988R or L or their equivalent when mounting dual aluminum wheels 18 19 Dualed wheels inner steel outer aluminum stud located ball seat mounting 4 7 On occasion Alcoa aluminum truck wheels are operated dualed with a steel inner wheel In the event a steel inner wheel is used extreme care must be exercised to properly seat it to the hub or drum prior to mounting the outer aluminum wheel Selection of an inner cap nut capable of fixing the steel inner wheel and providing adequate external thread length to secure the outer aluminum dualed wheel 15 critical to a safe assembly Alcoa rec ommends the use of inner cap nuts 7896R L Grade 8 or equivalent for this purpose Inner Steel Wheel Alcoa Aluminum Wheel Y Drum 3 Outer Cap Nut P N 5996R or L 3 4 Stud
6. service until they are certified by either the manufacturer of a Registered Professional Engineer as meeting the strength requirements of paragraph d 3 i of this section OSHA Regulations continued 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 iii A sufficient length of hose between the clip on chuck and the in line valve ii An in line valve with a pressure gauge or a presettable regulator and if one is used to allow the employee to stand outside the trajectory 5 Current charts rim manuals containing instructions for the types of wheels being serviced shall be available in the service area 6 The employer shall furnish and assure that only tools recommended in the rim manual for the type of wheel being serviced are used to service rim wheels e Wheel component acceptability 1 Multi piece wheel components shall not be interchanged except as provided in the charts or in the applicable rim manual 2 Multi piece wheel components and single piece wheels shall be inspected prior to assembly Any wheel or wheel component which is bent out of shape pitted from corrosion broken or cracked shall not be used and shall be marked or tagged unserviceable and removed from the service area Damaged or leaky valves shall be replaced 3 Rim flanges rim gutters rings bead seating surfaces and the bead
7. A 4 7625 5 1504 5 9531 8 7459 7 1438 7 5406 Rt sri 8 7313 9 1281 9 5250 gui 10 3188 0 7156 1125 SEH 9063 1 91 12 7000 0 6406 0 6563 0 6875 0 7031 0 7188 D 7344 0 7500 0 7558 0 7813 0 7969 0 8125 DEHN 0 8438 0 6594 0 8750 0 8906 LANI ix 0 9218 0 B 175 0 5531 0 9588 0 9844 1 000 15 0813 15 4781 15 8750 18 2718 18 14 17 4825 17 8554 15 2545 18 5531 19 0500 19 4562 13 8538 zu 24906 2 E375 21 LE 3144 21 4313 1 B261 22 2250 22 E19 24 0188 23 4156 23 8125 zd COO 24 z 9 DT 25 4000 42 Conversion Inches to Millimeters Formulas 9 2 Inches 25 4 Millimeters Millimeters to Inches Millimeters 0 03937 Inches PSI to kPa PSI 6 8948 kPa kPa to PSI kPa 0 145 PSI Pounds to Kilograms Pounds 0 4536 kg Kilograms to Pounds kg 2 2050 Pounds Foot pounds to Kilogram Meters Ft lbs 0 13826 kgm Kilogram Meters to Foot pounds kgm 7 23 Ft Ibs 43 Alcoa Inc Wheel Products International 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 Alcoa Inter America Inc 115 A Matheson Blvd West Suite 207 Mississauga Ontario Canada L5R 3L1 800 668 1150 Copyright O 1997 Alcoa Inc All Rights Reserved Form E37 13584 Printed in USA 1 99 50M
8. areas of tires shall be free of any dirt surface rust scale or loose or flaked rubber built 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 When the tire has been driven underinflated at 8096 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 36 OSHA 37 Regulations continued 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 re
9. cause loss of torque broken studs and cracked WARNING Wheels conditions which can lead to injury or death Use only hardware designed specifically for each wheel type See 4 2 page 15 for proper hardware assemblies Cap nut thread engagement stud located wheels ball seat mounting 4 8 Tightening stud located ball seat cap nuts 4 9 The actual length of thread engagement present in an assembled wheel can not always be determined by visual inspection or measurement of a tightened assembly The rela tionship of the wheel cap nut seatto the end of the stud may vary If there is any doubtthat enough thread engagement is present the number of engaged threads may be counted Tighten all nuts in the regular manner then loosen one to hand tightness The number of turns to disengage a 1 1 8 inch nut should be at least five full turns At least seven full turns should be required to disengage a 3 4 inch nut Ideally when torqued to the proper load the stud should be flush with the face of the nut The face of the nut may be recessed in nuts that are taller for improved wrenching With most of the nuts in present use a few unengaged threads at the outer end will cause no problem provided at least 5 7 full turns are required to disengage the nut depending on thread size Cap nuts made to Alcoa specification usually give more than the necessary thread engagement on a given stud The number of turns to disengage a 1 1 8 inch nut s
10. escapes roll tire or use bead expander to force tire beads against rim Be sure to stay out of the path of potential explod ing parts or air blasts NOTICE Alcoa aluminum 19 5 RW and non symetrical well wide base wheels require tires be mount ed and dismounted over the disc side of the wheel only For a free instruction wall chart contact Alcoa Inquiry Fulfillment Markinetics Inc Box 809 Marietta OH 45750 Use of a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build up in the tire and may result in an explosion Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire or later on the road Loss of vehicle control can result which can cause serious injury or death Use only approved mechanical or pneumatic bead seating devices CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface CAUTION Severely corroded wheels are unsuitable for service Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced under the Alcoa limited warranty 12 Mounting of tubeless tires continued Heavy duty truck tires have a guide rib molded into the sidewall next to the tire bead When the tire is inflated this ring should be evenly spaced from the wheel rim all the
11. may appear elsewhere If you do not have a copy ofthe Service Manual you may obtain one along with other specification literature by contacting Alcoa Wheel Products International at 800 242 9898 or the address below Alcoa Inc Wheel Products International 1600 Harvard Avenue Cleveland OH 44105 hs n ph n M n A n A A h D h J 1 L 1 n n I I h M n n h h hA 1 1 I J I n th P H a n iH How to use this manual This manual is written in a style called structured text Throughout the manual you will find numbers which look like this See 3 1 page 12 These numbers are cross ref erences to other sections of the manual The numbers 3 1 refer to section 3 subtopic 1 When you turn to page 12 you will find the section number and subtopic number under the heading in each section as shown here Recommendations for mounting tubeless tires 3 1 The cross references will help you find related information in the manual For example in section 4 1 you will read the following sentence Make sure all wheel cap nuts are torqued check them often see 4 9 page 20 properly By turning to section 4 subtopic 9 on page 20 you will find information on proper torquing Note The Alcoa Heavy Duty Wheel Service Manual contains information for proper service and operation of Alcoa heavy duty wh
12. mounting with 3 4 inch stud located ball seat mount Alcoa Aluminum Wheel t Dun qu r L ber Csm Bud Fit sien L 1 6 Inch minimum la Correct single mounting with 1 1 8 inch stud located ball seat mount Dualed wheels Rear wheels are most frequently mounted as duals Each inner aluminum wheel is stud located ball attached by 10 inner cap nuts Alcoa recommends use of inner cap nuts 5978R 5978L or seat mounting 5988R 5988L see 4 2 page 15 Cap nuts recommended by Alcoa are compatible with Alcoa wheels Hardware of equal dimensions and strength may be used 4 6 Continued on next page 17 Dualed wheels Most vehicles have standard length studs 1 31 1 5 16 to 1 44 1 7 16 stud standout stud located ball Some vehicles use studs longer than standard up to 1 88 1 7 8 standout seat mounting When changing types of brake drums be sure to check for excessive stud standout t d greater than 1 88 1 7 8 Excessive stud standout may cause the inner cap nut to con nue bottom out on the longer stud preventing proper seating of the wheel Each outer dual wheel is attached by 10 single cap nuts which thread on the inner cap nuts Use Alcoa outer cap nuts Part Nos 5996R 5996L or equivalents Match mounted dual wheels should be put on the vehicles with the valve stems180 apart Alcoa Aluminum Wheels Drum Outer Cap Nut P N 5996R or L 3 4
13. 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 orlocking ring designed to hold the tire on the wheel by interlocking components when the tire is inflated Restraining device means an apparatus such as a cage rack assemblage of bars and other components that will constrain all rim wheel components during an explosive separation of a multi piece rim wheel or during the sudden release of the contained air of a single piece rim wheel Rim manual means a publication containing instructions from the manufacturer or other qualified organization for correct mounting demounting maintenance and safety precautions peculiar to the type of wheel being serviced Rim wheel means an assemblage of tire tube and liner where appropriate and wheel components Service or servicing means the mounting and demounting of rim wheels and related activities such as inflating deflating installing removing and handling Service area means that part of an employers premises used for the servicing of rim wheels or any other place where an employee services rim wheels Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components Single piece wheel means a vehicle wheel consisting of one part designed to hold the tire on the wheel when the tire is inf
14. 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 continued Appendix B Ordering Information for NHTSA Charts OSHA has reprinted the NHTSA Charts as part of a continuing campaign to alert rim wheel servicing personnel of the industry accepted procedures for servicing multi piece rim wheels Reprints of the charts are available through Occupational Safety and Health Administration OSHA Area Offices The address and telephone number of the nearest OSHA Area Office can be obtained by looking in the local telephone directory under U S Government U S Department of Labor Occupational Safety and Health Administration Single copies are available without charge Individuals establishments and other organizations desiring multiple copies of these charts may order them from the Publications Office U S Department of Labor Room N4101 Washington D C 20210 Telephone 202 523 9667 FR Doc 84 2884 Filed 2 2 84 8 45 a m BILLING CODE 4510 26 M 38 39 8 Glossary of Common Terms Glossary of Common Terms 8 1 1 2 DUAL SPACING One half the distanc
15. unless the rim wheel will be bolted onto a vehicle during inflation 3 Restraining devices and barriers shall comply with the following requirements 1 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 separation of the rim wheel components or sudden release of contained air Any restraining device or barrier exhibiting damage such as the following defects shall be immediately removed from service A Cracks at welds 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
16. uu uu nonu nu nun ne LD 4 1 Recommendations for proper installation of 5 15 2 2 c rr 15 4 3 Howto measure stud SESDgOLE MEME MAE 16 4 4 Stud located ball seats are 5 17 4 5 Single wheel stud located ball seat 17 4 6 Dualed wheels stud located ball seat mounting 17 4 7 Dualed wheels inner steel outer aluminum stud located ball seat mounting 19 4 8 Cap nutthread engagement stud located wheels ball seat mounting 20 4 9 Tightening stud located ball seat cap nuls eer tremere x urhe rna E Urna br abe we pui 20 4 10 Single dualed and wide base wheels hub piloted mounting two piece flange nuts 22 4 11 Tightening hub piloted mounting two piece flange 23 4 17 JIncorect assemblies 25 5 Care and Maintenance 26 sl A aD Tec 26 5 2 Keep wheel nuts emi P e Ra arr ru Rar cca aan 26 5 3 Lead balance weights clip vagi ait Duaci cda 26 5 4 Wheels 26 5 5 Owner in servic
17. way around the wheel Check the position of the ring before removing the assembly from the inflation cage If the ring and wheel are not concentric deflate the assembly in the cage and remount the tire Rim width to tire Rim to tire matching chart for medium and heavy trucks matching Tire Size Approved Tire Size Approved 3 3 for both radial Rim Widths for both radial Rim Widths 2271 and bias tires and bias tires 13 8 225 70 245 70 265 70 305 70 8 9 255 70 6 00 6 75HC 6 75HC 7 50HC 8 25HC 00 6 75 50 25 0 10 o 00 00 00 1 000 15 675RW 15 6 75RW 50 7 50RW 295 15 305 75 315 80 15 16 5 18 385 65 425 65 445 65 11 12 285 75 DOONNUUY O po pa Ua CQ NN tO tO 11 75 12 25 12 25 13 00 13 00 L175 12 25 11 75 12 25 13 00 13 00 Recommendations for demounting tubeless tires WARNING tires or wheels lead to an explosive sepa ration of tires and wheels Explosive separation can result in serious injury or death Inspect tires and wheels for damage before vehicle If damage is found tire must be completely deflated before loosen ing cap nuts Remove damaged tires or wheels from service WARNING 3 4 1 When hand demounting tires from wheels placing aluminum wheels on a clean wooden floor or ru
18. weights clip on weight clamp over the rim flange 9 3 Do not straig hten Do not heat wheels in an attempt to soften them for straightening to repair damage from wheels striking curbs or other causes The special alloy used in these wheels is heat treated and uncontrolled heating will weaken the wheel Do not rework weld heat or braze Alcoa aluminum wheels for any reason This does 5 4 include normal wheel maintenance as described and approved by Alcoa 26 Owner in service identification 9 9 Valves 9 6 Maintenance against corrosion 5 7 27 Some fleets wish to specially identify wheels as to OWNERSHIP and IN SERVICE dates Alcoa recommends that fleets and owner operators adopt the practice of permanently stamping wheels with the date they are first placed into service 1 Use Lo Stress stamps or equivalent 2 Location of stamped areas on outside disc should be in space outward from a line between hand hole centers and a minimum of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Alcoa drop center wheels for tubeless tires come from the factory with air valves installed If it becomes necessary to replace an air valve install it using the following torque values 10 14 foot pounds 7 11 foot pounds for Part Nos for Part Nos 542 Series 543 Series TR 544 Seri
19. Abbreviation for inches INNER CAP NUT Cap nutused to mount the inner wheel in a dualed stud located wheel system INSET The distance from the wheel mounting surface to the rim centerline when the centerline is placed inboard of the mounting surface kg Abbreviation for kilogram weight measurement equal to 1000 grams kPa Abbreviation for kilo Pascals pressure measurement Glossary of Common Terms continued LOCK RING The third piece of a three rim assembly which positions and supports the side ring to the rim base MAXIMUM INFLATION The highest amount of air pressure allowed measured at normal ambient temperatures mm Abbreviation for millimeters MULTI PIECE WHEEL A wheel assembly in which the rim portion of the wheel consists of two or more separate parts OFFSET See OUTSET OPEN SIDE The side of the wheel opposite the disc face Abbreviation for the U S Department of Labor Occupational Health and Safety Administration OUTER CAP NUT A cap nut used to secure the outer stud located wheel a dualed wheel pair and thread onto the inner cap nut OUTSET The distance from the mounting surface of the wheel to the rim centerline when the rim centerline is mounted outboard of the hub face This dimension is the same as the 1 2 DUAL SPACING dimension PILOT PAD The raised surfaces on a hub used to center a hub piloted wheel PSI Abbreviation for pounds per square inch REV
20. ERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tire centerline RIM CENTERLINE A line to the radial axis of the wheel running through the mid point between the rim flanges RIM FLANGE That portion of the rim which extends above the rim surface which retains the tire bead RIM That portion of the wheel which supports the tire SIDE RING A removable piece of a multi piece wheel assembly which provides lateral support for one tire bead SINGLE CAP NUT A cap nut used to secure single wheels or outer dual wheels STUD A threaded bolt extending from the hub surface to which the wheels are secured by the cap nuts STUD LOCATED BALL SEAT MOUNTING A wheel mounting system which uses the studs and spherical ball seat cap nuts to center and secure the wheel TIRE BEAD That surface of the tire which contacts the angled surface of the wheel rim TORQUE The amount of force used to tighten cap nuts Usually stated in foot pounds or kilograms and measured with a torque wrench WHEEL MOUNTING FACE That portion of the wheel face which contacts the hub or brake drum wt Abbreviation for weight 40 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 du
21. HAF D 77 124 127 THER 14 5850 883670 meu Ber description af Ju wi KI 17 Set Ole TS DC 15700 18 500 aW TX P hEAN T ETE ENGLISH UNITS META UNITS wheel lad n Its Wilxnama kingrnama GHIS 29132 2500 RAS Bus C45 31 30 Wihecl we 165 LE Inches rum Insc nches immi 4 37 4 742 4 78 3 28 134 0 75 148 Fal Mad mum mold HF er ninta cod 7571 TrAADU Taiga 22142 114 GEZAN 23 1 56 7 1 19 57 25 T S CX 251001 3004 2410 37 0 16 8 17 3 i Li EK c Gt 141 155 EST 1G7 4 72 120 5 20 134 5 7h aL 122 TR 5 amp 32 TR 5 amp 37 n ri 2 Dn not A Red Do not cesar Vela onte noted Capa Ep nar gae ame phy naci rada ni lon ena S edd 72 xg 26 ores ze toe 18 DC zz 0 157000 x o0 15 DEL ermm b
22. Inc b Loading beyond the applicable maximum wheel load as specified by Alcoa c Inflating beyond the applicable maximum as specified by Alcoa d Changing the original condition of the wheel by alteration or by subjecting it to processing such as heating welding straightening or machining e Accidents abnormal or severe operating conditions or f Failure to follow recommended maintenance on the wheel as set forth in Alcoa s Heavy Duty Wheel Service Manual Alcoa Technical Bulletins and other Alcoa literature Recommended maintenance includes without limitation periodic cleaning polishing valve replacement and rim flange wear inspections and procedures THERE IS NO WARRANTY THAT THE WHEEL SHALL BE MERCHANTABLE OR SATISFACTORY FOR ANY PARTICU LAR PURPOSE NOR IS THERE ANY OTHER WARRANTY EXPRESSED OR IMPLIED ON THE WHEEL ALCOA SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR ANY BREACH OF WARRANTY ITS LIABILITY AND THE PURCHASER S EXCLUSIVE REMEDY BEING EXPRESSLY LIMITED TO REPAIR OR REPLACEMENT OF THE WHEEL Repair or replacement will be handled by any authorized Alcoa wheel distributor or by any Alcoa wheel representative under Alcoa s return policy This warranty gives you spe cific legal rights You may also have other rights under other applicable laws This warranty should be used in conjunction with Alcoa s Heavy Duty Wheel Service Manual It is included with the Service Manual but
23. al spacing for the selected tires double the 8 2 wheel outset measurement of the Alcoa wheel used If the doubled outset measurement is equal to or greater than the tire manufacturer s recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel on pages 2 and 3 Both inset and outset wheels are measured from the mounting surface of the wheel to the center line of the rim Maintaining proper tire inflation and load ratings are essential to maintaining proper minimum dual spacing Dual Spacing Vehicle clearance Tire Clearance Tire section width m t L Soaks gt Center hole dia Wheel Wheel outset Inset z same as offset or dual spacing Backspace 1 Tire center Tire center line __ 41 Conversion Tables Inch inches Decimals Milllmeters Fraction 0 0158 0 263 0 5155 13 0068 Decimal and Millimeter 3 0 0313 0 7938 0 5313 13 4938 Equivalents 3j 00489 01 1906 138906 Y 0 0625 1 5875 0 5524 14 2875 0 0781 1 8844 0 5781 14 5844 inch z 9 1 0 1034 0 1250 0 1406 0 1553 1718 0 1875 9 2031 0 2188 Q 23445 0 26589 0 2813 0 2909 0 3122 0281 0 5438 0 559 3506 1953 219 0 3375 4531 0 2685 g 4 0 5000 13 2 7781 3 1750 3 5719 3 9GBB
24. bber mat is recommended 2 Always use a rubber leather faced or plastic mallet 3 Keep tire tools smooth Use them with care Rim gouges or nicks may cause cracks If using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel Demounting of tubeless tires 3 5 NOTICE Not all tire mount ing demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tires Remove the valve core from the valve stem to ensure complete deflation Place wheel on machine and position tool so flat end can be dri ven between tire bead and rim flange Straighten tool to a vertical position until bead is separated from wheel Insert curved end of tire tools between tire and wheel approximately 10 inches apart Pull one tool toward center of wheel then pull second tool in the same manner To free bead leave one tool in position take out and reinsert the other tool curved end between bead and flange a short distance from the spanned area Pry bead free of rim repeating process until entire bead is free from wheel Repeat procedure at intervals until bead is totally separated from wheel Repeat procedure on other side of tire Tire is now ready for demount ing Lubricate the tire bead Insert straight end of tire tool between beads and both rim flanges hooking stop on the tool over sec
25. be type tires Remount the wheel on the vehicle without the tire Be sure to follow proper mounting procedures to assure the wheel is well centered on the hub Place a dial indicator as illustrated below to trace the bead seats of the wheel Rotate the wheel noting the amount of variation shown on the dial indicator Note Alcoa aluminum wheels should be tested for radial run out only at the bead seat surface A total indicator reading of 045 inches is acceptable LF Tire wear can also be caused by improperly seated tires Inspect the tire for proper seat ing on the wheel The tire beads may not be seated properly If so remove the wheel from the vehicle deflate and break the bead seats see 3 5 page 14 for recommendations and instructions for demounting tubeless tires and 6 5 page 32 for recommendations and instructions for demounting tube type tires Adequately lubricate the bead seats and properly reseat the tire beads Reinflate the wheel in a safety cage or other suitable restraint refer to OSHA rule 1910 177 paragraph b see Section 7 page 33 Mounting area Stud hole cracks are usually caused by improper torquing see 4 9 page 20 and 5 2 page 26 excessive loading or insufficient mounting flange support by the hub or brake drum Remove wheel from service 2 3 Shown below are stud hole cracks emanating from stud hole to stud hole Causes are undersized diameter of wheel support surface see speci
26. bjects such as spacers or high hats into the contact surface areas of the mounting system unless approved by Alcoa Do not paint Alcoa forged aluminum wheels Wheel cap nuts WARNING Use of chrome plated cap nuts which have chrome plating on the surfaces which contact the wheel can cause reduced and inconsistent wheel clamping This condition can cause wheels to loosen and disengage from the vehicle 4 2 WARNING causing injury or death Never use cap nuts with chrome plated contact surfaces Use only recom mended hardware on Alcoa aluminum wheels There are many types of nuts and studs in use and their design and specifications are not standardized Alcoa recommends the following cap nuts for use with Alcoa aluminum truck wheels Cap Nuts 2 piece 33mm hex head flange Bg 2 piece 1 1 16 hex head nut Mounts single and dualed flange nut Mounts single and wheels to wheel centering hubs j uus dualed wheels to wheel center Right hand threads used on both ing hubs Right hand threads sides of vehicle Single wheels used in both sides of vehicle require 2 50 8 mm stud stand E P N 39946 5 8 x18 RH threads out Dualed wheels require mue 2 13 16 71 44 mm stud stand out P N 39701 supercedes P N 39691 M22 1 5 RH threads 2 piece 30mm hex head flange nut Mounts single and dualed wheels to wheel centering hubs Right hand threads used on both Sides of vehicle P N 39708 M20x1 5 RH threads Co
27. d parts Follow correct tightening sequences and torque levels Two piece flange nuts with a 33mm hex head design see 4 2 page 15 used with hub piloted wheels should be tightened to a torque of 450 to 500 foot pounds Two piece flange nuts with 1 1 2 inch hex head design and other designs have different torque requirements Inquire of the manufacturer for the proper torque values Wheel studs on both the right and left side hubs of vehicles utilizing the hub piloted wheel system have right hand threads Prior to mounting hub piloted wheels generously coat the wheel pilot or hub pads with a non water based lubricant to minimize corrosion product build up between the wheel and hub pilot Excessive corrosion build up between the wheel and hub pilots can make wheel removal difficult Do not lubricate the face of the wheel hub or brake drum see illustration on the next page Continued on the next page Tightening hub piloted mounting two piece flange nuts continued Lubricate the hub pads or the wheel hub bore generously with a non water based lubricant Before installing two piece flange nuts lightly lubricate the stud threads and the contact Surfaces between the cap nut and the washer as illustrated below with an SAE 30W oll This will minimize corrosion between the mating surfaces Lubrication is not necessary with new hardware Position one of the hub s pilot pads at the twelve o clock position After positionin
28. e 27 RR uu 27 5 7 Maintenance against 27 28 6 Flat Base Wheel for Tube type Tires O 6 1 Tube type wheel part nnn 29 6 2 Mounting recommendations for tubed tires 2222 00 0 0 30 6 3 Mounting oftubed Ures Serer er 31 6 4 Demounting recommendations for tubed 32 65 Demounting OF tubed 32 7 OSHA nnn 33 8 Glossary of Common T6rms aaan naana asana 29 Ol Gl ssary OF COMMON TONS a da UU ME a aa 39 92 Wheel TICES WTI SING EEE EEAS RNE 41 9 Conversion Tables O vs 9 1 Inch Fraction Decimal and Millimeter Equivalen
29. e between the two center lines of dualed wheels The dimension is the same as the OUTSET dimension 2 PIECE FLANGE NUT A two piece washer and nut combination used to secure hub piloted wheels AIR CHAMBER The space enclosed by a tire and wheel rim or inner tube BEAD SEAT The area along the outer edges of the rim where the mounted tire and rim are in contact BOLT CIRCLE The circle defined by the centers of the bolt holes stud holes of a wheel dimensions stated in diameter inches or millimeters BOLT HOLE Hole found in the disc of the wheel through which the bolt stud passes BORE See BORE CENTER BORE See BORE CONE LOCK CAP NUT See 2 PIECE FLANGE NUT DC Abbreviation for drop center DISC AREA The vertical wheel face which supports the rim DISC WHEEL A one piece forged or two piece welded assembly of a disc and a rim DROP CENTER The well or center portion of the wheel rim FLAT BASE WHEEL A multi piece wheel with a removable side ring FOOT POUNDS The measure of the amount of torque applied to a cap nut or other part May be measured with a torque wrench GUTTER FLANGE A groove which supports the removable portion of a multi piece wheel HUB BORE The center hole of a disc wheel dimensions stated in diameter inches or millimeters HUB PILOTED MOUNTING A wheel mounting system which uses the hub to center the wheel and two piece flange nuts to secure it in
30. ed or severely corroded wheel See Section 2 page 3 4 Clean the wheel face with mild detergent and the tire bead seat areas with a wire brush Be sure the wheel is dry before applying tire lubricant 5 Inspect the tire for damage Be sure the inside of the tire is dry before it is mounted 6 Use of a non water based lubricant is recommended as a rim surface protectant and tire mounting lubricant Coat the entire rim surface See 3 2 page 12 7 Lubricate the rim and tire bead immediately before mounting the tire Do not use any lubricant which contains water Water based lubricants can promote corrosion attack on the rim surface The use of non water based lubricants is especially important when mounting tubeless tires as the air in the tire is contained by the seal between the bead and tire rim 8 Never lubricate the rim or tire bead with a flammable solution This can lead to an explosion during airing of the tire or in subsequent operation of the vehicle see Warning below 9 If using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel 10 Use only dry air for tire inflation The use of moisture traps in the air compressor feed line is recommended 11 Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures listed in Section 1 Specifications of this manu al see page 1 12 When inflating a tire in an in
31. eels Alcoa heavy duty wheels for heavy duty trucks truck trailers and buses are Alcoa tubeless wheels with bead seat diameters measured in 5 inch increments and Alcoa tube type wheels Table of Contents V Section Number Page Number V ZAMS OSC WOW 2 1 dnspecttoroughly ahd frequently 2 3 2 2 Dimension checks d X ba UOI ERR paa da 4 23 PVC are A renee irs sa IE 6 LA prot pEU UHR 7 Ps odi 8 DO t H 8 PS tit 9 2 8 Rim lange WV AN 9 LI XXE x M m 10 3 Alcoa 15 Drop Center for Tubeless Tires eene 3 1 Recommendations for mounting tubeless een 11 3 2 Molun nd tubeless TSS aga cxtra exteris Orr n cut 12 3 3 gre miale DITIG rd a eirca dpa a da 13 3 4 Recommendations for demounting tubeless 14 3 5 bDemounung of Ttubeless TOS 14 4 Wheel Installation
32. ered end ofthe tire tool into the notch Using the same procedures as outlined in Step 1 on the locking ring Pry up carefully to avoid bend loosen the bead on the opposite side of the wheel ing the ring and gouging the wheel Do not drive tools into rim area Lift wheel from tire 32 y OSHA Regulations OSHA Federal Register i Vol 49 No 24 Regulations Friday February 3 1984 Rules and Regulations 7 1 Signed at Washington D C this 30th day of J anuary 1984 Thorne G Auchter Assistant Secretary of Labor Part 1910 AMENDED Section 1910 177 is amended by revising the title to read SER VICING MULTI PIECE AND SINGLE PIECE RIM WHEELS by revising paragraphs a b c 1 1 1 CML 2 2 11 C 2 ii C 2 v C 2 v c 2 vii c 3 d 2 d 3 d 4 d 5 e introductory text of f f 2 f 3 and f 4 and by adding new paragraphs c 2 iii d 6 9 11 and g As amended 1910 177 reads as follows 1910 177 Servicing multi piece and single piece rim wheels a Scope 1 This section applies to the servicing of multi piece and single piece rim wheels used on large vehicles such as trucks tractors trailers buses and off road machines lt 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 empl
33. ergent Clean the tire bead seat areas and gutter flange with a wire brush 4 Do notgouge or nick the wheel Place wheels on a wooden floor or rubber mat Always 6 2 use a rubber leather faced or plastic mallet 5 Inspect and clean the tire tube and flap before mounting replace if damaged badly worn or defective 6 Insert lubricated tube and flap in tire 7 Lubricate the tire beads and rim then mount tire tube and flap assembly onto rim Do not use any lubricant which contains water or a solvent which can injure rubber 8 Select the proper rim components and assemble to rim see 6 3 page 31 Discard bent damaged or corroded side and lock rings Do not use any side or lock ring which is not clearly identifiable WARNING Use of a Firestone 5 side and lock ring assembly with a wheel machined for Firestone DT or Goodyear LW split side ring and vice versa can lead to explosive separation of wheel and tire An explosive separation of miss matched wheel components can lead to injury or death WARNING Alcoa Aluminum Disc Wheels are available to accept 1 Firestone 5 side and lock rings or 2 Goodyear LW and Firestone DT split side rings Select the proper side and lock rings by referring to the Multipiece Rim Wheel Matching Chart on page of this manual Firestone R5 Goodyear LW or Firestone DT Always use the proper side and lock ring assembly or split side rings required for each particular wheel 9 Do not ov
34. erinflate Use the tire manufacturers recommended pressure but under no circumstances exceed cold tire pressures listed in Section 1 Specifications of this man ual see page 1 10 When inflating a tire in an inflation cage or while mounted on a vehicle always use a clip on air chuck and a remote valve with pressure gauge During inflation or handling an inflated wheel and tire assembly stay out of the path of potential exploding parts or air blasts 30 Mounting of tubed tires 6 3 When mounting Alcoa flat base wheels for tube type tires you must use the proper side ring or side and lock ring required for each wheel The table below lists the Alcoa tube type wheels currently in production and the proper side ring or side and lock ring identifi cation recommended for each wheel See the Multipiece Rim Matching Chart on page 1 for information on older wheels with part numbers not shown here Alcoa Flat Base Wheels for Tube type Tires That Use Goodyear LW or Firestone DT Split Side Rings Only 2 Piece Assemblies Wheel Size Alcoa Part Number Side Ring Identification Stamping Identification Stamping 22x8 00 LW 481010 R8022LW recommended or R22X7 5 8 0 9 0LB LW 22X7 5 8 0DT LB LW 3 22 7 50 LW 471010 R8022LW recommended or R22X7 5 8 0 9 0LB LW 22X7 5 8 0DT LB LW 3 Current Alcoa part numbers i e 481010 end in 0 1 2 or 3 indicating a finish condition which does not affect the compatibility of parts as shown i
35. es 545 Series Replacement valves may be obtained from your authorized Alcoa Wheel Distributor Always use silicone o rings not rubber when reinstalling valve stems Metal valve stem caps are recommended over plastic 1 Clean frequently with high pressure water from a hose The use of a mild detergent will speed the cleaning process Use no harsh alkaline cleaners 2 When tires are removed the entire wheel must be cleaned and inspected See Section 2 page 3 With a wire brush remove any foreign products from the tire side of the rim Do not use a wire brush to remove dirt and corrosion products from the appearance surface ofthe wheel Generously coatthe entire air chamber surface with an approved surface pro tectant and lubricant each time the tire is removed See 3 1 page 11 3 To maintain the original appearance of your Alcoa wheels the following procedures are recommended a After installing new wheels and prior to operating your vehicle use a sponge cloth or soft fiber brush to wash exposed wheel surfaces with a mild detergent and warm water solution b Rinse thoroughly with clean water c Wipe dry to avoid water spots d Wax the cleaned surface with Alcoa Advanced Aluminum Care System Polish or Simonize Mothers California Gold paste wax No 7 Car Wax or equivalent e Clean your Alcoa truck wheels as frequently as required to maintain their appearance Identification Alcoa wheel identification Si
36. fications below support surface not flat incorrect attachment parts see 4 12 page 25 and insufficient torque see 4 9 page 20 and 5 2 page 26 Remove wheel from service Support surface should be flat to the diameter recommended on the chart on the follow ing page Inspect the hub drum con tact area thoroughly for cracks or other damage Mounting area Support surface diameters continued Support surface backup diameter should be flat to the diameter recommended on the chart below Number of Bolts Bolt Circle Mounting Type Backup Diameter Thread Size Corrosion Due to aluminum s natural resistance to corrosion Alcoa aluminum disc wheels do not need to be painted for most operating conditions However certain envi ronments can lead to corrosion Some of these are salt chloride compounds 2 4 used for snow removal and highly alkaline materials If the air used to fill tubeless tires or the tire itself is not dry the areas of the wheel under the tire can corrode severely Bead seat and valve stem corrosion often are caused by entrapped moisture which contains corrosive elements Mild corrosion should be removed thorough ly by wire brush and the rim protected with a coating of non water based lubricant see 3 1 page 11 Remove any severely corroded wheel from service Stud holes If wheels are run loose both stud located wheels and hub piloted wheels can be damaged Look for wallowed out or elongated ball
37. flation cage or while mounted on a vehicle always use a clip on air chuck or threaded straight chuck and a remote valve with pressure gauge Securely anchor the inflation cage and during inflation or handling of an inflated wheel and tire assembly stay out of the path of potential exploding parts or air blasts WARNING WARNING Use of a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build up in the tire and may result in an explosion Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire or later on the road Loss of vehicle control can result which can cause serious injury or death Use only approved mechanical or pneumatic bead seating devices WARNING pressurized tire wheel assembly can explode and separate violently WARNING Always contain the tire wheel assembly in an inflation cage during inflation This violent separation can cause serious injury or death Mounting tubeless tires 3 2 NOTICE Not all tire mount ing demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tires NOTICE When match mounting tires on Alcoa wheels use the valve stem to locate the tire high point This location can be used to insure consistent high point orientatio
38. g wheels on the pilot pads hand tighten all two piece flange nuts then tighten to the recommend ed torque following the proper sequence shown below for your type wheel After 50 100 miles of operation torque should be rechecked Check torque frequently from then on If nuts require frequent tightening studs break frequently or wheel bolt holes are pound ing out hardware and mounting practices should be reviewed 1 2 1 5 7 d n d 7 C EN E 3 C Eis C 6 E A 77 m 5 C hs uz d LEN 5 4 3 8 2 Eight Stud Ten Stud 24 Incorrect WARNING Use of two piece flange nuts on ball seat wheels ball seat cap nuts on hub piloted wheels or single piece flange nuts place of 2 piece flange assemblies nuts is dangerous WARNING Using the wrong wheel nuts can cause loss of torque broken studs and cracked wheels conditions which can lead to injury or death Use only hardware designed specifically for each wheel type See 4 2 page 4 1 2 15 for proper hardware assemblies ES The following are examples of incorrect wheel assemblies komod 10E Incorrect use of two piece flange nut Hub pied d Bein cp nul Incorrect use of ball seat cap nut No positional location Incorrect use of one piece flange nut positioned on Alcoa ball seat wheel 5 Care and Maintenance Avoid abuse Ab
39. ghtening sequences and torque levels Continued on next page 20 21 Tightening stud located ball seat cap nuts continued Stud located ball seat mounting system Itis recommended that stud threads on stud located mounting systems be lubricated with SAE 30W oil and torqued between 350 and 400 foot pounds If threads are not lubricated torque to between 450 and 500 foot pounds Note when dualing steel wheels with Alcoa aluminum wheels follow the steel wheel manufacturer s recommendations regarding the proper torque and use of thread lubricants to mount the wheel WARNING Application of lubricant to the ball seats can cause excessive torque Over torque can stretch studs causing them to fail _ _ Overtorquing can lead to wheel disengagement causing injury or death WARNING Do not allow oil to contact ball seats or mounting surfaces of the wheel hub or drum Do not use aerosol cans for lubrication of stud threads On vehicles equipped to accept wheels manufactured for use with the stud located ball seat mounting system wheel studs on the right side of the vehicle have right hand threads and those on the left have left hand threads The R and L on the studs and nuts indicate right and left hand threads respectively see 4 2 page 15 After mounting a wheel over the studs snug up the cap nuts in the order shown in the illus trations that follow After all the cap nuts have been snugged tighten the cap nut
40. hould be at least five full turns At least seven full turns should be required to disengage a 3 4 inch nut WARNING Lubricants should not be applied to the cap nut seat or to the cap nut to wheel contact surface Oiled seats can lead to over torquing which can stretch studs causing failure of studs Failed studs can cause the wheel to disengage from the vehicle WARNING causing injury or death Lubricants must be completely removed from the cap nut seats and contact surfaces if applied accidentally Cap nuts must be kept tight and studs and nuts should be checked frequently Nuts Should be retorqued if necessary At tire changes nuts and studs should be inspected for cracks and stripped or damaged threads After each wheel mounting cap nut torque Should be checked with a torque wrench Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of cap nuts should be done in recommended sequences WARNING Undertorqued cap nuts allow wheels to run loose pounding out deforming the ball seats fatiguing studs or losing nuts Overtorquing stretch studs causing them to fail _ Both under and overtorquing can lead to wheel disengagement causing injury ADVERTENCIA or death Check all parts including wheels studs and cap nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damaged parts Follow correct ti
41. ire bead while under pressure WARNING Rims which lack proper dimension and contour can lead to explosive separation of tire and rim causing injury or death Follow dimension check procedures described in this section during each wheel inspection Remove any substandard wheel from service The circumference of the bead seat on the open side of the wheel should be checked with each tire change The open side is the side opposite the disc face In the case of center flange wide base wheels or wheels with Insets less than 3 inches both rim flanges should be checked Measure the circumference of the bead seat on the open side see illustration below with a ball tape Ball tapes used for measuring wheel circumference can be purchased from the Tire and Rim Association Inc 175 Montrose West Avenue Copley Ohio 44321 If the circumference of the bead seat does not match the required dimension as indicated by the ball tape remove the wheel from service Be sure to clearly mark the wheel as out of service or otherwise render the wheel unusable Continued on the next page Dimension Tire wear or ride problems checks continued If you experience tire wear or ride problems it may be helpful to check radial run out Remove the wheel from the vehicle deflate and remove the tire see 3 5 page 14 for recommendations and instructions for demounting tubeless tires and 6 5 page 32 for recommendations and instructions for demounting tu
42. is used to mount dualed or single wheels Proper stud standout for single wheels is 2 inch 50 8mm minimum dualed wheels require 2 81 inch 71 4mm minimum and single wide base wheels require 2 32 inch 59mm Note Some stud located ball seat wheels have the same of holes and bolt circle diameter as hub piloted wheels They should not be mixe 1 06 27mm _ Drum 4 gt mm hen hear J piece Tanke nil 3701 ue a 2 50 frm 2 x fanciout eed uid pase ime zB mi SITETII SREI SLA Le eee E s 22mm h heed zpi fango 365701 1 1 6 27 meni enim plot engin for dusied aluminum wheels Typical assembly of single and dual wheels of hub piloted type with 33mm hex head two piece flange nut Part No 39701 If hex nuts with higher overall height are used more stud length is required Part No 39691 Continued on the next page 22 Single dualed and wide base wheels hub piloted mounting two piece flange nuts continued Tightening hub piloted mounting two piece flange nuts 4 11 23 Hubs designed for steel hub piloted wheels may not have enough pilot length to locate dualed aluminum wheels Pay close attention to pilot length particularly when converting from steel to aluminum duals Measure the hub pilot to make sure the hub has a minimum pil
43. lated Irajectory 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 or the rim wheel at the time of separation or explosion 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 involved in servicing those rim wheels and the safety procedures to be fol lowed i The employer shall assure that no employee services any rim wheel unless the employ ee 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 applic able data contained in the charts rim manuals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts or rim manual the employer shall assure that the em
44. m pletely deflated and valve core removed before demounting WARNING An inflated tire contains air under pressure which can be a dangerous explosive force Explosive separation of a tire and wheel can cause serious injury or death Follow proper service procedures to avoid injury or death 1 Before removing wheel from vehicle remove the valve core from the valve stem to ensure complete deflation of tire 2 Do not gouge or nick the wheel Place aluminum wheels on a clean wooden floor or rubber mat 3 Always use a rubber leather faced or plastic mallet 4 Keep tire tools smooth Use them with care Rim gouges or nicks near the fixed flange can cause cracks 5 Remove steel side rings carefully If bead is well loosened rings can be removed without gouging the wheel 6 Discard bent damaged or corroded side and lock rings Using bent damaged or corroded rings can shorten service life of wheel and introduce the danger of an explosive separation If manually breaking the tire beads from the wheel Once the tool is inserted pry down and out as illus it is important to use the proper tools Tire tools trated Leaving one tool in position work the other may be inserted next to the tire side wall and the around the tire until the bead is completely free side ring or locking ring Tools must be smooth and used with care if gouging the rim is to be avoided A stop welded to the tool is recommended Insert the tap
45. main in the trajectory during inflation 5 Tires shall be inflated outside a restraining device only to a pressure Sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead 6 Whenever a rim wheel is in a restraining device the employee shall not rest or lean any part of his body or equipment on or against the restraining device 7 After tire inflation the tire and wheel components shall be inspected while still within the restraining device to make sure that they are properly seated and locked If further adjustment to the tire or wheel components is necessary the tire shall be deflated by removal of the valve core before the adjustment is made 8 No attempt shall be made to correct the seating of side and lock rings by hammering Striking or forcing the components while the tire is pressurized 9 Cracked broken bent or otherwise damaged rim components shall not be reworked welded brazed or otherwise heated 10 Whenever multi piece rim wheels are being handled employees shall stay out of the trajectory unless the employer can demonstrate that performance of the servicing makes the employee s presence in the trajectory necessary 11 No heat shall be applied to a multi 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 emplo
46. n and opti mum ride quality For dual wheel positions position the valve stems 180 apart NOTICE Alcoa aluminum 19 5 RW and non symetri cal well wide base wheels require tires mounting and demounting over the disc side of the wheel only Position wheel on machine Lubricate wheel entire air chamber surface and tire bead using approved lubricant Tire beads closest to drop center well should be mounted over wheel flange Push bead overflange as far as possible 2 Insert curved end of tool between bead and wheel flange with tool stop against flange In cir cular motion use short successive bites to work the bead over the flange Push down on tool as bead is worked over flange Lubricate the second tire bead Startsecond bead into the well holding it in position with the clamp to the rim flange Lubricate bead half way around With curved end of tool between tire bead and flange and the stop towards the wheel push tool outward to work tire over flange Continue to pry bead over flange using the tool until remaining bead is over flange Seat the tire bead using any air ring or other mechanical bead seating aid Place tire wheel assembly inside safety cage or other suitable restraint refer to OSHA rule 1910 177 paragraph b see Section 7 page 33 Using a clip on air chuck or threaded straight chuck and remote valve with pressure gauge inflate the tire wheel assembly to proper pres sure If air
47. n the table Lubricate tube flap and wheel Insert tube and flap into tire Place them on the wheel so that the valve is aligned with the valve slot Place side ring on wheel and tire and stand on the ring to position it below the lock ring groove If a split side ring is required start the leading edge and walk the side ring onto the wheel Seat the second end of the Ns side ring or lock ring with a rubber plastic or leather facet mallet as shown Check carefully to see that the split side ring or side ring and lock ring assembly is in the proper position If not completely remove the components and start over i wheel requires a a lock ring ud leading m of the lock ring being sure that it is seating in the machined groove Then walk the lock ring onto the wheel as illustrated Inflate to 10 psi Check to see that all components are properly in place If not deflate the tire by removing the valve core and reposition components properly Place ina a safety cage or other suitable restraining device refer to OSHA rule 1910 177 paragraph B see Section 7 page 33 Use clip on chuck and stand behind barri er during inflation Do not lean on cage Inflate to rec ommended pressure Deflate completely to avoid local ized over stretching of the tube Reinflate to the tire manufacturer s recommended pressure Demounting recommendations for tubed tires 6 4 Demounting of tubed tires 6 5 NOTICE Tire must be co
48. nce 1977 all Alcoa aluminum disc wheels have been identified with a stamp that shows 5 8 the wheel load rating maximum inflation pressure date of manufacture part number wheel description and DOT marking designation Prior to June 1996 all Alcoa heavy duty truck wheels had the Alcoa identification symbol X on the outside of the disc neat the hand hole in line with the valve location This marking was phased out on heavy duty truck wheels manufactured after J une 1996 Load PUSS 120 Pounds Inflation Frazsu p Daeegranion ALCOAGFOnGED luaxpPu m lr norl DES PC fado pua 5x25 15 DS Wheel 28 Flat Base Wheel for Tube type Tires Tube type wheel part interchangeability WARNING Mismatched rim wheel components can lead to explosive Separation of wheel components Explosive separation of wheel parts can cause serious injury or death WARNING See chart below for matching components kikkri Me Dori TETTE EEE The following is the Alcoa Aluminum Wheel interchangeability information from the OSHA M rn Multipiece Rim Matching Chart For a complete matching chart write to U S Department of P ROS Labor Occupational Health and Safety b Administration Publications Department Room N4101 Washington DC 20210 m i Read across the chart to find interchangeable componen
49. ntinued on next page 13 Wheel cap nuts continued How to measure stud standout 4 3 2 piece 33mm hex head flange nut Mounts dualed wheels to wheel centering hubs with 32mm bolt holes Right hand threads used on both sides of vehicle P N 4307 32 M22x1 5 RH threads 1 1 8 cap nut Mounts standard single wheels and wide base wheels to 1 1 8 studs Also mounts outer dualed wheel to 1 1 8 inner cap nut P N 5996R 5996L replaces P N 5552R 55521 3 4 x16 cap nut Mounts Alcoa wide base wheels to 3 4 studs Do not use on steel wheels P N 5995R 59951 replaces P N 5554R 55541 shoulder Inboard mounted drum 2 piece 33mm hex head flange nut Mounts single wheels to wheel centering hubs with 32mm bolt holes Right hand threads used on both sides of vehicle P N 4306 32 M22x1 5 RH threads Inner cap nut inner wA thread 3 4 x16 outer bj thread 1 1 8 x16 For use ji with steel inner dual wheel an aluminum outer dual wheel with 1 31 1 5 16 to 1 44 1 7 16 stud standout P N 7896R 7896L Grade 8 Inner cap nut inner thread 3 4 x16 outer thread 1 1 8 x16 For use with standard length studs 1 31 1 5 16 to 1 44 1 7 16 stud stand out or longer studs not to exceed 1 88 1 7 8 stud standout Full internal and external threads P N 5978R 5978L Grade 8 For studs with out exposed shoulders Do not use with steel inner dualed wheel Inner cap nut f
50. ond flange Position inserted tool at 90 angle to tire assembly at top of wheel and lubricate bead areas on both sided of tool Lean tire assembly toward tool and rock or bounce to pry off the tire 14 Wheel Installation Recommendations 1 For the same reason the best tires are run on the front axle the best wheels also should be used on the front axle for proper n n 2 Make sure all wheel cap nuts are properly torqued check them often see 4 9 page 20 If the installation of wheel is loose the holes will pound out deform If some cap nuts are tight and others are loose the wheels wheel may develop cracks or studs may break Dirt streaks radiating from stud holes can indicate loose nuts see 2 1 page 3 3 Be sure the end of the wheel wrench is smooth or cover the wheel mounting surface with a protec tive shield prior to tightening the cap nuts The wrench end will mar the wheel around the cap nuts if 4 1 it is not smooth 4 Keep all component contact surfaces smooth and clean Dirt or projections in mounting area may lead to loose wheels Remove all projections resulting from burrs nicks etc Be sure that loose dirt does not fall into mounting area during assembly 5 Check for and replace bent broken cracked or damaged studs When replacing broken studs replace studs on both sides of the broken stud also If two or more studs are broken replace all the studs for that wheel 6 Do not introduce any foreign o
51. or 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 stand out Full internal and external threads counter bore 5 16 deep at open end Prevents stud from bottoming out in cap nut P N 5988R 5988L Grade 8 For use with studs with exposed shoulders Do not use with steel inner dualed wheel Stud standout is measured from the axle end mounting surface to the end of the stud End of Stud Mounting surtace Outboard mounted drum 16 Stud located ball seat are The nut seat for the stud located ball seat mounting system is a precision machined spherical surface Cap nuts must be properly manufactured to spherical assure seating Never use one or two piece flange cap nuts on a wheel designed with ball seats see 4 12 page 25 Ball seat cap nuts may be 4 4 obtained from your Alcoa Wheel Distributor E Single wheel Front wheels are mounted as singles and require 1 6 1 39 64 minimum stud standout Most vehicles have large 1 1 8 inch bus type studs on the front hubs Alcoa single cap stud located ball nuts Part Nos 5996R and 5996L or equivalents should be used Some front hubs have seat mounting 3 4 inch studs On these hubs use Alcoa single cap nuts Part Nos 5995R and 5995L or equivalents 4 5 MCI JA Alcoa Aluminum Wheel Cap Hut 1 6 inch minim la Correct single
52. ot length of 1 06 inch or 27mm for dualed wheels Typically hub piloted Alcoa aluminum wheels are mounted using two piece flange nut Part No 39701 with a 33mm hex head and a nut height of 1 06 inches 27mm If nuts with higher over all height are used more stud length is required When mounting painted steel inner dual wheels with outer aluminum wheels be cautious of excessive paint build up on the inner steel wheel Excessive paint can reduce the clamp ing force and allow the wheels to become loose Match mounted dual wheels should be put on the vehicle with the valve stems 180 apart Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices Should be reviewed Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of flange nuts should be done in recommended sequences WARNING Undertorqued flange nuts allow wheels to run loose and fatigue studs or lose nuts Overtorquing can stretch studs causing them to fail Both under and overtorquing can lead to wheel disengagement causing injury or death Check all parts including wheels studs and flange nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damage
53. oyment regulated under the Construction Safety Standards 29 CFR Part 1926 the Agriculture Standards 29 CFR Part 1928 or the Maritime Standards 29 CFR 1915 1918 3 All provisions of this section apply to the servicing of both single piece rim wheels and multi piece rim wheels unless designated otherwise b Definitions Barrier means a fence wall or other structure or object placed between a single piece rim wheel and an employee during tire inflation to contain the rim wheel components in the event of the sudden release of the contained air of the single piece rim wheel Charts means the United States Department of Transportation National Highway Traffic Safety Administration NHTSA publications entitled Safety Precautions for Mounting and Demounting Tube Type Truck Bus Tires and Multi Piece Rim Wheel Matching Chart or any other publications such as rim manuals containing at a minimum the same instruc tions safety precautions and other information contained on those charts that are applic able to the types of rim 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 compo nents to form a rim wheel including inflation Demounting means the opposite of mounting 33 OSHA Regulations continued Multi piece
54. ployee is instructed concerning the contents of the charts and rim manual in a man ner which the employee is able to understand 2 The employer shall assure that each employee demonstrates and maintains the abili ty to service rim wheels safely including performance of the following tasks 34 Regulations continued 39 i Demounting of tires including deflation ii Inspection and identification of the rim wheel components iii Mounting of tires including inflation with a restraining device or other safeguard required by this section iv Use of the restraining device or barrier and other equipment required by this section v Handling of rim wheels vi Inflation of the tire when a single piece rim wheel is mounted on a vehicle vii An understanding of the necessity of standing outside the trajectory both during inflation of the tire and during inspection of the rim wheel following inflation and viii Installation and removal of rim wheels 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
55. ra haie zz ox 13400 1600 rniHA gd rubis u RMT taper Dear post numer nci than in Tile oru iore wheels coniicit you Aksoy Wheel for pooper kx hiin and part comporibli y imarsadan xD bad fcu rou LU rad rou inr cerra Lar ued ul rer peered piece am Hee ot Shes wheal menmi ara TIF chin periny TEJU 35501 FRA 2550 545 eo 0 55 25 00 380 28 9 z 24 0 6 71 1441 5 71 1148 1 39 135 Ix sr TNI CDM Those musi be installed anty In ihe inert positon bocauee spherical ball caris aec on one side of the diac EIL E p EE TITIO SITO E Basso 70 Inspect thoroughly and frequently 2 1 Safe operation requires thorough examination of wheels both on and off the vehicle and attachment hardware at frequent intervals Wheels that have been in service need to be inspected at regular intervals to assure proper and safe performance Like tires and other vehicle components that work hard wheels will eventually wear out Itisn t always possible to predict exactly when the useful life of a wheel will end But generally older wheels and wheels operating in extreme conditions should be examined more frequently for obvious signs tha
56. s to the recommended torques following the same tightening sequence 1 1 C M 3 7 F N Y NU 40 2 Five Stud Six Stud 1 1 O 3 10 O n O _ f 80 aC 1 OO p Eight Stud Ten Stud Continued on the next page Tightening stud located ball seat cap nuts continued Single dualed and wide base wheels hub piloted mounting two piece flange nuts 4 10 After 50 100 miles of operation torque should be rechecked Loosen outer cap nuts on every other stud to check the torque on inner cap nuts then retorque outer cap nuts Repeat steps on remaining studs Check torque frequently from then on If nuts require frequent tightening studs break frequently or wheel nut seats are pounding out hardware and mounting practices should be reviewed Note whenever the outer cap nut is loosened ALWAYS retorque the inner cap nut before retorquing the outer cap nut Most U S manufacturers of highway trucks tractors and trailers which incorporate the hub piloted wheel mounting system require wheel studs and cap nuts which utilize metric threads Most frequently these are of a size designated as M22x1 5 Generally the same diameter stud is used to mount either single or dualed wheels Studs on both sides of the vehicle are right hand threads thereby eliminating the need for cap nuts peculiar to either the right or left side of the vehicle The same cap nut
57. seats on stud located wheels On hub piloted wheels look for elongated stud holes Over torquing can lead to damaged ball seats on stud located wheels and can damage the disc surface of 2 5 hub piloted wheels Remove damaged wheels from service Damages hub piloted bolt hole Damaged ball seat contact area Elongation from true round dashed cir Pounding of stud on ball seat contact cle indicated by arrows area identified by arrows Disc area 2 6 Inspect both sides of disc area for hand hole cracks If cracks are found remove wheel from service Rim area Check the entire rim area for nicks gouges and cracks Loss of air may be caused by cracks in areas around the valve stem hole Wheel should be removed from service 2 7 2 i a 1 setae ey det T wear Irregular wear on the surface of the rim flange is caused by the chafer and side wall area of the tire working on the surface of the rim flange Remove from service when rim flange wear is excessive Excessive wear can be determined using an Alcoa approved wear gauge and procedures Contact Alcoa for availability If rim flange wear becomes sharp and or cuts the tire contact Alcoa for recommended 2 8 maintenance procedures Gutter area 2 9 Projections on the side of the wheel gutter area can cause uneven seating of the side and lock ring and chipping of the gutter Such projections m
58. t they should be removed from service As an aid to the owner in determining the period of time a wheel has been in ser vice itis recommended the owner stamp an in service date onto the wheel atthe time he receives it See 5 5 page 27 for recommended stamping locations Pay particular attention to front end assemblies Examine all exposed areas fre quently Clean wheels and look for cracks or other damage Also check the inner dualed wheel when the outer wheel is removed During tire changes thoroughly examine the entire wheel Pay particular attention to the rim contour and the surfaces of the rim On tube type wheels carefully inspect the gutter area normally concealed by the side rings Be sure that the best wheels are on the front of the vehicle Hidden damage Some forms of wheel damage can be hidden beneath the tire so whenever a tire is removed thoroughly examine the complete wheel Remove all grease and road dirt Use a wire brush or steel wool to remove rubber from the bead seats Check mounting holes for the enlargement and elongation which can occur if the cap nuts are not kept tight see 2 5 page 8 Dirt streaks radiating from stud holes may mean that the cap nuts are loose see 4 9 page 20 Dimension checks 2 2 Open side circumference check Warning Wheels that have been subjected to a high pressure tire and rim separation or other abuse may no longer have sufficient dimension and contour to retain t
59. ts Chart Up to 1 Inch 42 CUR 43 E Eg pm 1 S pecifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J 694 August 98 Part numbers listed for all sizes are machine finish Polished finishes are indicated by changing the last digit of the part number listed to one of the following For polished outside only part number should end in 1 For polished inside only part number should end in 2 For polished both sides part number should end in 3 Valve hole is on the inside CLASS O TUBELESS WHEELS mund hand hole ENGLISH UNITS Ahead h lEs Ibe B hol stud booted kall cnt mou 8 750 in bokt cine 6 405 in hub bors det drum robes Fab coki 10 hole stud ball sent mounting 1 1 25 in bolt irole Vave Tao _ I EE 2 ERERODAEDC 9000 amp ion TRASH OC SC amp Sad 25400 44 400 62 EE 425 TR c40E soneno Se ee 44 400 275 Gas TREE 0 225420540 4 000 5 84 4 55 ion 45 a 228422540 6 000 5 42 ion 45 sone 0 mm Edd spe o T 425 ii 220654670480 o 72
60. ts for specific size and type of Alcoa wheel The information which is found in the shaded areas of the OSHA Multipiece Rim Matching Chart is represented in the table below IIT rr Ea ia ity I OB gets Tiam amem c5 T0 ando 7i PCT dala haa T ae 1 x 7 1 a mN T h mE 1 P d h T r p TE za cm ps sss nnus nuu nuam numm GUN GR TI acte wal Som l HC eo ee eae 477 ga L ars Esas T bd XS att Sw s ee iet kd 3 il Ee a oe ee a ETT my wb we EH EF I I L Ik 7 1 i 284 cur Le Lee MERE Tep oe n CHR TIT E cud 4 t Ea H EA dJ oa B 1 HE PIT g lol GE 4 LT out 29
61. use can shorten the life of a wheel Lack of care in changing a tire heavy pounding of the wheel rim overloading or hitting curbs at high speed or a sharp angle can damage wheels 5 1 Keep wheel nuts Wheel cap nuts must be kept tight see 4 9 page 20 When checking the cap nuts on tig ht dual disc wheels utilizing the stud located ball seat mounting system loosen every other outer cap nut and then check the torque of the inner cap nuts Retorque the loosened outer cap nuts Check all cap nuts for proper torque after the first use or any removal Inspect wheels and check wheel nuts during service stops See Section 2 page 3 Dirt 5 2 streaks from cap nuts may indicate looseness Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting prac tices should be reviewed The proper torque for ball seat cap nuts is between 350 and 400 foot pounds for stud threads lubricated with SAE 30W oil and between 450 and 500 foot pounds if threads are not lubricated The proper torque for M22 1 5 two piece flange nuts 33 mm hex head is between 450 and 500 foot pounds Lead balance Lead balance weights for Alcoa wheels are available from your Alcoa Wheel Distributor With radial tires it may be necessary to reduce the tire pressure to allow clearance of the
62. ust be removed Remove wheel from service if damaged A 0 0 es Cracking in bottom of gutter flange Occasionally circumferential cracks may appear in the bottom of the gutter area This area should be thoroughly cleaned and carefully inspected after a tire is removed from the wheel Also check the side underneath gutter flange for circumferential cracks Gutter flange cracks can ulti mately lead to the separation of the rim area from the disc Immediately remove from service a wheel that exhibits any cracks 10 Alcoa 15 Drop Center Wheel for Tubeless Tires Recommendations for mounting tubeless tires 3 1 NOTICE For complete information on tube type wheels contact Alcoa NOTICE Alcoa aluminum 19 5 RW and non symetrical well wide base wheels require special tire mounting techniques See Section 3 2 11 WARNING Use of inner tubes in tubeless wheels will hide slow leaks Slow leaks may indicate cracked or damaged wheels which lead to wheel failures WARNING Wheel failures can cause accidents which may result in serious injury or death Never use an inner tube on an Alcoa tubeless wheel and always remove cracked or damaged wheels from service 1 Do not gouge or nick the wheel Place aluminum wheels on a clean wooden floor or rubber mat when hand mounting tires 2 Always use a rubber leather faced or plastic mallet 3 Inspect the wheel for damage Do not use a damag
63. yees 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 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 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

Alcoa Wheel Service Manual Jan. 99 US English

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