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5 axle owners manual - Rackley Bilt Custom Trailers

1. ili Check all wheels at each tire change for proper contour of the open side of the rim Place the long leg of a carpenter s square across the center of the disc side of the wheel Extend the short leg across both rim flanges of the wheel as shown above Repeat this process at four equidistant points around the wheel The short leg should touch both rim flanges at each point If a distance greater than the thickness of a credit card appears between the short leg and the rim flange the wheel should be removed from service and scrapped 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 330 666 8121 or at www us tra org If the circumference of the bead seat does not match the required dimension as indicated by the ball tape remove the wheel from service Any wheel known to have been run with a flat tire or operated under abnormal conditions should be checked before continued service If a ball tape is unavailable roll the unmount
2. 6 Metal bow withievelgauge ____ 0 5 tolol lo A 8 Flow direction Rimen O O Drain cock wih barb tting o6 E am mo Z A A A ATATALATATA ESL A LA gt Note 1 10 11 are metal bowl with level gauge that comes with Standard Specifications Model AL10 AL20 AL30 140 40 06 AL50 AL60 Port size M5x0 8 1 8 1 4 1 4 3 8 1 4 3 8 1 2 3 4 1 Fluid Proof pressure 1 5 MPa Maximum operating pressure 1 0 MPa Note 1 4 30 1 4 30 Minimum dripping flow rate ANR 4 15 3 8 40 50 190 220 3 8 40 1 2 50 7 25 Oil capacity 135 Hecommended lubricant Class 1 turbine oil ISO VG32 Ambient and fluid temperature 5 to 60 With no freezing Bowl material Polycarbonate Bowl guard Option Standard Weight kg 1 13 Note 1 The flow rate is 5 drips min under the following conditions Inlet pressure of 0 5 MPa Class 1 turbine oil ISO VG32 Temperature at 20 Oil adjustment valve fully open Use air consumption flow rate for minimum dripping flow rate Accessory Part No Accessory Applicable model apo AL20 AL30 140 AL40 06 AL50 AL60 Bracket assembly Note AF20P 050AS 05045
3. 9 Routine Visual Operational Checks 5 Service and Lubrication Intervals 5 Foundation Brake Operational Check and Troubleshooting 6 Brake Adjuster Checking Procedures 8 Brake Adjuster Operational Check 8 Typical Parts Identification and Location 9 Torque Specifications 10 Frequently Asked Questions 11 Additional Parts and Service Information 12 Important Notice This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage The description and specifications contained in this service publication are current at the time of printing Haldex Brake Products Corp reserves the right to discontinue or modify its models and or procedures and to change specifications at any time without notice The automatic brake adjuster is a clearance sensing brake adjuster that maintains a nominal distance or clearance between lining and drum When the Brake Applies Upon brake application the brake adjuster rotates and moves the shoes into contact with the drum The clearance notch corresponds to the normal lining to drum clearance As the brake application continues the rack moves upward and rotates the one way clutch which slips in this direction As the brake torqu
4. Backspace 3 Wheel outset 86 same as offset Tire center line Tire center line J 47 9 Conversion Tables Inch Fraction Decimal and Inches Decimals Millimeters 1 64 0 0156 0 3969 Millimeter Equivalents 1 32 0 0313 0 7938 Chart 3 64 0 0469 01 1906 Up to 1 inch 1 8 0 1250 3 1750 9 1 17 64 11 64 0 1719 4 3656 3 16 0 1875 13 64 0 2031 5 1594 7 32 0 2188 15 64 0 2344 5 9531 1 4 0 2500 0 2656 6 7469 9 32 0 2813 38 95250 13 32 0 4063 10 3188 27 64 0 4219 7 16 0 4375 11 1125 29 64 0 4531 48 mones Decimals Miter 17 32 0 5313 13 4938 43 64 0 6719 17 0656 45 64 0 7031 17 8594 47 64 0 7344 18 6531 49 64 0 7656 19 4469 222250 22620 29 32 0 9063 23 0188 15 16 0 9375 23 8125 171140 25 4000 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 to PSI kPa x 0 145 PSI Pounds to Kilograms Pounds x 0 4536 Kilograms to Pounds kg x 2 2050 Pounds Foot pounds to Newton Meters Ft lbs 0 135582 N m Newton Meters to Foot pounds N m x 737561 Ft Ibs 49 Alcoa Wheel Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright O 2007 Alcoa Wheel Products Rights Reserved Form E37 13584 Printed in USA
5. NN 5607 1 GLAND RING 9 88 N8 1 _ TUE SOT END CAP RACKLEY 2 600 110 EI BILT CUSTOM TRAILERS DWG NAME DATE 9 2 2009 6 FRONT CYL A SCALE NONE SHEET 1 OF 1 MATERIAL NONE allt f WX 555 SA SS SEN BRAKE PARIT LISI PER WHEEL END REF NUMBER DESC MANUF NUMBER QUANITY 1 0 2 0 0 0 4 5 6 7 8 2 10 11 12 13 LDCK WASHER LELAND 1327 1 14 INSIDE NUT LELAND 2176 1 15 INSIDE WASHER LELAND Ey 1 EACH 16 340 4009 1 17 BRAKE SHUE LELAND rear 1 PAIR 18 BRAKE KIT W SPRINGS LELAND K501 1 KIT 19 20 S CAM RIGHT BENDIX Mi WKRiS 074 1 EACH 21 S CAM LEFT BENDIX 15 074 1 EACH 22 SLACK ADJUSTER HALDEX 40910216 1 EACH 23 CHAMBER TYPE 16 BENDIX 229816 EACH 1 EACH 24 CLEVIS KIT W PIN BUYERS ALUMINUM WHEEL SATIN 663170 POLISHED 6 LUG ALCOA ALUMINUN POL ISHED 6 pen 663178 ey 1 EACH 1 EACH Lubricator Series AL 10 to 60 How to Order AL 30 H F 03 Lubricator Bo dy size Description Applicable model 1000 cm tank AL30 to 60 10 20 30 40 50 60 10 1000 cm tank with level switch Lowest limit ON AL30 to 60 Thread type 11 1000 cm tank with level switch Lowest limit OFF AL30 to 60 2 Metal bowl A
6. 2 2 This manual is written in a style 3 Inspection and 6 2 seL Jdnspeebihorossbly and BDequentl y acea gt 6 Throughout the manual you losses 6 will find numbers which look 5 like this See Section 3 1 These NORTE 8 3 numbers are cross references to 3 5 Cracked or damaged wheel checks eese ettet toin tette tits tn essen testen 9 other sections of the manual The a eee GE 10 numbers 3 1 refer to section ere err 11 3 subtopic 1 You will find the 22 PSR CN Mem 12 section number and subtopic ao DT 12 4 number under the heading SENE E ce NEN 13 in each section CARES RU mm 13 3 12 Rim flange yy 14 3 13 Maintenance against corrosion Dura Bright surfaced treated WHEEIS 19 3 14 Dura Bright surface treated wheels cleaning and maintenance reet etia etn tnnt as 19 5 4 Alcoa 15 Drop Center Wheel for Tubeless 20 6 4 1 Recommendations Tor mounting tubeless 20 4 2 Mounting tubeless Gre Utd Extat 21 4 3 Mounting tires on reduced well 22 4 4 Rim width to tire matching Nm 23 4 5 Recommendations f
7. Then back off the adjuster by turning the adjusting hex counter clockwise 1 2 of a turn fig 12 A minimum of 13 ft 16 is necessary to overcome the internal clutch A ratcheting sound will be present Do NOT use an impact wrench internal damage will occur FINAL INSPECTION With full service brake application assure that spring brakes are released and check that the Installation Indicator is within the slotted area IF NOT REPEAT Step 3 Figure 12 Note To ensure proper fit and function always replace both adjuster and mounting bracket Routine Visual Operational Checks Haldex strongly recommends that routine visual operational checks including brackets and control arms be performed at each Preventative Maintenance Service Interval Adjusters or anchor brackets that have visual damage or which fail the operational checks MUST be replaced immediately Automatic adjusters should not be operated as manual adjusters except as may be necessary to get the vehicle off the road for service Service and Lubrication Intervals Lubrication Type of Visual Check Adjuster Type Interval Lubricant Interval Standard Brake Adjuster 419 10 4 000 to 6 000 Standard Chassis Each Preventative miles or every Grease Maintenance 3 months Service Interval Notes Moly disulfide grease should not be used because it may affect the function of the internal friction clutches and
8. 11 Stud holes If wheels are run loose both stud located wheels and hub piloted wheels can be damaged Look for wallowed out or elongated ball seats on stud located wheels On hub piloted wheels look for elongated stud holes Over torquing can lead to damaged ball seats on stud located wheels and can damage the disc surface of hub piloted wheels Remove damaged wheels 3 9 from service Damaged hub piloted bolt hole Elongation Damaged ball seat contact area Pounding from true round dashed circle indicated by of nut on ball seat contact area identified by arrows arrows Disc area 3 9 Inspect both sides of disc area for hand hole cracks If cracks are found remove the wheel from service 12 Check the entire rim area for nicks gouges and cracks Loss of air may be caused by cracks in areas around the valve stem hole Remove the wheel from service 3 10 Bead seat cracks Loss of air may be caused by cracks in the bead seat areas around the rim Remove the wheel from service if damaged 3 11 Bead seat cracks are normally caused overloading of the wheels If you have this type of wheel breakage it would be recommended to look into severe service wheels 13 Rim flange wear 3 12 Irregular wear on the surface of the rim flange is caused by abrasion from the tire chafer and sidewall Rim flange wear happens most often in applications with heavy or shifting loads If you are experi
9. How far do 1 back off the automat ic brake adjuster at a brake reline 1 2 turn NOTE for the first 1 8 turn you may not hear the ratcheting this is normal o How do know if need an offset angled straight armed adjuster Haldex manufactures the right adjuster arm for your specific application Haldex adjusters are unhanded no lefts or rights in the majority of applications Please refer to the Haldex Parts and Cross Reference Guide for your specific application 100090 o Why does my replacement ABA look different from the original I took off The Haldex ABA replacement adjuster has been designed to fit a number of applications It is the same original equipment quality and design of the adjuster you removed however it may look different on the outside If you use all the parts included in the kit the results will be the same as the original equipment adjuster Why is the applied stroke pressure range 90 100 psi at the reservoir This is the pressure recommended by the CVSA Commercial Vehicle Safety Alliance Anything beyond 100 psi measures deflection within the foundation brake and not true push rod stroke 8 Some brake chambers have round port openings and some square what is the difference otandard brake chambers are identified by round ports Long stroke chambers are identified by square ports and trapezoid ID tags 9 Can I vary the amount of lining to drum clearance
10. 3 Do not use in a place subject to heavy vibrations and or shocks 4 Do not mount the product in locations where it is exposed to radiant heat Warning 1 Maintenance procedures are outlined in the operation manual Not following proper procedures could cause the product to malfunction and could lead to damage to the equipment or machine 2 Maintenance work If handled improperly compressed air can be dangerous Assembly handling and repair of pneumatic systems should be performed by qualified personnel only 3 Drain flushing Hemove drainage from air filters regularly Refer to the specifications 4 Shut down before maintenance Before attempting any kind of maintenance make sure the supply pressure is shut of and all residual air pressure is released from the system to be worked on 5 Start up after maintenance and inspection Apply operating pressure and power to the equipment and check for proper operation and possible air leaks If operation is abnormal please verify product set up parameters 6 Do not make any modifications to be product Do not take the product apart DESCRIPTION The rotochamber is an actuator which converts the energy of air pressure into mechanical force The type number of the rotochamber indicates the actuator s diaphragm effective area Type 30 30 sq in of diaphragm and the various sizes available give a wide range of output force and length of stroke The rolling type diap
11. Dualed wheels stud cap nuts Alcoa recommends use of inner cap nuts 5978R 5978L or 5988R 5988L see 5 2 page 26 located ball seat mounting Cap nuts recommended by Alcoa are compatible with Alcoa wheels Hardware of equal dimensions and strength may be used Continued on next page 5 6 28 Dualed wheels stud located ball seat mounting 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 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 Most vehicles have standard length studs 1 31 inch 1 5 16 inch to 1 44 inch 1 7 16 inch stud standout Some vehicles use studs longer than standard up to 1 88 inch 1 7 8 inch standout When changing types of brake drums be sure to check for excessive stud standout greater than 1 88 inch 1 7 8
12. OVAL PARK MIDTURN LAMP GROTE G6003 9242 2 EACH MOUNTING RUBBER OVERSIZE LUAD PLUG VARIES NONE 4 EACH PARALLEL WIRE PHILLIPS 2 403 AS NEEDED REAR 1 PHILLIPS 36 9400 5050 1 EACH CUSTOM HARNESS EXTENSION PHILLIPS 60 5019 05 2 REAR T PIG TAIL PHILLIPS 36 9501 2 EACH LICENSE PLATE LIGHT GROTE 60101 LUE OPTIONAL MARKER LIGHT 3002 7 92120 2 10 REAR T LICENSE 0 MARKER PHILLIPS 36 9601 1 EACH HARNESS 11 ID MARKER LIGHT TRUCK LIGHT 60101 1 EACH 7 WAY WIRE PHILLIPS 3 326 AS NEEDED MID TURN HARNESS PHILLIPS 36 9000 360 1 7 SOCKET SOCKET BOOT PHILLIPS 16 722 15 740 2 MALE 7 WAY PLUG PHILLIPS 15 730 1 HARNESS PHILLIPS 10 7319 00 1 EACH STOP TAIL TURN LLIGHT MT G400279174 RUBBER 4 EACH CLEARANCE MARKER LIGHT G100479140 m RUBBER RED OPTIONAL MARKER LIGHT PANEL LITE MILLENIUM go 21 me RR BILT CUSTOM TRAILERS DWG NAME DATE 9 2 2009 5 AXLE ELECTRICAL SCALE NONE SHEET 1 OF 1 MATERIAL NONE TRAILER 5 EXPANDO PNEUMATIC AIR VALVECREXROTH QUICK COUPLER 3 VALVE ole cco BILT CUSTOM TRAILERS DWG NAME DATE 9 2 2009 5 AXLE PNEUMATIC SCALE NONE SHEET 1 OF 1 MATERIAL NONE TRAILER 5 EXPANDO MWY MOS
13. or 2 when used in an outset position t Indicates European New Generation Wheels tt Check with vehicle manufacturer or axle manufacturer before retrofitting to outset wide base wheels to insure compatibility with axle and wheel end components P Ns 841100 841400 and 841600 are not recommended for use on spindle trailer axles Hub cover system kits P N 076085 front and P N 077085 rear contain screw on Hug A Lug cap nut covers and require a minimum of four threads of the stud to extend above the tightened cap nut for use The minimum stud standout required for P N 833580 is 2 375 inches 60 3mm when using wheel nut P N 39874 Taller nuts will require more stud standout P Ns 885600 and 985600 are Alcoa Severe Service Wheels Effective April 1 2007 the DB Finish Option will fall under the Non Stock Policy Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 with bead seat diameters measured in 0 5 inch increments opecifications are subject to change without notice To request a copy of the current Alcoa Specifications Data brochure for aluminum wheels for trucks trailers and buses call toll free 800 242 9898 option 1 To view online go to www alcoawheels com The Spec Data brochure contains current part number availability and complete specifications such as wheel dimensions load rating wheel weight ou
14. s circum ference and make sure that no area of the flange is below what the gauge indicates is accept able If the entire wheel flange is within the limits of the rim flange wear gauge the wheel may be returned to service STEP 7 Always inspect the wheel for any other conditions that would warrant removal from service Consult the Alcoa Wheel Service Manual or the TMC User s Guide to Wheels and Rims WARNING Welding or brazing the rim flange or any area of an Alcoa aluminum wheel will weaken the wheel Weakened or damaged wheels can lead to an explosive separation of tires and wheels or wheel failure on the vehicle WARNING Explosive separations of tires and wheels or wheel failure on the vehicle could cause injuries or death Never attempt to weld or braze any surface of an Alcoa aluminum wheel WARNING Returning wheels to service with inadequate flange height as determined by the Alcoa Rim Flange Wear Gauge can lead to an explosive separation of tires and wheels Explosive separation can result in serious injury or death WARNING Wheels with flange height that falls below the Alcoa gauge have inadequate rim flange height to support the tire on the rim Permanently remove any wheel from service that has inadequate rim flange height WARNING Excessive heat from fire brake malfunction wheel bearing failure or other sources may weaken the metal and cause the wheel tire assembly to separate explosively Exploding wheel tire as
15. 9 75 365 70R 10 5 15 11 75 12 25 385 65R 11 75 12 25 425 65R 11 75 12 25 13 00 16 5 12 25 13 00 18 13 00 14 00 445 508 14 00 445 556 14 00 445 658 12 25 13 00 14 00 8 5 25 6 00 6 75 11 7 50 8 25 225 70R 6 00 6 00RW 6 75 275 80R 7 50 8 25 285 75R 8 25 245 70R 6 75 6 75RW 7 50 12 8 25 9 00 7 50RW 305 75R 8 25 9 00 265 70R 7 50 7 50RW 8 25 8 25RW 285 708 8 25 8 25RW 9 00 305 70R 8 25 8 25RW 9 00 445 65R 13 00 14 00 There may be additional rim to tire matches not shown above Contact the tire manufacturer or your Alcoa wheel representative for additional information Recommendations for WARNING aluminum wheel can be structurally weakened by uncontrolled excessive demounting tubeless heat tires Tire wheel assemblies using wheels that have been exposed to excessive heat may WARNING experience a sudden and unpredictable tire wheel separation causing serious injury or death Immediately and permanently remove any wheel from service that has been subjected to uncontrolled excessive heat such as a tire fire wheel bearing failure or braking system 4 5 drag seize or a high pressure tire wheel separation WARNING Damaged tires or wheels can lead to an explosive separation of tires and wheels Explosive separation can result in serious injury or death WARNING Inspect tires and wheels for damage before removing from vehicle If damage is found tire must be completely deflated bef
16. BUS RV and MOTORHOME WHEELS Wheels with bead seat diameters measured in 5 inch increments and Alcoa tube type wheels Alcoa warrants to the original purchaser from Alcoa or its authorized distributor that a new Alcoa aluminum disc heavy duty truck truck trailer bus 19 5 inch and 22 5 inch RV or motorhome wheel is free from defects in material and workmanship Alcoa agrees without charge to repair or replace a wheel that fails in normal use and service because of defects in material and workmanship Truck truck trailer Dura Flange and the Dura Bright surface treatment wheels not used in transit service are warranted for 60 months from the date of manufacture as shown on the wheel except the Dura Flange rim flange treatment is warranted for a period of 24 months Alcoa bus mount wheels 10 hole 11 25 inch bolt circle 8 670 inch hub bore with 1 22 inch diameter bolt holes and other wheels used in transit service are warranted for 120 months from date of manufacture except the Dura Bright surface treatment on bus and transit service wheels is warranted for a period of 60 months from the date of manufacture and the Dura Flange rim flange treatment is warranted for 24 months Satin finish polished and Dura Bright surface treatment 19 5 inch and 22 5 inch RV and motorhome wheels are warranted for 120 months from the date of manufacture as shown on the wheel Alcoa does not warrant and will not repair or replace or make adjust
17. Rear inner cap nuts 4000 29 6 5 0 4 25 110 Do not exceed maximum wheel load Customer must compare vehicle load rating to maximum wheel load rating Do not overinflate Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to ensure proper clearance from any obstructions Capacity ratings as dual or single in highway service bias ply or radial Load ratings in Ibs for items 31 through 42 rounded to nearest multiple of 5 Part numbers listed for all sizes are satin finish the last digit of the six digit numerical part number is 0 Polished finishes are indicated by changing the 0 with any of the suffixes in the adjacent column Available Finishes Some wheels may bear part numbers not shown in this manual Before servicing these wheels contact your Alcoa wheel representative for proper load inflation and part compatibility information Outset positive inset negative The distance from the rim centerline to the mounting face of the wheel Inset negative places the rim centerline inboard of the wheel mounting face and outset positive places the rim centerline outboard of the wheel mounting face dual spacing offset The Dura Bright surface treatment and the Dura Flange options are not currently available together on the same wheel Part numbers should end in 1 or 9 when used in an inset position and 0
18. amp R 5996 L amp R 10 hole stud located ball seat mounting 8 750 bolt circle 6 495 hub bore 1 219 bolt hole diameter DiscMate nut covers 150 Hub covers Rear inner cap nuts 5988 L amp R Rear inner cap nuts 51 7896 L amp R 15 3 4 Stud 5995 L amp R 2 17 5x6 75 15 DC 5070 31 9 00 4 72 125 TR543C 663070 0 2 2125 1 1 8 Stud 5996 L amp R 5996 L amp R 10 hole stud located ball seat mounting 1 1 25 in bolt circle 8 73 hub bore 1 219 bolt hole diameter DiscMate 3 4 016000 1 1 8 017000 Lug nut covers 150 Hub covers Front 076015 Hub Covers Rear 077015 Rear inner cap nuts for wheel P Ns 883110 893000 and 983120 only 5988 L amp R AI Stl 7896 L amp R All other wheel P Ns 3 22 5 8 25 150 7200 53 6 66 5 68 120 5450 883110 E DE 2225 4 22 5 9 00 1506 9000 60 694 5 94 130 TR543C 893000 0 1 2 2127 2 5 22 5 12 25 15900 11 400 62 0 130 543 823000 0 2 6 22 5 12 25 152006 11 400 66 388 276 130 TONS 823050 0 1 2 9 2 7 22 5 12 25 15000 11 000 70 584 4 68 130 TR545E 8230604 0 1 7 8 22 5 14 00 1506 12 800 71 20 130 TR543E outset 841100 0 2 9 24 5 8 25 1500 7200 59 66 559 120 TR545D 983120 0 1 2 3 4 Stud 5995 L amp R 1 1 8 Stud 5996 L amp R Eight hole hub piloted mounting 275mm circle 221 1 hub 26 75 bolt hole diameter use two piece flange n
19. and in good condition B Every year or after each 100 000 miles or 3 600 operating hours depending on type of operation 1 Disassemble and clean all parts 2 Install new diaphragm or any other parts if they are worn or deteriorated When the diaphragm spring or both are replaced they should be replaced in the corresponding chamber on the same axle OPERATING AND LEAKAGE TESTS A Operating Test 1 Apply brakes and observe that the push rods move out promptly and without binding 2 Release brakes and observe that the push rods return to the released position promptly and without binding Check push rod travel Push rod travel should be as short as possible without brakes dragging Adjust travel of push rod at slack adjuster if necessary B Leakage Test 1 Loosen rubber boot from around push rod hole in cover Make and hold a full brake application Coat area with soap suds and check for leakage No leakage is permissible If leakage is detected the diaphragm must be replaced REMOVING 1 Block vehicle wheels 2 Disconnectline to rotochamber Remove the yoke pin 4 Remove the rotochamber INSTALLING 1 Before installing chamber check bracket for distortion cracks or any condition which might cause chamber misalignment or malfunction 2 Re install the chamber the bracket Tighten the mounting nuts securely and evenly 3 air lines to the rotochamber and check for leaka
20. front face Turning the needle clockwise increases the amount of the lubricant and turning it counterclockwise until fully opened shuts off the lubricant The needle on the side that is not used should be left fully opened Note The operating principle for AL20 to 60 types is different from that of AL10 j Be sure to read before handling jRefer to pages 14 21 3 to 14 21 4 Safety Instructions and Common Precautions Warning 1 Do not introduce air from the outlet side as this can damage the damper Caution 1 Use a check valve Series AKM to prevent back flow of the lubricant when redirecting the air flow before the lubricator Warning 1 For AL 10 and 20 type replenish the lubricant after releasing the inlet pressure Lubrication cannot take place under a pressurized condition A Caution 1 Check the dripping amount once a day Drip failure can cause damage to the components that need lubrication Lubricator Series AL 10 to 60 Construction AL10 AL20 JIS Symbol lt gt c SE gt 3 3 S gt Dim AL30 40 m oe LL Y PPA gt Component Parts M Material een AL10 20 Zinc die casted Platinum silver Replacement Parts Part no bii AL10 AL20 AL30 AL40 AL40 06 AL50 AL60 Sightdome assembly _ PC_ AL10P 080AS AL20P 080AS AL20P 080AS AL20P 080AS AL20P 080AS AL20P
21. studs not to exceed 1 88 1 7 8 stud standout Full 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 internal and external threads P N 5978R 5978L Grade 8 For studs without exposed shoulders Do not use with steel inner dualed wheel 3 4 x16 cap nut Mounts Alcoa wide base wheels to 3 4 studs Do not use on steel wheels P N 5995R 5995L replaces P N 5554R 5554L Inner cap nut for use with _ standard length studs P9 1 31 1 5 16 to 1 44 _ 1 7 16 stud standout or longer studs not to exceed 1 88 1 7 8 stud standout Full internal and external threads counter bore 5 16 deep at open end Prevents stud from bottoming out in cap nut P N 5988R 5988L Grade 8 For use with studs with exposed shoulders Do not use with steel inner dualed wheel 26 How to measure Stud standout is measured from the axle end mounting surface the hub for inboard mounted drums stud stand out and the drum for outboard mounted drums to the first complete thread at the outside end of the 5 3 Exposed zs shoulder First full thread Stud standout First full thread Stud standout NS Mounting Mounting surface surface Inboard mounted drum Outboard mounted drum stud located ball seats are spherical The nut seat for the stud located bal
22. 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 BORE The center hole of a disc wheel dimensions stated in diameter inches or millimeters HUB PILOTED MOUNTING A wheel mounting system which uses the hub to center the wheel and two piece flange nuts to secure it in Abbreviation for inches INNER CAP NUT Cap nut used to mount the inner wheel in a dualed stud located wheel system INSET The distance from the wheel mounting surface to the rim centerline when the centerline is placed inboard of the mounting surface kg Abbreviation for kilogram weight measurement equal to 1000 grams kPa Abbreviation for kilo Pascals pressure measurement 45 46 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 N m Abbreviation for
23. 080AS AL20P 080AS 3 Lubrication plug assembly AL20P 060AS AL30P 060AS AL40P 060AS AL40P 060AS AL40P 060AS ALAOP 060AS Damper retainer assembly 0 030AS ALSOP 5 Damper assembly Synthetic resin AL50P 040AS ALGOP 040AS 6 C 2 AL20P 030AS AL30P 030AS 50 030 8 ALGOP 030AS NBR 5 2605 25 2605 C3SFP 260S C4SFP 260S CASFP 2608 CASFP 260S 2605 C1SL C2SL C3SL 3 C4SL 9 C4SL 9 C4SL 3 C4SL 3 Note 1 Add 1 at end of the part number when ordering a damper retainer assembly for 1000 Example 030 1 Note 2 Including O ring Please contact SMC regarding the bowl assembly supply for PSI and F unit specifications Note Bowl assembly for AL30 60 comes with a bowl guard steel band material SMC 14 2 63 Y Series AL 10 to 60 Dimensions AL10 AL20 Bracket Option Port size Port size Min clearance for maintenance Min clearance A i for maintenance AL30 40 AL50 60 Port size Bracket Option Bracket Port size Option Min clearance for maintenance Min clearance for maintenance Applicable model AL10 AL20 AL40 AL40 06 AL50 AL60 Metal bowl with Metal bowl with Metal bowl with Metal bowl with drain Drain cock with With drain cock Metal bowl With drain cock level gaug
24. 3 8 T 1 2 3 8 T 1 Dora 4 1 2 T4 2 1 4 T 1 2 1 4 T 4 1 1 4 1 4 1 1 3 16 T 1 2 1 4 T 1 1 3 8 X 89 3 4 T 1 1 1 4 T 1 1 OPT 1 4 1 1 1 4 T 1 2 1 4 T 1 2 1 4 T 1 2 3 T 1 5 4 X 6 STRAP X 6 OPTIONAL 3 4 X 6 STRAP STH WHEEL PLATE MEMBER 5 0010 NECK RAMP 5 0018 RAMP CATCH CROSS MEMBER 5 0008 RAMP SUPPORT MEMBER 5 001 RAMP SUPPORT CHANNEL 5 0019 GUSSET 5 0007 RAMP CATCH GUSSET BTM PLATE 5 0009 5 AXLE NECK CATCH DOG FORMED EXPANDO NECK BRACE 5 0017 P N 5 0005 NECK WEB 5 0001 SHACKLE LOCK 5 0012 5 AXLE NECK PIN 200720 NECK SHACKLE 5 NECK 0002 NECK FISH PLATE 5 0004 NECK LATCH PLATE 5 0005 TRAILER 5 EXPANDO 43 4 520 OVERALL LENGTH 10 11601 EXPANDED 9 1081 CLOSED BILT CUSTOM TRAILERS DWG NAME DATE 9 2 2009 5 AXLE DIMENSIONS SCALE NONE SHEET OF 1 MATERIAL NONE gt 991 9o 2 gt e gt gt S NO 3JAVN SHSaTIVaL 121419913 20 gt Im 20 lt U m gt gt lt m m gt lt T gt Z TRAI
25. Circle Mounting Type Backup Diameter Thread Size 11 1125 inch inch U US Stdpilt Stud 05 Stud pilot 13 2 13 13235 13235 1201 125 in 285 75mm Hub pilot 13 2 13 4 in 150452 __ _____ Gem nemen Certain environments can lead to corrosion Some of these are salt magnesium chloride and rrosion Corrosio calcium chloride compounds used for snow removal and highly alkaline materials If the air used to fill tubeless tires or the tire itself is not dry the areas of the wheel under the tire can corrode severely Bead seat and valve stem corrosion are often caused by entrapped moisture Mild corrosion should be removed thoroughly by wire brush and the rim protected with non water based tire lubricant see Section 4 1 Remove any severely corroded wheel from service 3 7 d T lt aix ife d dx LEA Pu ri m a 220222 2 54 Hub bore gauge with severe corrosion Remove severely corroded wheel from service Hub bore with severe corrosion Remove any severely corroded wheel from service CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface CATION 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
26. Newton meters OFFSET See OUTSET OPEN SIDE The side of the wheel opposite the disc face OSHA Abbreviation for the U S Department of Labor Occupational Health and Safety Administration OUTER CAP NUT A cap nut used to secure the outer stud located wheel in a dualed wheel pair and thread onto the inner cap nut OUTSET The distance from the mounting surface of the wheel to the rim centerline when the rim centerline is mounted outboard of the hub face This dimension is the same as the 1 2 DUAL SPACING dimension PILOT PAD The raised surfaces on a hub used to center a hub piloted wheel PSI Abbreviation for pounds per square inch REVERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tire centerline RIM CENTERLINE A line to the radial axis of the wheel running through the mid point between the rim flanges RIM FLANGE That portion of the rim which extends above the rim surface which retains the tire bead RIM That portion of the wheel which 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 wheel mounting system which uses the studs and sphe
27. Treated Wheels are warranted against a Filiform corrosion worm or hair like lines generally milky in appearance underneath surface protective treatment and emanating from damage to the surface treatment such as nicks scratches or damage from mounting hardware or wheel weights b Blistering due to loss of adhesion of the surface treatment c Lift off of the surface treatment due to physical damage nicks scratches gouges If nicks dings scratches or other damage does occur to the Dura Bright treatment that exposes the aluminum underneath the metal exposed may naturally oxidize but any corrosion will be confined to the metal exposed and will not extend into or underneath the Dura Bright treatment Normally any washing materials or chemicals including mild acid washes that can safely be used on a vehicle its painted surfaces and components can safely be used on the Dura Bright surface treatment The Dura Bright treatment prevents corrosion of aluminum wheels and protects their shine So long as the treatment remains in place see comments g and h above and is maintained in accordance with the Alcoa Dura Bright Care and Maintenance manual it is warranted against corrosion If corrosion does occur within the treatment warranty period subject to the limitations stated above Alcoa will replace any wheel exhibiting such corrosion There is no warranty that the wheel shall be merchantable or fit for any particular
28. compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer recommendation for proper tire pressure Before mounting the tire perform wheel fitment check to insure proper clearance from any obstructions NOTICE When match mounting tires on Alcoa wheels locate valve stem adjacent to low point mark on the tire NOTICE Alcoa aluminum 19 5 RW nonsymmetrical wheels require tires to be mounted and demounted over the disc side of the wheel only NOTICE Refer to tire 5 recommendation for proper tire pressure 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 CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface Severely corroded wheels are unsuitable for service Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced under the Alcoa limited warranty Heavy duty truck tires have a guide rib molded into the sidewall
29. inch Excessive stud standout may cause the inner cap nut to bottom out on the longer stud preventing proper seating of the wheel Each outer dual wheel is attached by 10 single cap nuts which thread on the inner cap nuts Use Alcoa outer cap nuts Part Nos 5996R 5996L or equivalents Match mounted dual wheels should be put on the vehicles with the valve stems 180 apart DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the dual aluminum wheels as shown below DiscMate when used Alcoa aluminum wheels Outer cap nut P N 5996R or L See 5 2 page 26 Hub Inner cap nut P N 5978R or L or P N 5988R or L See 5 2 page 26 1 31 to 1 44 stud standout Correct mounting for dual aluminum stud located ball seat mount wheels WARNING Incorrect inner nuts used with dualed aluminum wheels bottom out on the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running wheels can lead to stud WARNING breakage Use only cap nut 5978R or L 5988R or L or their equivalent when mounting dual alumi num wheels O
30. navigation vehicles medical equipment food and beverages recreation equipment emergency stop circuits clutch and brake circuits in press applications or safety equipment An application which has the possibility of having negative effects on people property or animals requiring special safety analysis 5 14 21 3 Common Precautions Be sure to read before handling For detailed precautions on every series refer to main text A Warning 1 Confirm the specifications Products represented in this catalog are designed for use in compressed air appllications only including vacuum unless otherwise indicated Do not use the product outside their design parameters Please contact SMC when using the products in applications other than compressed air including vacuum A Warning Instruction manual Install the products and operate them only after reading the instruction manual carefully and understanding its contents Also keep the manual where it can be referred to as necessary Securing the space for maintenance When installing the products please allow access for maintenance 3 Tightening torque When installing the products please follow the listed torque specifications A Caution Before piping Make sure that all debris cutting oil dust etc are removed from the piping 2 Wrapping of pipe tape When screwing piping or fit
31. next to the tire bead When the tire is inflated this ring should be evenly spaced from the wheel rim all the way around the wheel Check the position of the ring before removing the assembly from the inflation cage If the ring and wheel are not concentric deflate the assembly in the cage and remount the tire Mounting tires on reduced well wheels Reduced well wheels feature an increased underwell diameter and also have a nonsymmetrical sloping rim profile which provides additional brake drum clearance Although tires can be fitted to these reduced well wheels from either side mounting and particularly demounting is easier from the disc side of the wheel In order to minimize the possibility of bead damage tires should be fitted to and removed from all Alcoa reduced well wheels only across the disc side of the wheel Tires should be mounted gt demounted only across the disc side of the wheel S Rim to tire Rim width to tire matching chart for medium and heavy trucks matching Tire Size Tire Size for both radial Approved for both radial Approved and bias tires Rim Widths and bias tires Rim Widths 4 4 8R 6 00HC 8 5 25 6 00 6 75 215 756 6 00 6 75 9 6 00 6 75 7 50 9R 6 75 10 6 75 7 50 8 25 6 75 7 50 245 756 6 75 7 50 245 756 6 75 7 50 11 7 50 8 25 8 25HC 255 70R 7 50 8 25 265 75R 7 50 8 25 12 8 25 9 00 295 75R 8 25 9 00 305 85R 8 25 9 00 315 80R 9 00
32. 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 recommend ed 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 WARNING Check all parts including wheels studs and flange nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damaged parts Follow correct tightening sequences and torque levels Two piece flange nuts with a 33mm hex head design see Section5 2 used with hub piloted wheels should be tightened to a torque of 450 to 500 foot pounds Two piece flange nuts with 1 1 2 inch hex head design and other designs have different torque requirements Inquire of the manufacturer for the proper torque values 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
33. point 1a 1b AMR 05 ITV d MOAN VY1 a c Float switch PPA Part no 15400 1 to 2 AL PE 9 6 S 5 gt 12 3 40 70 i8 883 sa 388 38 75 35 4t 90 35 47 382 AL60 385 SMC 14 2 65 O Safety Instructions These safety instructions are intended to prevent a hazardous situation and or equipment damage These instructions indicate the level of potential hazard by labels of Caution Warning or Danger To ensure safety be sure to observe ISO 4414 Note 1 JIS B 8370 Nete 2 and other safety practices Caution 2 Operator error could result in injury or equipment damage Warning Operator error could result in serious injury or loss of life Danger In extreme conditions there is a possible result of serious injury or loss of life Note 1 ISO 4414 Pneumatic fluid power General rules relating to systems Note 2 JIS B 8370 General Rules for Pneumatic Equipment Z Warning The compatibility of pneumatic equipment is the responsibility of the person who designs the pneumatic system or decides its specifications Since the products specified here are used in various operating conditions their compatibility for the specific pneumatic system must be based on specifications or after analysis and or tests to meet y
34. seal between the bead and tire rim 8 Never lubricate the rim or tire bead with a flammable solution This can lead to an explosion during airing of the tire or in subsequent operation of the vehicle see Warning on next page 9 f using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel 10 Use only dry air for tire inflation The use of moisture traps in the air compressor feed line is rec ommended 11 Do not overinflate Use the tire manufacturers recommended pressure but under no circumstances exceed cold tire pressures listed in Section 2 Specifications of this manual see page 3 12 When inflating a tire in an inflation cage or while mounted on a vehicle always use a clip on air chuck or threaded straight chuck and a remote valve with pressure gauge Securely anchor the inflation cage and during inflation or handling of an inflated wheel and tire assembly stay out of the path of potential exploding parts or air blasts Recommendations for WARNING Use of a volatile or flammable material such as ether or gasoline as an aid mounting tubeless tires to seating the tire beads on the wheel can lead to an uncontrolled pressure build up in the continued tire and may result in an explosion WARNING Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire on or off the vehicle or later on the road Loss of veh
35. 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 lubri cate the face of the wheel hub or brake drum see illustration on the next page Continued on the next page Lubricate the hub pads or the wheel hub bore generously with non water based Tightening hub lubricant piloted mounting two piece flange nuts continued 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 SAE 30W oil This will minimize corrosion between the mating surfaces Lubrication is not necessary with new hardware Lubricate here Lubricate here Position one of the hub s pilot pads at the twelve o clock position After positioning wheels on the pilot pads hand tighten all two piece flange nuts then tighten to the recommended torque following the proper sequence shown below for your type wheel After 5 50 miles of operation or at least the first service opportunity torque should be rechecked Check torque frequently from then on If nuts require frequent tightening studs break frequently or wheel bolt holes are pounding out hardware and mounting practices should be reviewed NOTICE In service stud dimensions and condition may change over time due to 1 2 1 environmental condit
36. 0 000 53 3 12 130 545 893630 0 1 008 108 39874 19 22 5x10 50 15 DC 10 500 68 6 61 5 5 130 TR543 803600 0 1 008 108 39874 20 22 5 12 25 1506 12 300 63 130 TR543E 823600 0 2 39874 0 1 2 008 T TR543E outset 1DB 2DB _ 21 22 5 12 25 150 11 400 66 3 88 275 130 12320159 823650 ODF 1DF 206 39874 9 SDB 9DF 0 1 ODB 22 22 5 12 25 1506 11 000 71 58 468 130 TR542 823640 1DB ODF 39874 1DF 23 22 5x13 00 15 DC 12 300 73 3 5 2 38 130 833650 0 1 2 9 39874 inset 24 22 5 13 00 150 11 000 74 6 42 5 3 130 TR542 833640 0 1 39874 25 29 5x14 00 15 DC 12800 71 20 130 841600 02008 39874 1DB 2DB 0 1 2 9 126 225x14 00 15 DC 12 800 71 1 13 0 130 545 841610 008 108 39874 TR543E inset 2DB 9DB 0 1 2 3 ODB 108 208 308 27 24 5 8 25 1520 7400 56 6 6 5 73 130 5450 983640 ODF 1DF 2DF 8864 39874 3DF 0 1 2 ODF 28 24 5 8 25 1520 8000 65 6 6 5 63 130 TR545D 985600 2DF 39874 10 hole hub piloted bus mounting 1 1 25 in bolt circle 8 670 in hub bore 1 219 in bolt hole diameter use two piece flange nuts DiscMate 015000 Lug nut cover 182 Hub covers Rear inner nuts 0 3 ODB 29 22 5 8 25 1506 7300 53 666 5 82 120 TR545D 883610 ODF 4 3DF 30 24 5x8 25 15 DC 7300 62 6 6 ou 120 TR545D 983610 0 3 0DB 3DB 2245 TUBELESS WHEELS round hand holes EN
37. 0021 READR CROSS MEMBER WELDMENT 5 0009 BUCKET SKID 5 DECK 0023 ROLL PLATE STRG BACK 5 DECK 0022 DECK RUB BAR 5 DECK 0008 ROLL PLATE o DECK 0020 o DECK 0016 5 DECK 0017 0018 STD CROSS MEMBER 5 0007 STD 3 4 X 6 REAR DECK FISH PLATE STRAP 5 0006 FRONT PIN FISH PLATE 5 DECK 0005 DECK PIN 200719 C E gt 5 DECK 00015 YOY DECK PIN PLATE O Q 9 Y 5 0019 STD 210 DECK 5 000 216 DECK 5 DECK 0002 220 DECK 5 0005 250 DECK 5 0004 FRONT ISL TOP PLATE 5 0025 FRONT ISLAND 5 DECK 0024 REAR FISH PLATE 5 REAR 0008 ISLAND CLEAT 5 REAR 0007 OUTSIDE ISL PLATE 5 REAR 0012 INNNER ISL BOX 5 REAR 0012 ISLAND PLATE 5 REAR 0006 OUTSIDE ROLL PLATE 5 0019 REAR WEB 5 0005 Ix 3 STRAP 5 0011 QQ INSIDE ISL PLATE gt REAR ISL CAP 5 REAR 0014 5 0010 x REAR ISL ROLL PLATE 5 REAR 0015 INSIDE ISL ROLL S REAR 0018 5 AXLE BEAVER TAIL PARTS LIST PART NUMBER 5 REAR 0001 5 REAR 0002 5 0003 5 REAR 0004 5 REAR 0005 5 REAR 0006 5 REAR 0007 5 REAR 0008 5 REAR 0009 5 0010 5 REAR 0011 5 REAR 0012 5 0013 5 REAR 0014 5 REAR 0015 5 REAR 0016 5 REAR 0017 5 REAR 0018 5 REAR 0019 5 0020 PART DESCRIPTION CATCH BLOCK SMALL CATCH BLOCK LARGE CATCH BLOCH SMALL CATCH BLOCK LARG
38. 03 07 5M
39. 1 3 show typical brackets for automatic brake adjuster applications on steer axle brake assemblies Refer to pages 4 and 5 for detailed installation procedures Figure 1 Steer axle with clamp bracket and round anchor stud Figure2 Spider mount Figure 3 Steer axle with strap bracket Approx 1 16 Drive Axle Figures 4 6 show typical brackets for automatic brake adjuster applications on drive axle brake assemblies Refer to pages 4 and 5 for detailed installation procedures Figure 4 34 drive axle with strap bracket Figure 6 Integral cam support bracket Spider mounted strap bracket Note Refer to fundamental parts identification and location on page 8 Installation Procedures Note Configuration of anchor bracket and brake adjuster housing may vary depending upon axle Refer to typical applications on Page 2 Anchor Bracket Note Block wheels to prevent vehicle from rolling Ensure system tank pressure is above 100 PSI Check that the push rod is fully retracted apply air to release spring brake If air is not available spring brake must be manually caged back B install anchor bracket loosely as illustrated fig 7 Some strap brackets have two mounting holes Proper mounting location is determined by the length of adjuster arm 5 and 5 1 2 adjuster arm lengths utilize the shorter hole location while 6 and 6 1 2 length adjusters utilize th
40. 3 ft lbs or no racheting sound occurs Unknown Perform automatic brake adjuster operational check see below Off Vehicle Inspection Component Cause Action Adjuster not Low clutch gt Place adjuster in vise Rotate the 7 16 functioning torque adjustment hex counterclockwise one full turn to properly check de adjustment torque After control arm stops rotating a minimum of 13 ft Ibs will be required and a ratcheting sound will occur Replace brake adjuster if the torque is less than 13 ft 165 or no de adjustment ratcheting sound is present Control Arm Place adjuster arm in vise Rotate the control arm slippage counterclockwise until the control arm rotates to an INTERNAL STOP If the installation indicator goes past the indicator notch or does not stop rotating arm slips freely replace the brake adjuster Unknown lf torque is above 13 ft Ibs scribe a line on the adjustment hex Manually pull the brake adjuster control arm clockwise then push back counter clockwise until the installation indicator stops in the indicator notch The hex will move in a clockwise direction when the control arm of the brake adjuster is pushed back counterclockwise Replace adjuster is hex does not move Worn missing gt Remove and replace and bushings If adjuster control arm wear has passed the above checks re install adjuster bushing and on v
41. 5 axle owners manual lt 2 LO O N N N LO YTY O 5 Ot gt 19 o 2 5 6 c N E lt CUSTOM TRAILERS 4350 Newton Road Stockton Ca Ph 209 948 8586wFax 209 948 0452 Rackley Bilt Custom Trailers Warranty With the purchase of a new Rackley trailer we provide a 30 day all inclusive warranty and 12 months on products manufactured by us If within 30 days you should have a problem with any part of the trailer you can bring 1t back to our facility for repair After the 30 days our remaining warranty covers only the workmanship and or materials that were originally manufactured by Rackley Bilt All repairs required within this time shall be subject to approval at our facility Transportation of trailers to our facility 1s not cover ed in the warranty and is the sole responsibility of the trailer owner This warranty shall be limited to repair replacement of components manufactured by Rackley Bilt at our discretion Under no circumstance will Rackley Bilt Customs trailers be responsible for any lost revenue damages or injury Please be aware that each individual product manufacture may have a warranty that varies from our warranty in which case it would then be addressed by the respective product manufacturer 1 e wheels lights bearings etc If at any point in the warr
42. 7 2 BILT CUSTOM TRAILERS DWG NAME DATE 9 2 2009 5 REAR CYL SCALE NONE SHEET 1 OF 1 MATERIAL NONE TRAILER 5 EXPANDO gt BURE CYLINDER PARTS REF NUMBER DESC MANUF ACTURER PART NUMBER QUANITY RETAINING PIN RACKLEY 5 100 100 1 PISTON RETAINER RACKLEY 5 100 101 10001 PISTON ACKLEY SOS 9 394 1 RLANDURIG 5505 1 550 5 50 07 55008 5509 RACKLEY 1 500 110 BILT CUSTOM TRAILERS DWG NAME DATES 2 2009 REAR SCALE NONE SHEET 1 OF 1 MATERIAL NONE TRAILER 5 EXPANDO J 2 Sm E YAN Kt ES BILT CUSTOM TRAILERS DWG NAME DATE 9 2 2009 6 FRONT CYL SCALE NONE SHEET 1 OF 1 MATERIAL NONE TRAILER 5 EXPANDO 6 BURE CYLINDER PARTS REF NUMBER DESC MANUF ACTURER PART NUMBER QUANITY RETAINING PIN NONE 5 100 100 1 PISTON RETAINER 5 100 101 10001 SEAL NONE 9 89 88 a PISTON 989 8 1 9 894 1 LARGE GLAND 1 WAND NN 98946 1
43. 8 option 1 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 0898 option 1 or on the web at www alcoawheels com Important information available free from Alcoa Alcoa Wheel Service Manuals Disc Wheel Service Manual Flat Base Wheel Service Manual for Tube Type Tires Videos Safe Wheel and Tire Changing Practices for Heavy Duty Trucks and Buses Maintaining Your Edge Rim Flange Maintenance Simple Facts about Hub Piloted Wheel System Maintenance Maintenance Charts Zipper Rupture Published by RMA Tire Information Service Bulletin Published by RMA Heavy amp Medium Truck amp Trailer Torque Specifications Published by WRIS Demounting amp Mounting Procedures for Truck Bus Tires Published by RMA Multipiece Rim Matching Chart Published OSHA Mounting Demounting Instructions for Alcoa Aluminum 19 5 RW Published by Alcoa Wheel Products Wheels and Steel Disc 19 5 Wheels Published by Alcoa Wheel Products Alcoa Rim Flange Safety Material Maintaining Alcoa Aluminum Wheels Rim Flange Wear Instructions Rim Flange Wear Gauge Alcoa Technical Bulletin dated Nov 10 1997 Rim Flange Wear Table of Contents How to use Section Number Page Number 0 this manual E A 2 peel Gd Oll E
44. AF40P 050AS 07045 AF50P 050AS AFBOP 050AS The part number for bracket assembly for 1000 cm is AF50P 050AS applicable to AL30 to AL60 Note Assembly includes a bracket and 2 mounting screws 7 SNC 14 2 61 lt gt TI gt lt lt m lt 55 gt lt IC lt L VY1 PPA AL Series AL10 to 60 Flow Characteristics Representative values AL10 M5 AL40 06 Rc 3 4 Condition Inlet pressure 0 7 MPa p MPa Pressure dro Pressure drop MPa gt Conditions P1 0 5 MPa Needle One side fully open 50 100 150 2000 4000 6000 Flow rate Flow ANR 1000 2000 3000 5000 10000 Flow rate ANR Flow rate ANR 5000 10000 Flow rate ANR 4000 6000 Flow rate min ANR 14 2 62 5 Working Principle AL10 Needle Section AA A portion of the air introduced from the IN side pressurizes the lubricant inside the bowl The remainder of the air passes through the needles 9 and flows to the OUT side The pressure differential between the inside of the bowl and the inside of the sight dome 2 causes the lubricant inside the bowl into the oil passage 9 The lubricant drips from the dripping tube 7 and lubricate the OUT side The amount of lubricant is adjusted by the needle 9 on the
45. E REAR WEB ISLAND PLATE ISLAND CLEAT REAR FISH PLATE INSIDE ISLAND PLATE OUTSIDE ISLAND BOX REAR INNER ISLAND BOX REAR OUTER BOX OUTSIDE ISLANDS PLATE REAR ISLAND CAP PLATE REAR ISLAND ROLL PLATE REAR INNER BOX REAR OUTER BOX INSIDE ISLAND ROLL BEND RIGHT LEFT OUTSIDE ROLL PLATE TAIL LIGHT PLATE BEND FOR RIGHT LEFT QTY MATERIAL jT 1 T 1 YTA jT 1 4 T 1 1 4 T 1 3 8 T 1 3 8 T 1 3 16 T 1 3 16 T 1 3 16 T 1 3 16 T 1 3 16 T 1 3 16 T 1 3 16 T 1 1 4 1 1 4 1 3 16 1 3 16 1 3 16 1 i E po DOGO G 6 GROUP FRONT NECK PART NUMBER NECK 5 NECK 0001 5 NECK 0002 5 NECK 0003 5 NECK 0004 5 NECK 0005 5 NECK 0006 5 NECK 0007 5 NECK 0008 5 NECK 0009 5 3 NECK 0010 5 NECK 001 1 5 NECK 0012 5 NECK 0013 5 NECK 0014 5 NECK 0015 5 NECK 0016 5 NECK 0017 5 3 0018 5 0019 200720 PART DESCRIPTION NECK WEB NECK SHACKLE NECK LATCH PLATE NECK FISH PLATE NECK CATCH DOG ROLLER BRACKET RAMP CATCH GUSSET RAMP CATCH CROSS MEMBER RAMP CATCH GUSSET BOTTOM PLATE 5TH WHEEL PLATE CROSS MEMBER RAMP SUPPORT CROSS MEMBER SHACKLE LOCK 5TH WHEEL PLATE STRAP 26 5TH WHEEL PLATE 40 OPTIONAL 5TH WHEEL PLATE FORMED EXSPANDO NECK BRACE NECK RAMP SHARED WITH 3 AXLE RAMP SUPPORT CHANNEL 5 AXLE NECK PIN QTY MATERIAL 2 1 4 T 1 244 27 T 1 2
46. E 1 ccs os ccr 38 T 39 FB 40 40 Common 45 Glossary of Common 45 pO ___ __ __ E 47 VEG mU T Tm 48 9 1 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 48 922 eC m 49 Safety Safe E WARNING An inflated wheel and tire assembly contains enough air pressure to cause are a matter of life explosive separation and death Unsafe handling or failure to follow approved mounting and demounting procedures can WARNING lead to serious injury or death Study understand and follow the procedures contained in this manual Safety is serious business All tire shops must know and follow OSHA work regulations no matter how small the shop Safety is everybodys 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 manufacturers 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 Removal of tire and wheel assemblies from vehicles Demounting tire from wheel nflation of tire Handl
47. GLISH UNITS METRIC UNITS Maximum Maximum wheelload Wheel Outset Inset inflation in 165 wt Ibs inches inches PSI cold Valve Part Available Front outer Rear outer Item no Wheel description kg kg mm mm KPa stem number Finishes Stabilizer cap nuts cap nuts Eight hole hub piloted 275 circle 221 1 hub 24 75 bolt hole diameter use two piece flange nuts DiscMate 014000 Lug nut covers 181 Hub covers N A Rear inner cap nuts N A o 5515 295 5 55 4 72 142 31 17 5x6 75 15 DC 2500 134 141 120 979 TR543C 663470 0 2 2125 39874 5515 370 555 472 142 6615 37 7 6 10 5 28 142 Continued the next TUBELESS WHEELS round hand holes ENGLISH UNITS METRIC UNITS continued Maximum Maximum wheel load Wheel Outset Inset inflation in lbs wt lbs inches inches PSIi cold Valve Part Available Front outer Rear outer Item no Wheel description kg kg mm mm KPa stem number Finishes Stabilizer cap nuts cap nuts 10 hole hub piloted mounting 225mm bolt circle 176 1mm hub bore 26 50mm bolt hole diameter use two piece flange nuts DiscMate Lug nut covers 181 Hub covers N A Rear inner cap nuts N A o 5515 28 0 9 04 4 49 142 34 17 5x6 00 15 DC 2500 127 133 114 976 TR543D 663200 0 1 2 2125 39874 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hol
48. Information to be used in the training program shall include at a minimum the appli cable data contained in the charts rim manuals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts or rim manual the employer shall assure that the employee is instructed concerning the contents of the charts and rim 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 1 Demounting of tires including deflation 1 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 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 ass
49. L10 to 60 3 With drain cock AL10 to 60 6 Nylon bowl Including sight dome AL10 to 60 8 Metal bowl with level gauge AL30 to 60 C With bowl guard AL20 R Flow direction Right Left AL10 to 60 3W Drain cock with barb fitting 06 x 04 nylon tubing to 60 Z plate and caution plate for bowl in imperial units PSI F AL10 to 60 Accessory When more than one specification is required indicate in alphanumeric order Note 2 For 5 thread types symbol Applicable model This product is for overseas use only Nil EUER according to the new Measurement Law The SI unit type is provided for With bracket AL20 to AL 60 Note 1 Bracket is not assembled and is supplied loose at the time of shipment DEM Combination available 7 Combination not available Accessory Optional Specifications Combinations varies depending on the model Available only with NPT thread Sania Applicable lubricator Accessory Optional specifications E 1 1101112 3 6 8 Z ALIO AL20 01060 AL40 oA 1000 tank wih onesna O To 5 1000 tank wih evel m wihdancok o 9 Nyonbow mdudngsgtdomg 6 0
50. LER 5 EXPANDO ELECTRICAL PARTS LIST REF NUMBER ___ DESC MANUFACTURER PART NUMBER QUANTY CLEARANCE MARKER LIGHT MTN 61003 79140 OVAL PARK MIDTURN LAMP GROTE G6003 7 9242 2 FACH MOUNTING RUBBER OVERSIZE LOAD PLUG VARIES NONE 4 EACH PARALLEL WIRE PHILLIPS 2 1 1900 AS NEEDED REAR PHILLIPS 36 9400 5050 1 EACH CUSTOM HARNESS EXTENSION PHILLIPS 60 5019 05 LAMP PIG PHILLIPS 36 9501 2 EACH LICENSE PLATE LIGHT 60101 LE 3 OPTIONAL MARKER LIGHT 3002 7 92120 2 REAR LICENSE 10 MARKER PHILLIPS 36 9601 1 EACH HARNESS 11 MARKER LIGHT TRUCK LIGHT 60101 1 EACH 12 7 WAY WIRE PHILLIPS 3 326 AS NEEDED 13 MID TURN HARNESS PHILLIPS 36 9000 360 1 14 7 WAY SOCKET SOCKET BOOT PHILLIPS 16 70 2 15 740 e EACH 15 MALE 7 WAY PLUG PHILLIPS 15 730 1 EACH 16 HARNESS PHILLIPS 10 7319 00 1 EACH 17 Cee 18 STOP TAIL TURN LLIGHT GRUTE G4002 9174 4 EACH 19 2 S S OPTIONAL MARKER LIGHT PANEL LITE MILLENIUM BILT CUSTOM TRAILERS DWG NAME 9 2 2009 5 AXLE ELECTRICAL A SCALE NONE SHEET 1 OF 1 MATERIAL NONE TRAILER 5 EXPANDO ELECIRICAL PARIS LIST REF NUMBER DESC MANUF AC TURER PART NUMBER QUANITY CLEARANCE MARKER LIGHT GROTE G1003 9140 2 EACH RUBBER CAMBER
51. anty period the trailer should receive any unauthorized structural repair and or loads beyond the rating of the trailer all warranties shall become null and void BILT CUSTOM TRAILERS 4350 Newton Road Stockton Ca Ph 209 948 8586wFax 209 948 0452 Please take a moment to read through the manual and get familiar with your new trailer operators helpers should be qualified and or supervised at all times when working on and around the expando to ensure the safety of themselves as well as others If after reading this manual you should have any questions we can be contacted at the above phone number and address I Under no circumstances should you load have a load on the neck of the trailer without the tractor attached neck needs to be supported 2 When loading unloading trailer make sure all bystanders are at a safe distance 3 necessary to have a spotter near the trailer when loading make sure to keep feet from underneath trailer as heavy loads may cause trailers to drop causing injury e 4 When trailer is to be opened closed make sure all people and misc items i e chains and pry bars are clear from slide boxes and tires 5 Before each load the driver should inspect the trailer for any damage This would include all liehts working properly no leaking air lines and no structural damage is evident 6 Parking should be done on flat ground only When the trailer has no air it also has no brakes to prevent it
52. applied stroke is too long there is probably a problem with the foundation brake Check the following and reference CVSA out of service criteria Component Cause Brake drums Action Cracked or out of round Replace or check drum run out Brake shoes Shoe span out of spec Refer to OEM specs and replace if necessary Brake shoes Uneven lining wear Check spider concentricity Brake shoes Shoe pad missing Remove amp replace shoes Brake shoes Cracked shoes Remove amp replace shoes Cam bushings Excessive movement Remove amp replace cam bushings per OEM specs Camshaft Flat spots on cam head Replace camshaft Camshaft Cracked broken splines Replace camshaft Camshaft Worn bearing journals Replace camshaft Chamber bracket Broken bent Replace bracket Clevis yoke and pin Worn Remove amp replace Return springs Broken stretched or missing Remove amp replace springs Rollers Flat spots grooved pin worn Remove amp replace roller and pin Rollers Wrong size Remove amp replace with correct parts opider anchor pins Grooved or scored worn Replace spider or pins as appropriate for OEM Free Stroke Above the Range If the free stroke is above the range and the applied stroke is too long there is a problem with the foundation brake or the adjuster Check the following Component Cause Action Camshaft Bind
53. are and mounting practices should be reviewed For proper nut torque refer to the chart below Nut Torque Level Ft Lb Torque Level Ft Lb Thread Lubricated Dry 11 16 16 300 400 M20 x 1 5 280 330 M22 x 1 5 450 500 Hub piloted using two piece flange nut Stud piloted double cap nut standard type 7 8 radius 3 4 16 350 400 450 500 1 1 8 16 350 400 450 500 Stud piloted double cap 15 16 12 750 900 nut heavy duty type 1 1 8 16 650 800 750 900 1 3 16 radius 1 5 16 12 750 900 For nuts used on hub piloted wheels apply two drops of oil to the point between the nut and flange and two drops to the first two or three threads at the tip of each stud see Section 5 10 For nuts used on stud piloted wheels apply two drops of oil to the first two or three threads at the tip of each stud only see Sections 5 8 NOTE 1 If using specialty fasteners cap nuts consult the manufacturer for recommended torque values 2 Tightening wheel nuts to their specified torque is extremely important Undertightening which results in loose wheels can damage wheels studs and hubs and can result in wheel loss Overtightening can damage studs nuts and wheels and results in loose wheels as well 3 Regardless of the torque method used all torque wrenches air wrenches and any other tools should be calibrated periodically to ensure the proper torque is applied 37 Balance weights for Alcoa wheels are available fr
54. are manufacturer s recommendations when replacing studs 1 Make sure all wheel cap nuts are properly torqued check them often see Section 5 8 If the wheel is loose the holes will pound out deform If some cap nuts are tight and others are loose the wheel may develop cracks or studs may break This condition may cause wheel to loosen and disengage from the vehicle Dirt streaks radiating from stud holes can indicate loose nuts see Section 3 2 Be sure the end of the wheel wrench is smooth or cover the wheel mounting surface with a protective shield prior to tightening the cap nuts The wrench end will mar the wheel around the cap nuts if it is not smooth 3 Keep all component contact surfaces smooth and clean Dirt or projections on mounting surfaces may lead to loose wheels Remove all projections resulting from burrs nicks etc Be sure that loose dirt does not fall onto mounting surface during assembly 4 Do not introduce any foreign objects such as spacers or high hats into the contact surface areas of the mounting system unless approved by Alcoa Do not paint Alcoa forged aluminum wheels 5 Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 3 14 for specific cautions care and maintenance procedures 6 DiscMate is a protection gasket designed to be placed between the wheels and also the brake drum wheel contact surfac
55. at 90 100 psi Check that push rod is fully retracted apply air to release spring brake North American Commercial Vehicle Safety Alliance CVSA Uniform Vehicle Inspection Criteria The applied stroke of the brake should be checked per CVSA guidelines at 90 100 PSI reservoir pressure Applied stroke should be at or less than the specified adjustment limits as follows Standard Clamp Type Brake Chamber Long Stroke Type Brake Chamber Type Adjustment Limit Type Adjustment Limit 9 1 3 8 24 1 3 4 12 1 3 8 30 2 16 1 3 4 36 2 1 4 20 1 3 4 DD 3 2 1 4 Type Adjustment Limit Type Adjustment Limit 16L 2413 2 1 2 20L 3013 2 1 2 24L 2 NOTE Long stroke chambers are identified with square air ports or port bosses and special trapezoid ID tags Free Stroke Measuring the Free Stroke Free stroke is the amount of movement of the adjuster arm required to move the brake shoes against the drum With brakes released measure from the face of the chamber to the center of the clevis pin A fig 13 Use a lever to move the brake adjuster until the brake shoes contact the drum fig 13 The difference between the fully retracted and drum contact measurement fig 13 is the free stroke The free stroke range should fall between 3 8 3 4 Free Stroke Within Range If the free stroke is good but the
56. at or to the cap nut to wheel contact surface Oiled seats can lead to over torquing which can stretch studs causing failure of studs Failed studs can cause the wheel to disengage from the vehicle causing injury or death WARNING Lubricants must be completely removed from the cap nut seats and contact surfaces if applied accidentally WARNING Undertorqued cap nuts allow wheels to run loose pounding out deforming the ball seats fatiguing studs or losing nuts Overtorquing can stretch studs causing them to fail Both under and overtorquing can lead to wheels coming off causing injury or death WARNING Check all parts including wheels studs and cap nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damaged parts Follow correct tightening sequences and torque levels Continued on next page 31 Tightening stud located ball seat cap nuts continued NOTICE In service stud dimensions and condition may change over time due to environmental conditions multiple re installations improper torquing and other factors Consult with your hub and stud manufacturer for maintenance and replacement recommendations 32 Stud located ball seat mounting system It is recommended that both inner and outer stud threads on stud located mounting systems be lubricated with SAE 30W oil and torqued between 350 and 400 foot pounds If threads not lub
57. ation Prior to June 1996 all Alcoa heavy duty truck wheels had the Alcoa identification symbol X on the outside of the disc near the hand hole in line with the valve location This marking was phased out on heavy duty truck wheels manufactured after June 1996 Wheel Load Rating Maximum FMVSS 120 Pounds Inflation Pressure Designation ALCOA FORGED LOAD 7300 PSI 120 ALCOA MADE IN U S A 082205 883640 22 5X8 25 15 DC Date of Manufacture Wheel Description Month Day Year prior to 2000 some wheels may have only Month Year Dura Bright surface treated wheels are designated by the letters DB following the part number such as 883640DB Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with earlier wheels have part numbers ending in a 4 7 with bead seat diameters measured in 0 5 inch increments Not all Alcoa wheels are available with the Dura Bright surface treatment Dura Flange wheels are designated by the letters DF following the part number such as 883640DF 39 OSHA Regulations 40 OSHA Regulations 7 1 Sec 1910 177 Servicing multi piece and single piece rim wheels a Scope 1 This section applies to the servicing of multi piece and single piece rim wheels used on large vehicles such as trucks tractors trailers buses and off road machines It does not a
58. aximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform 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 DiscMate when used Alcoa aluminum wide base wheel Outer cap nut P N 5996R or L See 5 2 page 26 Correct wide base wheel mount ing with 1 1 8 stud located ball seat mount 1 8 minimum stud standout DiscMate when used Single Alcoa aluminum wheel Outer cap nut P N 5995R or L 4 See 5 2 page 26 Hub Correct single mounting with 3 4 stud located ball seat 1 8 minimum mount stud standout DiscMate when used Alcoa aluminum wide base wheel Outer cap nut P N 5995R or L See 5 2 page 26 Correct wide base wheel mount ing with 3 4 stud located ball seat mount 1 8 minimum stud standout Rear wheels are most frequently mounted as duals Each inner aluminum wheel is attached by 10 inner
59. be on Alcoa tubeless wheel and always remove cracked damaged wheels from service 1 Do not gouge or nick the wheel Place aluminum wheels on clean wooden floor or rubber mat when hand mounting tires Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 3 14 pages 19 for specific cautions care and maintenance procedures DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring 2 Always use a rubber leather faced or plastic mallet 3 Inspect the wheel for damage Do not use a damaged or severely corroded wheel see Section 3 4 Clean the wheel face with mild detergent and the tire bead seat areas with a wire brush Be sure the wheel is dry before applying tire lubricant 5 Inspect the tire for damage Be sure the inside of the tire is dry before it is mounted 6 Use of a non water based lubricant is recommended as a rim surface protectant and tire mounting lubricant Coat the entire rim surface see Section 4 2 7 Lubricate the rim and tire bead immediately before mounting the tire Do not use any lubricant which contains water Water based lubricants can promote corrosion attack on the rim surface The use of non water based lubricants is especially important when mounting tubeless tires as the air in the tire is contained by the
60. by moving the control arm No that clearance is set at the factory If long or short stroke continues please refer to the foundation brake checking procedures on pages 6 amp 7 of this manual 10 use an air ratchet on the adjuster It will damage the internal mechanism of the adjuster and render it inoperative 11 Can access the adjuster through the rear cover No do not tamper with the rear cover it will release the factory set pressure on the spring and destroy the adjuster and its ability to properly function 12 How much control arm bushing and anchor stud pin wear is acceptable before replacement is required No more than 1 16 13 What is the acceptable amount of camshaft bushing wear Automatic adjusters cannot compensate for worn foundation brake parts Please refer to the foundation brake manufacturer s recommendations for maximum bushing and camshaft wear limits 14 Can wheel bearing adjustment affect the brake adjuster Yes Improper wheel bearing adjustment could result in improper brake adjustment It is necessary to refer to the axle manufacturer s wheel bearing adjustment recommendations A loose bearing preload could cause a tight brake continued on page 12 11 Frequently Asked Questions continued 15 Are all Haldex automatic brake adjusters pre lubed Yes All Haldex brake adjusters are lubricated at the factory Please consult the Service and Lubrication Secti
61. ce opportunity 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 located ball seat 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 cap nuts Note whenever the outer cap nut is loosened ALWAYS retorque the inner cap nut before retorquing the outer continued cap nut single dualed Most U S manufacturers of highway trucks tractors and trailers which incorporate the hub piloted wheel mounting system require wheel studs and cap nuts with metric threads Most frequently these and wide base are M22x1 5 wheels hub piloted Generally the same diameter stud is used to mount either single or dualed wheels mounting two piece Studs on both sides of the vehicle are right hand threads thereby eliminating the need for flange nuts flange nuts peculiar to either the right or left side of the vehicle The same flange nut is used to mount dualed or single wheels Proper stud standout for single wheels is 2 36 inch 60mm minimum dualed wheels require 3 346 inch 85mm minimum and single wide base wheels require 2 36 inch 60mm Some states have laws which dictate full thread engagement or thread engagement past the nut body 5 9 Make sure you know the laws for the states in which you operat
62. ching to cover 12 Install lock nut and yoke on push rod TESTING OF REBUILT ROTOCHAMBER Perform Operating and Leakage checks WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park vehicle on a level surface apply parking brakes and always block the wheels Always wear safety glasses 10 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Follow
63. chment 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 an assemblage of tire tube and liner where appropriate and wheel components Service or servicing means the mounting and demounting of rim wheels and related activities such as inflating deflating installing removing and handling Service area means that part of an employer s premises used for the servicing of rim wheels or any other place whe
64. cle use a sponge cloth or soft fiber brush to wash exposed wheel surfaces with a mild detergent and warm water solution b Rinse thoroughly with clean water c Wipe dry to avoid water spots d Wax the cleaned surface with Alcoa Advanced Aluminum Care System Polish or any automotive polish equivalent e Clean your Alcoa truck wheels as frequently as required to maintain their appearance 1 Clean frequently with high pressure water Use a mild detergent rinse thoroughly with clean water and wipe dry to avoid water spots Do not clean with abrasives abrasive brushes steel wool scouring pads or strong chemicals such as acids or lye based products Never spray cold water on extremely hot wheels Always allow time to cool before cleaning DO NOT USE the Alcoa Aluminum Care System on Dura Bright wheels at any time during their service life 2 When tires are removed the entire rim must be cleaned and inspected see Section 3 With a soft brush remove any foreign products from the rim portion of the wheel that supports the tire Generously coat the entire air chamber surface with an approved surface protectant and lubricate each time the tire is removed see Section 4 1 3 Once in service Dura Bright wheels can become nicked or scratched by road debris and or mechanical damage If this occurs continue to follow the normal washing and cleaning instructions provided above The surface of an Alcoa Dura Bright wheel is designed to lim
65. d the addition of DB at the end Finishes are indicated by changing the last numerical digit of the part number to one of the following For brushed both sides the number is 0 For buffed outside only the number 15 1 For buffed inside only the number is 2 For buffed both sides the number is 3 Only the wheel part numbers with available surface finishes having the DB suffix are available with the Dura Bright option Dura Flange wheels are identified by using the regular numerical part number and the addition of DF at the end Only the wheel part numbers with available surface finishes having the DF suffix are available with the Dura Flange option Note The Dura Bright surface treatment and the Dura Flange options are not currently available together on the same wheel TUBELESS WHEELS round hand holes ENGLISH UNITS Maximum Maximum wheelload Wheel Outset Inset inflation Valve Part Available Front outer Rear outer Item no Wheel description inlbs Ibs inches inches PSI cold stem number Finishes Stabilizer cap nuts cap nuts Six hole stud located ball seat mounting 8 750 in bolt circle 6 495 in hub bore 1 219 in bolt hole diameter DiscMate Lug nut covers 150 Hub covers N A Rear inner cap nuts 5988 L amp R Rear inner cap nuts Al Stl 7896 L amp R 15 3 4 Stud 5995 L amp R 1 17 5x6 75 15 DC 5070 32 5 559 4 72 125 TR543C 663170 0 2 2125 iia Shia 5066
66. e increases the coil spring load is overcome and the wormshaft is displaced axially releasing the cone clutch When the Brake Releases When the brake begins its return stroke the coil spring load returns to normal and the cone clutch is again engaged The rack is pulled back to its original position in the notch and any additional travel brought about by lining wear causes the rack to turn the locked one way clutch and rotates the wormshaft through the locked cone clutch The wormshaft then rotates the worm wheel and camshaft adjusting the brakes Adjustment Bushing Clutch Assembly Heat Treated Housing O Ring Direction of Applied Stroke Wormshaft 9 Coil Spring Enclosed Rack Indicator Ring Worm Wheel Clearance Notch Control Arm Fixed Point Part Number Identification 300 10xxx Standard service adjuster kit 419 10xxx Standard service adjuster 300 50xxx lt Severe service adjuster kit Anchor Control Arm Installation Stud Pin FT Single Bend Indicator Control Arm Anchor Wear Wear Double Bend Bracket Bushing Bushing Part Number Identification 419 50xxx 7 Severe service adjuster serial Number Identification First 3 digits Day of year built Last 2 digits Year of build Adjustment Anchor Hex Nut Stud Pin Anchor Bracket Indicator Notch Typical Applications Steer Axle Figures
67. e unless the tire or wheel manufacturer recommends against it 4 Ifa tire on a vehicle is underinflated but has more than 80 percent of the recommended pressure the tire may be inflated while the rim wheel is on the vehicle provided remote control inflation equipment is used and no employees remain in the trajectory during inflation 5 Tires shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead 6 Whenever a rim wheel is in a restraining device the employee shall not rest or lean any part of his body or equipment on or against the restraining device 7 After tire inflation the tire and wheel components shall be inspected while still within the restraining device to make sure that they are properly seated and locked If further adjustment to the tire or wheel components is necessary the tire shall be deflated by removal of the valve core before the adjustment is made 8 No attempt shall be made to correct the seating of side and lock rings by hammering striking or forcing the components while the tire is pressurized 9 Cracked broken bent or otherwise damaged rim components shall not be reworked welded brazed or otherwise heated 10 Whenever multi piece rim wheels are being handled employees shall stay out of the trajectory unless the employer can demonstrate that performance of the servicing makes the em
68. e and comply DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the dual wheels as shown NOTICE Do not exceed maximum wheel load Customer Note Some stud located ball seat wheels have the same number of holes and bolt circle diameter as must compare OEM vehicle load hub piloted wheels They should not be mixed rating to maximum wheel load rating DiscMate when used DiscMate when used Refer to tire manufacturer 5 recommendation for proper tire Drum pressure Before mounting the tire perform wheel fitment check to insure proper clearance from any obstructions NOTICE Check for and replace bent broken cracked or 5 damaged studs When replacing stud 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 the stud manufacturer for regular maintenance and stud replacement 1 06 27mm i Drum 33mm hex head 4 2 piece flange nut P N 39874 4 M22x1 5 stud Alcoa Alcoa Grooved Grooved 1 4 lt Bore Hub practices Hub 2 36 60mm minimum 2 36 60mm minimum stud standout single wheels stud standout wide base s
69. e cock amp level gauge barb fitting Optional specifications m Port size i Barb fitting Applicable tubing T0604 mm Accessory specifications Bracket mounting size A D P J 1 M 0 M5x08 25 77 26 25 28 35 AL20 1814 40 115 36 40 60 30 27 22 54 84 40 23 AL30 1 43 8 53 142 38 53 57 80 41 40 23 65 8 53 23 0 1 3 8 1 2 70 176 40 70 73 110 50 54 26 85 105 70 23 AL40 06 34 75 i76 38 70 73 110 50 54 25 85 105 70 23 ALSO 341 90 250 41 90 110 47 70 66 35 11 13 90 32 ALGO 1 268 45 95 110 47 70 66 35 13 90 32 Optional specifications Model With drain cock With barb fitting Metal bowl Metal bowl with drain cock Metal bowl with level gauge Metal bowl with drain cock amp level gauge B 8 _ HS 0 129 Standard specifications AL30 186 AL40 220 AL40 06 220 ALSO 294 AL60 312 14 2 64 7 SNC Lubricator Series AL 10 to 60 Dimensions Option 1000 cm tank 106 90 Bracket Port size 106 Option fi mm cmm A HL I M AU _ e o 7 AR IR With float switch E 1 VEX Contact capacity 15 VA AC 15 W DC D Contact
70. e diameter use two piece flange nuts DiscMate 011000 Lug nut covers 181 Hub covers Front 076018 0760851 hear 077018 or 0770851 Rear inner cap nuts o 6615 37 610 528 142 35 19 5x 7 50RW 15 DC 3000 171 155 134 978 TR543C 773600 0 1 2 3 2126 39874 10 hole hub piloted mounting 335mm bolt circle 281 2mm hub 26 75mm bolt hole diameter use two piece flange nuts DiscMate 013000 Lug nut covers 181 Hub covers for P N 833580 only 5811 polished with view port other P Ns Rear inner cap nuts N A 136 22 5x8 25 15 DC 5650 236 148 952 70MS7 886520 0 3 008 308 39874 137 22 5 9 00 15 0 125 046 105 153 78 70MS7 896520 0 3 008 308 39874 H38 22 5x13 00 15 DC 5606 4 I 185 896 TR543 833580 0 1 39874 39 24 5x8 25 15 DC 98 4 1725 495 857 TR544D 983500 0 3 39874 10 hole hub piloted mounting 335mm circle 281 2mm hub 32 87 hole diameter use two piece sleeved cap nuts DiscMate 018000 Lug nut covers N A Hub covers N A Rear inner cap nuts N A 22 58 25 15 0 8047 520 657 570 138 2259001500 9094 542 689 602 142 7067 896510 0 3 0DB 3DB 4306 32 4307 32 32mm hole 4125 246 175 153 978 Six hole hub piloted mounting 205mm circle 160 2mm hub bore 21 5mm hole dia use two piece flange nuts DiscMate Lug nut covers Hub covers
71. e life of a wheel Lack of care in changing a tire heavy pounding of the wheel rim overloading exposure to excessive heat or hitting curbs at high speed or a sharp angle can damage wheels Avoid abuse stances exceed cold tire pressures listed in Section 2 Specifications of this manual Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstruc tions 6 1 Do not overinflate Use tire manufacturer s recommended pressure but under no circum Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Keep wheel nuts tight ed eel cap nuts must be kept tight see Section 5 8 When checking the cap nuts dual disc wheels utilizing the stud located ball seat mounting system loosen every other outer cap nut and then check the torque of the inner cap nuts Retorque the loosened outer cap nuts Repeat proce dure with the rest of the nuts Check all cap nuts for proper torque after the first use or any removal 6 Inspect wheels and check wheel nuts during service stops see Section 3 Dirt streaks from cap nuts may indicate looseness Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardw
72. e longer hole locations Do not tighten anchor bracket fasteners at this time Apply Anti Seize type lubricant to camshaft splines B install the brake adjuster onto the camshaft Figure7 brake chamber fig 8 Secure the brake adjuster the camshaft Use at least one inner washer and enough outer washers to allow no more than 060 movement of adjuster on camshaft Per TMC recommended practice RP609 A Note Do NOT pull push rod out to meet the brake adjuster Rotate the 7 16 adjusting hex nut CLOCKWISE until the clevis hole lines up with the brake adjuster arm hole Apply anti seize to clevis pin install and secure with cotter pin Figure8 Installation Procedures Rotate the control arm away from the adjusting hex toward the air chamber until it comes to a definite internal stop fig 9 Most adjusters will be equipped with an Installation Indicator Indicator must fall within the slot for proper installation with brakes fully released fig 10 the control arm position 15 wrong tight brakes will occur fig 11 B Tighten all anchor bracket fasteners make sure the control arm does not move from its position while tightening fasteners ECI The adjuster must be manually adjusted Figure9 at this time Rotate the adjusting hex clockwise until the Bai eed lining lightly contacts the drum Figure 10 Figure 11
73. ed wheel without a tire several revolutions over a smooth flat level clean surface Any deviation from rolling in a straight line is an indication of a potential lack of proper dimension and con tour Remove the wheel from service until it can be properly checked with a ball tape Continued on the next page Dimension checks Tire wear or ride problems 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 Section 4 5 for recommendations and instructions for demounting tubeless tires Remount the wheel on the vehicle without the tire Be sure to follow proper mounting procedures to assure the wheel is well centered on the hub Place a dial indicator as illustrated below to trace the bead seats of the wheel Rotate the wheel noting the amount of variation shown on the dial indicator Note Alcoa aluminum wheels should be tested for radial run out only at the bead seat surface A total indi cator reading of 040 inches is acceptable Tire wear can also be caused by improperly seated tires Inspect the tire for proper seating on the wheel The tire beads may not be seated properly If so remove the wheel from the vehicle deflate and break the bead seats see Section 4 5 for recommendations and instructions for demounting tubeless tires Adequately lubricate the bead seats and properly reseat the tire beads Reinflate
74. eel approxi Insert straight end of tire tool between beads and both rim mately 10 inches apart Pull one tool toward center of wheel flanges hooking stop on the tool over second flange Position then pull second tool in the same manner To free bead leave inserted tool at 90 angle to tire assembly at top of wheel and one tool in position take out and reinsert the other tool lubricate bead areas on both sides of tool Lean tire assembly curved end between bead and flange a short distance from toward tool and rock or bounce to pry off the tire the spanned area Pry bead free of rim repeating process until entire bead is free from wheel 24 Wheel Installation Recommendations for proper installation of wheels 5 NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions 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 hardw
75. ehicle with new hardware anchor stud pin if applicable Automatic Brake Adjuster Operational Check Functional operation of the brake adjuster can be performed on the vehicle by using the following procedure Block wheels to prevent vehicle from rolling 5 Ensure tank pressure is at 90 100 psi Check that the push rod is fully retracted apply air to release spring brake If air is not available spring brake must be manually caged back Manually de adjust brakes turn adjustment hex counterclockwise one full turn to create an excessive drum to lining clearance condition A ratcheting sound should occur Make a full service brake application On release allow sufficient time for brake to fully retract During the brake release observe rotation of the adjustment hex attaching a wrench on the hex or scribing the hex will make this rotation easier to see This rotation indicates that an excessive clearance condition has been determined by the brake adjuster and it is making an adjustment to compensate On each subsequent brake release the amount of adjustment and push rod travel will be reduced until the desired clearance is achieved If rotation of the adjustment hex is not observed refer to Foundation Brake Operational Check and Troubleshooting Procedures on pages 6 amp 7 If foundation brake assembly checks out okay and hex still does not turn check control arm and mounting bracket for possible worn ben
76. encing excessive rim flange wear in your operation consider using Alcoa Dura Flange aluminum wheels These wheels have been specially treated to significantly reduce rim flange wear Remove wheels from service when rim flange wear is excessive Excessive wear can be determined using an Alcoa approved wear gauge and procedures detailed below If rim flange wear becomes sharp and or cuts the tire contact Alcoa for recommended maintenance procedures Alcoa Rim Flange Wear Gauge Instructions Rim Acceptable Rim Acceptable Rim NOT Acceptable Rim Gauge Rim Gauge Rim G Alcoa P N 000700 Alcoa P N 000700 Im Wauge Alcoa P N 000700 EX Ay Daylight in this Daylight in this area indicates area indicates acceptable rim acceptable rim Wheel rim excessive Wheel rim Wheel rim wear No daylight in this area indicates Remove from service immediately To obtain a gauge s at no charge and information on free training on proper installation and maintenance procedures contact Alcoa Wheel Products at 800 242 9898 option 1 or on the web at www alcoawheels com Determining Rim Flange Wear STEP 1 Remove the wheel tire assembly from the vehicle Remove the valve core to deflate the tire completely Remove the tire from the wheel according to OSHA regulations recommended practices for tire and rim safety procedures and or the Alcoa Wheel Service Manual Photo 1 Acceptable Rim Flange Wear Condition 14 Ri
77. es see Sections 5 2 5 6 5 7 5 9 DiscMate is recommended to be replaced when the tire wheel assemblies are removed and reinstalled WARNING Wheels that are not properly installed or maintained may not work properly Failure to follow proper wheel installation or maintenance practices may result in injury or WARNING 494 Follow the proper wheel installation and maintenance practices as contained in this Alcoa Wheel Service Manual For training on proper installation and maintenance available free of charge from Alcoa or for the most recent updates contact Alcoa Wheel Products at 1 800 242 9898 option 1 or on the web at www alcoawheels com 25 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 causing injury WARNING or death 5 9 Never use cap nuts with chrome plated contact surfaces Use only recommended hardware on Alcoa aluminum wheels There are many types of nuts and studs in use and their design and specifications are not standard ized The and on cap nut part numbers indicate right and left hand threads respectively Alcoa recommends the following cap nuts for use with Alcoa aluminum truck wheels Cap Nuts 2 piece 1 1 16 hex head flange nut Mounts single and dualed wheels to wheel centerin
78. f wood photo 2 By running the sharpness indicator gauge along the wheel in the area of the wear determine if the wear is sharp enough to cut or damage the rubber on the sharpness indicator photo 3 If the rubber is cut then follow the edge removal instructions below Photo 2 A rubber sharpness gauge constructed from a section of tire side wall or a suitable piece of rubber attached to a block of wood Photo 3 Run the sharpness indicator gauge along the wheel in the area of the wear to determine if the wear is sharp enough to cut or damage the rubber on the sharpness indicator If the flange cuts or appears close to being sharp enough to cut the rubber on the sharpness indicator gauge the edge can be removed per the edge removal procedures below If the rub ber is not cut then the wheel can be returned to service without further work for rim flange wear CAUTION Do not run unprotected hands or fingers across worn rim flange areas of used wheels Worn rim flange areas are sharp and can cut hands or fingers Cuts can lead to CAUTION infection Always wear gloves when handling used wheels or when testing for edge sharpness 15 Rim flange Edge Removal Procedures wear continued There are many tools available to remove the sharp edge on the wheel caused by rim flange wear Here are some examples of commonly used tools File A file can be used very effectively to remove the edge photo 4 Photo 4 Rem
79. from rolling CUSTOM TRAILERS 4350 Newton Road Stockton Ca Ph 209 948 8586wFax 209 948 0452 Lubrication 1 Check level hubs a regular basis At this time 1t would be a good 1dea to inspect the condition of hubs for cracks and leaking seals If the hubs should require oil simply remove rubber plug and refill with 85w 140 gear oil to fill line On monthly intervals or as needed in extreme environments we recommend greasing the S Cam bushing to extend component life and quality of brake accuation On monthly intervals it is recommended to check refill the inline lubricator Doing so will minimize detrimental corrosion and wear to the pneumatic components on the trailer As a trailer ages 1 may necessitate more oil thus requiring more frequent oil inspection check oil level of lubricator SMC P N AL30 N03 7Z you will find 4 windows for viewing fluid level To remove bowl simply pull black tab down with thumb and rotate bowl 45 while pulling down on the bowl Fill with hydraulic oil or pneumatic tool oil then replace bowl Expanding the expando There are 2 options methods for the opening closing of our trailer 1 driver can actuate the air valve and drive a short distance prior to loading 3 With the use of our optional remote actuator valve the driver can open close the trailer without the need to exit the truck ROLL PLATE CLEATS 5 DECK
80. g hubs Right hand threads used on both sides of vehicle P N 39946 5 8 x18 threads 2 piece 33mm hex head flange nut Mounts single and dualed wheels to wheel centering hubs Right hand threads used on both sides of vehicle Single wheels require 2 50 8 mm stud standout Dualed wheels require 2 13 16 71 44 mm stud standout P N 39874 supersedes P Ns 39701 and 39691 M22 1 5 RH threads NOTICE One piece flange nuts are not approved for use on any Alcoa wheel application 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 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 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 2 piece 33mm hex head flange nut Mounts dualed wheels with 32mm bolt holes to wheel centering hubs Right hand threads used on wheel with 1 31 1 5 16 both sides of vehicle P N 4307 32 1 44 1 7 16 M22x1 5 RH threads standout P N 7896R 7896L Grade 8 Inner cap nut inner thread e A 3 4 16 outer thread 1 1 8 16 For use with standard length studs 1 31 1 5 16 to 1 44 1 7 16 stud stand out or longer
81. ge 4 nsertthe push rod yoke pin through the hole in the yoke and slack adjuster Make sure the same hole location in the slack adjuster on each side of the axle is used 5 yoke should be adjusted on the push rod so that with brakes released the angle formed by the push rod and slack adjuster will be greater than 90 and all slack adjusters should be at the same angle With properly adjusted brakes applied the angle should still be greater than 90 DISASSEMBLY For ease in disassembly if the rotochamber has been in service and shows signs of rust accumulation it is recommended that the chamber be immersed and soaked in the cleaning or rust dissolving solvent for 24 hours Remove yoke and lock nut from push rod rubber boot Hemove cap screws from cover p 199 ur no Hemove cover springs and spring guides if so equipped 5 Remove nuts from body These nuts secure the outer clamp to the body and are located at the air inlet end of the rotochamber 6 Grasp the push rod and by pulling and wiggling the entire assembly consisting of push rod and plate diaphragm guide diaphragm inner and outer clamps should ease out of the body 7 Straighten the rolled diaphragm Remove outer diaphragm clamp Remove nuts from inside of diaphragm guide 10 Disassemble inner diaphragm clamp diaphragm and push plate rod assembly from the diaphragm guide CLEANING AND INSPECTION 1 Clean all metal parts in a
82. gloves protective clothing and hearing protection when using hand or power tools oio nt ote ee corp DE Ern Cw sek es mer c SION p f Photo 8 Adequate repair for sharp edge result ing from rim flange wear removes just enough metal to smooth the edge STEP 4 The photographs show the process of removing the edge With whatever tool is selected work the tool around the wheel s circumference removing only enough material to eliminate the sharp edge This should only be a small amount of metal Perform this work on both flanges if there is evidence of sharpness Regardless of the method that you choose the objective is to remove the sharp edge photo 8 Remove just enough metal to smooth the edge Take care to make sure the edge removal is as uniform as possible Avoid gouging the wheel 17 Rim flange STEP 5 After the edge is removed run the sharpness indicator gauge along the area of edge removal to check for any remaining sharpness If the rubber is still cut perform the steps Wear continued again to remove the sharp edge Always remove the minimum amount of material necessary to eliminate the sharp edge STEP 6 Check the rim flange height with the Alcoa Rim Flange Wear gauge to make sure there is adequate height remaining to safely support the tire The photograph again shows how this gauge is used photo 1 Be sure to move the gauge all around the wheel
83. good cleaning solvent 2 Carefully inspect all metal parts for cracks distortion or damage Replace any parts not considered serviceable 3 Replace diaphragm and rubber boot ASSEMBLY 1 10 11 Position the diaphragm on end in the inner diaphragm clamp The smaller diameter end of the diaphragm should be against the diaphragm clamp Place and install the diaphragm guide within the diaphragm and over the inner diaphragm clamp studs Install the push plate push rod assembly within the diaphragm guide and over the inner diaphragm clamp studs Install nuts on the inner diaphragm clamp studs and tighten securely Place the assembly consisting of the push rod push plate diaphragm guide diaphragm and inner clamp inside of the outer clamp the free end of the diaphragm back and over the end of the outer diaphragm clamp Lubricate the inside wall of the body and the rolled surface of the diaphragm with Murphy s oil soap Slide the above assembly into the body The end of the diaphragm should fit snugly against the shoulder in the body Position the outer diaphragm clamp studs through the holes at the end of the body install nuts and tighten securely Install spring guide if so equipped and install spring over push rod and install spring guide on spring if so equipped Install cover over push rod and into body Attach cover to body with cap screws tightening securely Install boot over push rod atta
84. heel 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 infla tion 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 1 When the tire has been driven underinflated at 80 percent or less of its recommended 42 Regulations continued pressure or 11 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 tir
85. hragm provides long life and gives a constant output force throughout the entire stroke One end of the diaphragm is clamped to the inside wall of the body by the outer clamp The other end of the diaphragm is clamped between the diaphragm guide and inner diaphragm clamp The cover is fastened to the outer body by cap screws Mounting studs are used to mount the chambers A boot retained by a boot retainer is used to prevent entrance of moisture through the hole in the cover A lock nut and yoke with pin are screwed on the threaded push rod Most rotochambers now have 3 8 in NPTF inlet ports The long stroke Type 50 employ a 1 2 in NPTF inlet port OPERATION Controlled air pressure enters the rotochamber through the inlet port and acts upon the diaphragm moving the diaphragm guide and diaphragm forward The diaphragm moves along the inside wall of the cylinder body with a smooth rolling motion The forward motion of the diaphragm guide and diaphragm forces the push plate and push rod forward When the rotochamber is used to actuate cam type foundation brake assemblies the yoke is connected to a slack adjuster which in turn is connected to the brake cam shaft This forward motion of the push rod rotates the slack adjuster cam shaft and cam applying the vehicle brakes The rotochamber is also used in industrial applications and in such cases may be used in clamping or holding operations The greater air pressure admitted to the
86. icle control can result which can cause serious injury or death Use only approved mechanical or pneumatic bead seating devices WARNING A pressurized tire wheel assembly can explode and separate violently This violent separation can cause serious injury or death WARNING Always contain the tire wheel assembly in an inflation cage during inflation Mounting tubeless tires 4 2 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your Position wheel on machine Lubricate wheel entire Insert curved end of tool between bead and wheel particular machine before attempting air chamber surface and tire bead using approved flange with tool stop against flange In circular to mount or demount tires lubricant Tire beads should be mounted over the rim motion use short successive bites to work the bead flange closest to the wheel well Push bead over flange over the flange Push down on tool as bead is worked NOTICE Do not exceed maximum as far as possible over flange wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions NOTICE When match mounting tires on Alcoa wheels locate valve stem adjacent to low point mark on the tire NOTICE Alcoa alumin
87. ing Remove replace lubricate camshaft Camshaft bushings Excessive movement Remove and replace cam bushings per OEM specs Camshaft bushings Binding shaft Lubricate camshaft bushings or replace Air chamber return springs Broken weak missing Replace chamber Air chamber push rod Binding on chamber housing Check adjuster for proper shimming and air chamber position for proper adjuster arm length Air system Not exhausting completely Check for cause of air problem and repair Shoe return springs Broken weak missing Replace springs Automatic brake adjuster Unknown Automatic brake adjuster Unknown Free Stroke Below the Range If the free stroke is less than 3 8 a dragging brake Component Cause Check automatic brake adjuster for proper installation Refer to Installation Instructions on pages 3 amp 4 Refer to Automatic Brake Adjuster Checking Procedures and Operational Check on pages 8 amp 9 can occur Check the following Action Wheel bearing Out of adjustment Automatic brake adjuster Unknown Automatic brake adjuster Unknown Free Stroke B minus A Applied Stroke C minus A Readjust per OEM specs Check automatic brake adjuster for proper control arm position Refer to Installation Instructions on pages 3 amp 4 Refer to Automatic Brake Adjuster Checking Procedures and Operational Check on pages 8 amp 9 Fully Retracted Figure 13 Stroke Measurements gt taken f
88. ing and storing of inflated assembly Safety and service information is readily available Wheel tire and service equipment manufacturers offer service manuals and other training materials Stay up to date on proper procedures and keep current instructional materials handy in the shop Study safety and service information and use it on the job Statistics show that in most industries at worst only one in 1000 serious accidents result in a fatality But when the accident involves tires and wheels statistically one in every 10 serious accidents is a fatality That s 100 times more often than in most 1 in 1000 other industries 1 in 10 TYPICAL INDUSTRY TIRE SERVICE INDUSTRY 2 specifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J694 February 2001 Part numbers listed for all sizes are satin finish the last digit of the six digit numerical part number is 0 Polished finishes are indicated by changing the last digit of the part number listed to one of the following For polished outside only part number should end in 1 For polished inside only part number should end in 2 For polished both sides part number should end in 3 Only for item numbers marked with a single asterisk part numbers ending in 9 are inset position wheels satin finished see footnote Dura Bright surface treated wheels are identified by using the regular numerical part number an
89. ing the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition BW1561 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 3 2004 Printed in U S A L30036 Rev 5 03 SERVICE MANUAL Transit and Coach Applications AUTOMATIC BRAKE ADJUSTERS Innovativ Techn Table of Contents Sez TT 1 Typical Parts Identification and Location 1 Steer Axle Applications 2 Drive Axle Applications 2 Installation Procedures
90. ingle wheels DiscMates when used All wheel fastener hardware should be grade 8 or metric conversion Drum lt gt 3 346 85mm minimum 10 9 Follow the hardware Y stud standout dual wheels manufacturer s recommendations when replacing studs M22x1 5 stud 33mm hex head 2 piece flange nut P N 39874 __ Grooved 1 38 35mm minimum pilot length for dualed aluminum wheels Typical assembly of single and dual wheels of hub piloted type with 33mm hex head two piece flange nut Part No 39874 If hex nuts with greater overall height are used more stud length is required Continued on the next page 33 single dualed and wide base wheels hub piloted mounting two piece flange nuts continued Tightening hub piloted mounting two piece flange nuts 5 10 34 Hubs designed for steel hub piloted wheels may not have enough pilot length to locate dualed aluminum wheels Pay close attention to pilot length particularly when converting from steel to aluminum duals Measure the hub pilot to make sure the hub has a minimum pilot length of 1 38 inch or 35mm for dualed wheels When mounting painted steel inner dual wheels with outer aluminum wheels be cautious of excessive paint build up on the inner steel wheel Excessive paint can reduce the clamping force and allow the wheels to become loose Match mounted dual wheels should be put on the vehicle with the valve stems 180 apart Flange
91. inner steel wheel for flatness and adequate diameter before installing the outer wheel When the wheels are serviced check the mounting surfaces of both wheels for stud hole to stud hole cracks If cracks are found remove the wheel from service For the support surface diameter required by other bolt circle sizes ask your Alcoa representative WARNING Use of two piece flange nuts on ball seat wheels or ball seat cap nuts on hub piloted wheels is dangerous Using the wrong cap nuts can cause loss of torque broken studs and cracked wheels WARNING conditions which can lead to injury or death Use only hardware designed specifically for each wheel type See Section 4 2 for proper hardware assemblies Tightening stud located ball seat cap nuts 5 8 Cap nuts must be kept tight and studs and nuts should be checked frequently Nuts should be retorqued if necessary At tire changes nuts and studs should be inspected for cracks and stripped or damaged threads After each wheel mounting cap nut torque should be checked with a torque wrench Impact wrenches if used should be carefully adjusted to apply torques within the limits recommend ed Torquing of cap nuts should be done in recommended sequences Some states have laws which dictate full thread engagement or thread engagement past the nut body Make sure you know the laws for the states in which you operate and comply WARNING Lubricants should not be applied to the cap nut se
92. ions multiple 10 8 re installations improper torquing 6 3 7 O 4 3 6 and other factors Consult with Q Q your hub and stud manufacturer for maintenance and replacement 5 6 Oa recommendations 4 5 O O 8 2 Six Stud Eight Stud Ten Stud 35 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 two piece flange nuts is dangerous Using the wrong wheel nuts can cause loss of torque broken studs and cracked wheels conditions which can lead to injury or death WARNING Use only hardware designed specifically for each wheel type See Section 4 2 for proper 5 1 1 hardware assemblies The following are examples of incorrect wheel assemblies Stud located ball seat x aluminum wheel Two piece A flange nut Insufficient contact area Do not use two piece flange nuts with stud located ball seat wheels Hub piloted Alcoa aluminum wheel Ball seat cap nut 22 Insufficient contact area Incorrect use of ball seat cap nut on hub piloted system Do not use ball seat cap nuts with hub piloted wheels No positional location Incorrect use of flange nut positioned on Alcoa ball seat wheel Do not use any flange nut on Alcoa aluminum ball seat wheels 36 Proper Torque Wheel Identification and Valves Abuse can shorten th
93. it cracking and peeling if nicked or scratched while in service 4 Even as durable as Dura Bright wheels are the mounting area can become scratched marred or discolored when mounted against another wheel hub or drum The use of a wheel mounting surface guard such as Alcoa DiscMate is highly recommended The use of the Alcoa Hub Cover System on Alcoa Dura Bright wheels will also assist in limiting such damage and help maintain the appearance of your Alcoa Dura Bright wheels 19 Alcoa 15 Drop Center Wheel for Tubeless Tires Recommendations for mounting tubeless tires 4 1 NOTICE For complete information on tube type wheels contact Alcoa at 800 242 9896 option 2 NOTICE Alcoa aluminum nonsymmetrical wheels require special tire mounting techniques see Section 4 3 20 WARNING Damaged tires or wheels can lead to an explosive separation of tires and wheels Explosive separation can result in serious injury or death Inspect tires and wheels for damage before removing from vehicle If damage is found WARNING the tire must be completely deflated before loosening cap nuts Remove damaged tires or wheels from service WARNING Use of inner tubes in tubeless wheels will hide slow leaks Slow leaks may indicate cracked see Section 2 9 or damaged wheels which lead to wheel failures Wheel failures can cause accidents which may result in serious injury or death WARNING Never use an inner tu
94. ith 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 43 Regulations continued 10 Tires shall not be inflated above maximum pressure recommended by manufacturer to seat the tire bead firmly against the rim flange 11 No heat shall be applied to a single piece wheel 12 Cracked broken bent or otherwise damaged wheels shall not be reworked welded brazed or otherwise heated GRAPHIC OMITTED TC270C91 036 Appendix B Ordering Information for NHTSA Charts has printed two charts entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi piece Rim Matching Chart as part of a continuing campaign to reduce accidents among employees who service large vehicle rim wheels Reprints of the charts are available through the Occupational Safety and Health Administration OSHA Area and Regional Offices The address and telephone number of the nearest OSHA office can 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
95. l is removed During tire changes thoroughly examine the entire wheel Pay particular attention to the rim contour and the surfaces of the rim Hidden damage Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maxi mum wheel load rating Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures listed in Section 2 Specifications of this manual Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Some forms of wheel damage can be hidden beneath the tire so whenever a tire is removed thoroughly examine the complete wheel Remove all grease and road dirt Use a wire brush or steel wool to remove rubber from the bead seats Check mounting holes for the enlargement and elongation which can occur if the cap nuts are not kept tight see Section 3 8 Dirt streaks radiating from stud holes may indicate loose cap nuts Alcoa does not approve any form of alteration to wheels except minor cosmetic buffing for appearance purposes or sanding in the rim flange area see Section 3 12 Wheels should not be altered by welding brazing or other heat application in an attempt to repair or straighten a wheel Use of adapter plates or bead locks are not approved on Alcoa wheels Wheels should not be painted or otherwise coated in any way that may interfere with the mounting surfaces Any wheel that show
96. l seat mounting system is a precision machined spherical surface Cap nuts must be properly manufactured to assure correct seat ing Never use one or two piece flange nuts on a wheel designed with ball seats see Section 5 11 5 4 Ball seat cap nuts may be obtained from your Alcoa Wheel Distributor single and wide Front wheels are mounted as singles and require 1 8 inch 45 7mm minimum stud standout Most b heel d vehicles have 1 1 8 inch studs on the front hubs Alcoa single cap nuts Part Nos 5996R and 5996L ase wneel stu or equivalents should be used Some front hubs have 3 4 inch studs On these hubs use Alcoa single located ball seat cap nuts Part Nos 5995R and 5995L or equivalents mounting DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum as shown below and on the next page 5 5 DiscMate when used Single Alcoa aluminum wheel Outer cap nut P N 5996R or L See 5 2 page 26 Correct single mounting with 1 1 8 stud located ball seat mount minimum K stud standout Continued on the next page 27 single and wide base wheel stud located ball seat mounting continued NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to m
97. m 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 Ihe tire should be inspected at this time for any other damage and be treated per normal tire procedures recommended by the tire manufacturer NOTICE Check the wheel at every tire change or ONCE PER YEAR for rim flange wear and any sharp edges If you follow this practice you will significantly reduce the possibility of a rim flange cutting into the tire STEP 2 After the wheel is separated from the tire use a ball tape to verify the circumfer ence of the bead seat on the open side is acceptable see Section 3 4 Check the wheel flange with the Alcoa Rim Flange Wear Gauge to determine if the wheels must be removed from service for excessive rim flange wear photo 1 on previous page See Rim Flange Wear Gauge Instructions illustrations on previous page to make this determination If you do not have an Alcoa Rim Flange Wear Gauge contact Alcoa Wheel Products to obtain a gauge s at no charge by calling 800 242 9898 option 1 or on the web at www alcoawheels com STEP 3 If the wheel is deemed to be serviceable by the rim flange gauge examine the wheel flange edge for sharpness by using a rubber sharpness gauge These gauges are constructed by having a section of tire side wall or a suitable piece of rubber attached to a block o
98. ment with respect to any wheel that has been subjected to misuse or abuse including the following a Using a tire that is oversized according to standards recommended by the Tire and Rim Association Inc or other recognized tire and rim agencies such as ETRTO Europe or others b Loading the wheel beyond the applicable maximum wheel load as specified by Alcoa c Inflating beyond the applicable maximum as specified by Alcoa d Changing the original condition of the wheel by alteration or by subjecting it to any processing such as welding or straightening e Accidents abnormal or severe operating conditions including without limitation tire fires brake fires severe brake system drags or seizures or running with a flat tire or f Failure to follow maintenance and other instructions and warnings set forth in the Alcoa Heavy Duty Wheel Service Manual Alcoa Technical Bulletins and other Alcoa literature Recommended maintenance includes without limitation using proper torque periodic cleaning polishing valve replacement periodic inspection for damage loose lug nuts and rim flange wear inspections and procedures g Nicks scratches and other surface blemishes resulting from improper maintenance cleaning road debris curbing accident or operation are not warrantable h Damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline Dura Bright Surface
99. mmended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring DiscMate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the steel and aluminum wheels as shown below Inner steel wheel DiscMate when used Alcoa aluminum wheel Outer cap nut P N 5996R L See 5 2 page 26 WS CN 1 IN Hub Inner cap nut P N 7896R or L See 5 2 page 26 2 1 31 to 1 44 stud standout k Correct dual mounting for steel inner aluminum outer stud located ball seat mount WARNING Incorrect inner cap nuts used with steel wheels can bottom out on the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running wheels can lead to stud WARNING breakage Use only cap nut 7896R or L or its equivalent when mounting steel inner duals WARNING Inadequate wheel support surface can lead to stud hole to stud hole fracture resulting in separation of the outer disc and rim from the vehicle Separation of the wheel from the vehicle can cause injury or death Alcoa aluminum wheels with 11 1 4 inch diameter bolt circle require a support surface at least 13 3 16 inches in diameter Check the outer support surface of the
100. n occasion Alcoa aluminum truck wheels are operated dualed with a steel inner wheel In the event a steel inner wheel is used extreme care must be exercised to properly seat it to the hub or drum prior to mounting the outer aluminum wheel Selection of an inner cap nut capable of fixing the steel inner wheel and providing adequate external thread length to secure the outer aluminum dualed wheel is critical to a safe assembly Alcoa recommends the use of inner cap nuts 7896R and L Grade 8 or equiva lent for this purpose 29 30 Dualed wheels steel inner aluminum outer stud located ball seat mounting continued 5 7 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 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 DiscMate wheel spacers are reco
101. n on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impression stamp on Dura Bright surface treated wheels can affect the appearance and performance of the Dura Bright surface treatment local to the stamp Alcoa drop center wheels for tubeless tires come from the factory with air valves installed If it becomes Valves 2 necessary to replace an valve install it using the following torque values 6 5 10 14 foot pounds for Part Numbers 7 11 foot pounds for Part Numbers TR 542 or 552 Series TR 543 or 553 Series TR 544 or 554 Series TR 545 or 545 Series 60MS27N 70 57 Replacement valves be obtained from your authorized Alcoa Wheel Distributor Always use silicone o rings or grommets not rubber when reinstalling valve stems Metal valve stem caps are recommended instead of plastic It is recommended that valve stems with o rings or grommets be replaced at every tire change When replacing valve stems it is recommended to lubricate the threads and o ring with a non water based tire lubricant When valve stem extensions are used it is recommended that valve stem stabilizers be used 38 Identification 6 6 Alcoa wheel identification Since 1977 all Alcoa aluminum disc wheels have been identified with a stamp that shows the wheel load rating maximum inflation pressure date of manufacture part number wheel description and DOT marking design
102. om your Alcoa Wheel Distributor With radial tires Balance weights it may be necessary to temporarily reduce the tire pressure when installing clip on weights to allow clip on clearance of the weight clamp over the rim flange Use of coated balance weights is recommended to avoid staining and corrosion of the aluminum wheel surface Excessive rim flange wear see Section 3 12 could dictate the use of stick on or adhesive wheel weights if there is inadequate rim to properly hold a clip on style weight 6 3 Improperly installed weights could off during use and damage the vehicle or cause personal inju ry Always follow the recommended procedures in this manual or the wheel weight manufacturers Adhesive weights should be applied only to a clean surface on the brake side of the wheel rim These weights should be installed only in a location where they will not contact the brake components during vehicle operation T Some fleets wish to specially identify wheels as to OWNERSHIP and IN SERVICE dates Alcoa rec Owner in ommends that fleets and owner operators adopt practice of permanently stamping wheels with the identification 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 6 4 hole centers and a minimum of one inch from the periphery of any hand hole 3 Location of stamped identificatio
103. on on Page 5 for proper lubrication guidelines 16 Can I use moly lube with the Haldex automatic brake adjuster No Ahigh concentration of moly disulfide can lower the friction capabilities in the adjusting clutch parts and decrease automatic adjustment reliability 17 Can purchase anchor bracket wear items separately i e anchor stud pins wear bushings Yes Normal wear items like anchor stud pins and wear bushings are available Please refer to the Haldex Parts and Cross Reference Guide for your specific application 100090 Otherwise contact Haldex Technical Assistance for the appropriate bracket kit at 1 800 643 2374 Additional Information Available 18 Does the control arm need to be properly set and secured Yes Without proper placement and attachment the adjuster will not function properly Make sure the control arm anchor bracket and wear items are in good working order to assure the adjuster will operate as designed 19 If automatic adjustment stops can operate as a manual brake adjuster No Completely check out foundation brake and adjuster to determine cause of problem Repair or replace as needed to restore automatic adjustment Additional parts and service information on Haldex Automatic Brake Adjusters may be found in the following materials Service Information Installation and Maintenance Wall Chart Installation Video Service Manual Truck Traile
104. or demounting tubeless 23 4 5 Demo nting of tubeless EOS 24 MUN 25 5 1 Recommendations for proper installation of 25 a py MM TO 26 3 9 How to measure stud 2 lt 4 21 5 4 Stud located ball seats are 21 8 5 5 Single and wide base wheel stud located ball seat mounting 27 5 6 Dualed wheels stud located ball seat 28 5 7 Dualed wheels inner steel outer aluminum stud located ball seat mounting 30 5 8 Tightening stud located ball seat cap nuts Prose Napa be 31 9 5 9 Single dualed and wide base wheels hub piloted mounting two piece flange 33 5 10 Tightening hub piloted mounting two piece flange 34 36 6 Proper Torque Wheel Identification Valves and Surface 37 EA 37 27 BOBO WOES Se see Re eateries 38 DL 38 N
105. ore loosening cap nuts Remove damaged tires or wheels from service 23 1 When hand demounting tires from wheels placing aluminum wheels clean wooden floor or rubber mat is recommended Additional care should be used when demounting Alcoa Dura Bright Recommendations for demounting tubeless surface treated wheels since minor nicks and scratches can not be polished out see Section 3 14 for tires continued specific cautions care and maintenance procedures 2 Always use a rubber leather faced or plastic mallet 3 Keep tire tools smooth Use them with care Rim gouges or nicks may cause cracks 4 If using a tire mounting demounting machine on aluminum wheels should be taken to prevent gouging the wheel Demounting of tubeless tires 4 6 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your particu nel efo 6 Remove valve core from the valve stem to ensure complete Repeat procedure at intervals until bead is totally separated deflation Place wheel machine and position tool so flat end from wheel Repeat procedure on other side of tire Tire is now attempting 10 mount or demount can be driven between tire bead and rim flange Straighten tool ready for demounting Lubricate the tire bead tires to a vertical position until bead is separated from wheel Insert curved end of tire tools between tire and wh
106. our specific requirements The expected performance and safety assurance will be the responsibility of the person who has determined the compatibility of the system This person should continuously review the suitability of all items specified referring to the latest catalog information with a view to giving due consideration to any possibility of equipment failure when configuring a system Only trained personnel should operate pneumatically operated machinery and equipment Compressed air can be dangerous if an operator is unfamiliar with it Assembly handling or repair of pneumatic systems should be performed by trained and experienced operators Do not service machinery equipment or attempt to remove components until safety is confirmed 1 Inspection and maintenance of machinery equipment should only be performed once measures to prevent falling or runaway of the driver objects have been confirmed 2 When equipment is to be removed confirm the safety process as mentioned above Cut the supply pressure for this equipment and exhaust all residual compressed air in the system 3 Before machinery equipment is restarted take measures to prevent shooting out of cylinder piston rod etc Contact SMC if the product is to be used in any of the following conditions 1 Conditions and environments beyond the given specifications or if product is used outdoors 2 Installation on equipment in conjunction with atomic energy railway air
107. overed by Holland s Commercial Products Warranty Holland reserves the right without giving prior notice to change specifications and dimensions as designs are altered or improved PARTS BREAKDOWN d CLA Fg 0437 0250 7 gt 0249 2 XB 0165 25 XA 0421 31 XA 0422 38 XA 0408 50 XA 0423 CLL Le 0403 387 0410 o 507 XA 0426 XA 0409 3 507 XA 0411 2 007 XB 0418 XA 10031 XB 0351 EpL XB 0418 XB 0360 Copyright O September 2002 The Holland Group Inc Holland USA Inc Facilities Denmark SC Warrenton MO Holland International Inc Holland MI Dumas AR Whitehouse Station NJ Phone 616 396 6501 Phone Holland MI Wylie TX Fax 616 396 1511 Fax Muskegon MI Ph 888 396 6501 Fax 800 356 3929 2 Holland Hitch of Canada Ltd Woodstock Ontario Canada 519 537 3494 Phone 800 565 7753 Fax Holland Equipment Ltd Holland Hitch Western Ltd Norwich Ontario Canada Surrey British Columbia Canada 519 863 3414 Phone 604 574 7491 519 863 2398 Fax 604 574 0244 XL KP103 01 SAFEIY AND MAINTENANCE INSTRUCTIONS JANUARY 2007 HEAVY DUTY TRUCK LIGHT DUTY TRUCK TRAILER BUS MOTOR HOME 1 2 1 amp 9 3 5 o6 3 0 oM 9 5 4 4 o 7 2 9 3 8 5 2 HEELS LIMITED WARRANTY FOR HEAV Y DUTY TRUCK TRUCK TRAILER
108. oving sharp edge by hand with a Photo 5 Air or electric powered sander metal file Air or Electric Powered Sander This provides a very quick and effective method of remov ing the edge Operators should use all care to keep a uniform edge when using these tools photo 5 Air or Electric Grinder Another quick and effective method of removing the sharp edge caused by rim flange wear Be careful as grinding pads may gum up from the aluminum that is removed photo 6 Care must be used to avoid gouging the wheel Photo 6 Air or electric grinder Photo 7 Die grinder 16 Rim flange wear continued Die Grinder Used with a sanding wheel cutting stone or grinding tool this is a version of an electric grinder This tool is very quick and effective as well and care must be taken to remove metal as uniformly as possible and not to gouge the wheel photo 7 on previous page CAUTION Removing sharp edges with hand or power tools produces metal filings and sparks Many power tools have edges that are sharp or may become hot during use Some power tools produce excessive noise when used CAUTION 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 Cuts and burns can lead to infection Always wear appropriate safety gear such as protective eyewear
109. pical wheel would Any wheel run with a flat tire longer than the time necessary to immediately pull off the road should be checked for excessive heat damage A blistered charred blackened or cracked looking logo decal on an Alcoa wheel may indicate that the wheel has been exposed to excessive heat Inspect all axle end components for signs of exposure to excessive heat Pay particular attention to brake drums or discs DiscMate wheel liners and tire beads If these components show signs of over heating the entire assembly including the wheel should be replaced Dimension Open side circumference check checks WARNING Wheels that have been subjected to high pressure tire and rim separation run flat excessive heat or other physical damage may no longer have 3 4 sufficient dimension and contour to retain tire bead while under pressure WARNING Rims that lack proper dimension and contour can lead to explosive separation of tire and rim causing injury or death Follow dimension check procedures described in this section during each wheel inspection Photo 1 shows the carpenter s square even on both bead seats 2 UAM 2a 113 15 ale CEE T umor mm AANA A 12 12 undersized wheel that you can clearly place a 020 card between the square and the wheel Ay s v358 7 Pr 280 S 131 4 1 4 1 LW
110. ployee 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 Ifa tire changing machine is used the tire shall be inflated only to the minimum pressure necessary to force the tire bead onto the rim ledge while on the tire changing machine 5 Ifa bead expander is used it shall be removed before the valve core is installed and as soon as the rim wheel becomes airtight the tire bead slips onto the bead seat 6 Tires may be inflated only when contained within a restraining device positioned behind a barrier or bolted on the vehicle w
111. pply to the servicing of rim wheels used on automobiles or on pickup trucks and vans utilizing automo bile tires or truck tires designated LT 2 This section does not apply to employers and places of employment regulated under the Construction Safety Standards 29 CFR part 1926 the Agriculture Standards 29 CFR part 1928 the Shipyard Standards 29 CFR part 1915 or the Longshoring Standards 29 CFR part 1918 3 All provisions of this section apply to the servicing of both single piece rim wheels and multi piece rim wheels unless designated otherwise b Definitions Barrier means a fence wall or other structure or object placed between a single piece rim wheel and an employee during tire inflation to contain the rim wheel components in the event of the sudden release of the contained air of the single piece rim wheel Charts means the U S Department of Labor Occupational Safety and Health Administration pub lications entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi piece Rim Matching Chart the National Highway Traffic Safety Administration NHTSA publications entitled Demounting and Mounting Procedures Truck Bus Tires and Multi piece Rim Matching Chart or any other poster which contains at least the same instructions safety precautions and other information contained in the charts that is applicable to the types of wheels being serviced Installing a rim wheel means the transfer and atta
112. purpose nor is there any other warranty express or implied except such as is expressly set forth herein Alcoa shall not be liable for any incidental or consequential damages for any breach of warranty its liability and the purchaser s exclusive remedy being limited to repair or replacement of the wheel as stated in this limited warranty Alcoa Wheel Service Manual This limited warranty should be used in conjunction with the Alcoa Wheel Service Manual and the Alcoa Dura Bright Wheel Finish Care and Maintenance Manual The Wheel Service Manual contains important safety information and warnings and failure to read and understand this information may result in serious injury or death The limited warranty is included with the Wheel Service Manual but may appear elsewhere If you do not have copies of the Wheel Service Manual you may obtain copies free of charge from Alcoa Wheel Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 and on the web at www alcoawheels com WARNING Wheels that are not properly installed or maintained may not work properly Failure to follow proper wheel installation or maintenance practices may result in injury or 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 Products at 1 800 242 989
113. r Parts Information Parts and Cross Reference Guide Supplemental Automatic Brake Adjuster Kits oe L60047HBS ABA10017 T 5 00090 eee L20447 These materials may be ordered by contacting your Customer Service Representative at 1 800 643 2374 Or you may log in to our website www hbsna com with your customer password to place your order 12 Commercial Vehicle Systems North American Sales Division Haldex Brake Products Corporation 10707 N W Airworld Drive Kansas City MO 64153 1215 Phone 816 891 2470 Fax 816 880 9766 North American Sales Division Haldex Limited 525 Southgate Drive Unit 1 Guelph Ontario CANADA N1G 3W6 Phone 519 826 7723 Fax 519 826 9497 www haldex com www hbsna com Rev 5 03 5M CUT L30036 GO THE DISTANCE REMOVABLE KINGPIN SPECIFICATIONS HOLLAND HITCH COMPANY REMOVABLE KINGPINS PROVIDE e Multiple kingpin settings to vary weight distribution and overall length e A tapered design for secure installation and quick removal to prevent kingpin damage as may occur with folding goosenecks and to ease kingpin replacement Ihis series of kingpins is specifically designed for gooseneck drop frame and flatbed trailers but can be used for van and enclosed trailers if access is provided through the floor STANDARD FEATURES INCLUDE 1 Kingpins of AISI 4140 steel quenched and tempered for wear and streng
114. re an employee services rim wheels Regulations continued Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components Single piece wheel means a vehicle wheel consisting of one part designed to hold the tire on the wheel when the tire is inflated Trajectory means any potential path or route that a rim wheel component may travel during an explosive separation or the sudden release of the pressurized air or an area at which an airblast from a single piece rim wheel may be released The trajectory may deviate from paths which are perpendicular to the assembled position of the rim wheel at the time of separation or explosion See appendix A for examples of trajectories Wheel means that portion of a rim wheel which provides the method of attachment of the assem bly to the axle of a vehicle and also provides the means to contain the inflated portion of the assembly 1 the tire and or tube c Employee Training 1 The employer shall provide a program to train all employees who service rim wheels in the hazards involved in servicing those rim wheels and the safety procedures to be followed 1 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 1
115. reduce the reliability of the automatic adjustment In no case should the lubrication interval exceed the published intervals shown above Every automatic brake adjuster requires inspection at periodic intervals This inspection should coincide with the vehicle inspection program where norman vehicle lubrication intervals are scheduled or recom mended by the vehicle manufacturer Perform the following during these intervals 1 Measure air chamber push rod stroke 90 to 100 PSI per CVSA and DOT requirements 2 Record stroke measurements to within 1 16 and enter into inspection records 3 Grease each brake adjuster Note Some automatic brake adjuster models manufactured by Haldex do not require grease A hex plug may be installed into the adjuster casting to replace a grease fitting If present do not remove hex plug Contact Haldex if uncertain or require additional information 4 Visually inspect each brake adjuster for integrity and control arm connection to the associated bracket If air chamber stroke exceeds CVSA or DOT maximum allowances do not manually adjust the brake adjuster See Troubleshooting Procedures on page 5 to determine if the adjuster requires replacement MANUAL ADJUSTMENT TO THE BRAKE ADJUSTER COULD SHORTEN CLUTCH LIFE AND MAY VOID THE WARRANT Y Foundation Brake Operational Check and Troubleshooting Note Block wheels to prevent vehicle from rolling Ensure system tank pressure is
116. rical ball seat cap nuts to center and secure the wheel TIRE BEAD That surface of the tire which contacts the angled surface of the wheel rim TORQUE The amount of force used to tighten cap nuts Usually stated in foot pounds or kilograms and measured with a torque wrench WHEEL MOUNTING FACE That portion of the wheel face which contacts the hub or brake drum wt Abbreviation for weight Wheel measurement 9 2 NS BROKEN 52 XXI S 4 x p Center ed Bolt hole dia circle dia How to measure minimum dual spacing Minimum dual spacing measurement is determined by the tire manufacturer and may be obtained from the tire manufacturer s handbook To determine if the Alcoa aluminum dual wheel assembly has adequate minimum dual spacing for the selected tires double the wheel outset measurement of the Alcoa wheel used If the doubled outset measurement is equal to or greater than the tire manufacturer s 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 4 Dual spacing Vehicle clearance Tire clearance 2556 dual spacing
117. ricated torque to between 450 and 500 foot pounds Note when dualing steel wheels with Alcoa aluminum wheels follow the steel wheel manufacturers 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 and L on the studs and nuts indicate right and left hand threads respec tively see Section 5 2 After mounting a wheel over the studs snug up the cap nuts in the order shown in the illustrations that follow After all the cap nuts have been snugged tighten the cap nuts to the recommended torques following the same tightening sequence 1 4 5 2 Five Stud Six Stud 10 1 8 o6 79 2 Ten Stud xe 50 4 O 5 2 Eight Stud Continued on the next page 1 ghtening stud After 5 50 miles of operation or at least the first servi
118. rom face of air chamber Drum Contact Using a Lever to center of clevis pin reservoir pressure Brake Application at 90 100 PSI Automatic Brake Adjuster Checking Procedures If the brake adjuster is not maintaining the proper applied stroke before removing the brake adjuster check the condition of the foundation brake see pages 6 8 7 If after inspecting the foundation brake no apparent problems are found inspect the automatic brake adjuster to determine if it is operating properly The inspection can be performed on or off the vehicle using the following procedures Note Block wheels to prevent vehicle from rolling Ensure system tank pressure is at 90 100 PSI Check that push rod is fully retracted apply air to release spring brake If air is not available spring brake must be manually caged back Do not use air tools on brake adjuster On Vehicle Inspection Component Cause Action Tight or y Control arm gt Realign control arm and anchor bracket dragging brakes mispositioned Check installation procedures on pages 3 amp 4 Excessive Improper anchor lf anchor bracket to control arm connection chamber push bracket connection is worn loose bent or broken it must be rod travel to control arm re secured or replaced Low clutch torque WW Rotate the 7 16 adjustment hex one full turn counterclockwise Replace brake adjuster if the torque is less than 1
119. rotochamber the greater the force applied by the push rod and conversely the less air pressure applied to the rotochamber the less force applied by the push rod Push rod force is determined by multiplying the air pressure delivered by the effective diaphragm area For example if 60 psi is admitted to the Type 30 rotochamber the lineal force on the end of the push rod is approximately 1800 lbs When air pressure is released from the rotochamber the rotochamber spring returns the slack adjuster if applicable push rod diaphragm guide and diaphragm to the released position PREVENTIVE MAINTENANCE A Every month 8 000 miles or after 300 operating hours depending on type of operation 1 Check push rod travel and adjust travel at the slack adjuster if needed Push rod travel should be as short as possible without brakes dragging Excessive push rod travel reduces braking efficiency shortens diaphragm life gives slow braking response and wastes air 2 Check push rod to slack adjuster alignment from release to full stroke position to be sure push rod moves out and returns properly without binding at the cover hole or with other structures Also check the angle formed by the slack adjuster arm and push rod It should be 90 or greater when the chamber is in the applied or released positions 3 Checktightness of mounting nuts Check cotter pins to make sure they are in place 4 Check all hoses and lines They should be secure
120. sembly can cause death or serious injury WARNING Immediately and permanently remove from service any wheel that has been exposed to excessive heat Always follow safe mounting procedures as recommended using OSHA approved tire inflation cages See the Alcoa Wheel Service Manual or OSHA safety wall charts and procedures 18 Maintenance against corrosion non Dura Bright surface treated wheels 3 13 Dura Bright surface treated wheels cleaning and maintenance 3 14 The following information is for standard Alcoa forged aluminum wheels without the Dura Bright surface treatment See Section 3 14 for specific instructions on the care and cleaning of Alcoa Dura Bright surface treated wheels 1 Clean frequently with high pressure water from a hose The use of a mild detergent will speed the cleaning process Use no 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 products from the tire side of the rim Do not use a wire brush to remove dirt and corrosion products from the appearance surface of the wheel Generously coat the entire air chamber surface with an approved surface protectant and lubricant each time the tire is removed see Section 4 1 3 To maintain the original appearance of your Alcoa wheels the following procedures are recom mended a After installing new wheels and prior to operating your vehi
121. signs of alteration should be removed from service and scrapped 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 injuries or death Never attempt to weld braze or heat any surface of an Alcoa aluminum wheel Excessive heat damage WARNING Excessive heat from fire brake malfunction wheel bearing failure or other sources may weaken the metal and cause the wheel tire assembly to separate explosively Exploding wheel tire assembly can cause death or serious injury WARNING Immediately and permanently remove from service any wheel that has been exposed to 3 3 excessive heat Inspect for exposure to excessive heat A wheel that has been subjected to excessive heat may appear charred or burned A wheel that has been exposed to excessive heat may appear to be in good condi tion if it has been cleaned Do not use any wheel that has been overheated regardless of appearance Even if a wheel does not appear to be obviously burned check the valve hole labels tire bead brake drum and DiscMate for evidence of charring melting blistering or burning A wheel may discolor from excessive heat It can appear a dull grayish color and will not polish to a bright finish as a ty
122. sion 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 1 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 1 Aclip on chuck 1 An in line valve with a pressure gauge or a presettable regulator and 11 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 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 w
123. t of required bracing or cross members 3 Since the tapered hole in the housing is accurately machined a welding procedure which alternates from side to side and which minimizes heat buildup is recommended to avoid distortion hole should also be protected from weld spatter during coupler construction 4 An access opening must be provided through the trailer floor for field removal and installation of the kingpin KINGPIN INSTALLATION INSTRUCTIONS Ihe trailer must be securely chocked and supported to prevent the trailer from rolling or falling onto the installer WARNING 1 Clean all foreign material from the housing and the kingpin Ihe application of a VERY THIN coating of rust preventative lubricant to the kingpin prior to installation will aid subsequent removal 2 Insert the kingpin into the housing aligning the dowel pin in the housing with the key slot on the kingpin Hold in place while the washer and nut are installed by a helper from above 3 Tighten the nut to a minimum of 300 foot pounds and install retaining pin through the castellations of the nut Ihe kingpin must be checked periodically during use and retightened to proper torque if necessary IMPORTANT 4 Housing plugs are recommended to minimize corrosion and contamination when a kingpin is not installed in the housing Ihe plug is installed in a similar manner but is retained with a finger tight thumb nut These products are c
124. t or broken components If the control arm and mounting bracket check out okay replace the adjuster and hardware per procedures on pages 3 amp 4 Torque Specifications Note Tighten all fasteners to manufacturer s recommendations unless otherwise specified below Flat Anchor Stud Pin Torque to 40 50 ft Ibs Round Anchor when installed Stud Pin with Fabricated Ring Clamp Torque to 15 20 ft Ibs when installed Round Anchor Stud Pin with Slide Nut Torque to 15 20 ft Ibs when installed 3 8 16 Bolt Torque to 15 20 ft Ibs when installed Strap Style Bracket Torque to 8 12 ft Ibs when installed U Bolt Style Bracket Torque to 20 30 ft Ibs when installed 10 Frequently Asked Questions 1 Will the side of the brake adjuster with the installation indicator always face in No Haldex adjusters are normally unhanded Always install with the adjusting hex pointing away from the air chamber N My adjuster doesn t have installation indicator should I be concerned No A few applications aren t manufactured with installation indicators However the set up and function are the same regardless Refer to pages 3 amp 4 for proper installation procedures G3 Why is there resistance when backing off the adjuster It takes approximately 20 25 Ib ft of torque to back off the adjustment hex A ratcheting sound should occur T
125. th 2 engagement with the housing for firm secure installation 3 Locking dowel pin to prevent rotation an aid in installation and removal 4 Two models one for standard 2 SAE kingpins one which is convertible from 27 to 3 57 5 Housings with protective plugs are sold separately BOLSTER PLATE THICKNESS 4 00 DIA gt 2 KINGPIN HOUSING BOLSTER WITH HOUSING WITH PLUG PLATE d lable f n KP 0427 KP 0438 0 25 and are available for mu tiple positions KP 0428 KP 0439 0317 Bolster plate thicknesses are designed into the KP 0412 KP 0440 0 38 housings as shown below Only one kingpin of 0429 0441 0 50 the proper configuration is required if replacement is necessary XL KP103 01 6 00 SQ BOLSTER PLATE THICKNESS 27 KINGPIN 31 2 KINGPIN HOUSING BOLSTER KP 0413 KP 0414 KP 0444 0 387 0432 0433 0445 0 507 HOUSING INSTALLATION RECOMMENDATIONS 1 Ihe housing is designed for welded installation into the upper coupler assembly Ihe design of the upper coupler is the responsibility of the installer and must be consistent with the type and capacity of trailer and design loads for the upper coupler 2 Ihe housing is manufactured from AISI 1020 steel which is readily weldable a low hydrogen welding process is recommended The square external shape of the housing will aid the attachmen
126. the wheel in a safety cage or other suitable restraint refer to OSHA rule 1910 177 paragraph b see Section 7 Cracked or WARNING Cracked or damaged wheels may cause wheels to fail or come off the damaged wheel vehicle while the vehicle is moving checks Wheels that fail or come off the vehicle while it is moving can cause serious injury or WARNING Cath Immediately remove cracked or damaged wheels from service Visually inspect wheels for cracks or damage according to Section 3 Inspection and Maintenance Remove wheels from service with known or suspected damage Mounting area Stud hole cracks are usually caused by improper torquing see Sections 5 8 and 6 2 excessive load ing or insufficient mounting flange support by the hub or brake drum Remove wheel from service 3 6 Shown below are stud hole cracks emanating from stud hole to stud hole Causes are undersized diameter of wheel support surface see specifications on next page support surface not flat incorrect attachment parts see Section 4 12 and insufficient torque see Sections 5 8 5 11 6 2 Remove wheel from service Support surface should be flat to the diameter recommended on the chart on the following page Inspect the hub drum contact area thoroughly for cracks or other damage 10 Mounting area Support surface diameters continued Support surface should be flat to the diameter recommended on the chart below Number of Bolts Bolt
127. tings into ports ensure that chips from the pipe threads or sealing material do not get inside the piping Also when the pipe tape is used leave 1 5 to 2 thread ridges exposed at the end of the threads Warning 1 Operating fluid Please consult with SMC when using the product in applications other than compressed air including vacuum Regarding products for general fluid please ask SMC about applicable fluids Install an air dryer aftercooler etc Excessive condensate in a compressed air system may cause valves and other pneumatic equipment to malfunction Installation of an air dryer after cooler etc is recommended Drain flushing If condensate in the drain bowl is not emptied on a regular basis the bowl will over flow and allow the condensate to enter the compressed air lines If the drain bowl is difficult to check and remove it is recommended that a drain bowl with the auto drain option be installed For compressed air quality Equipment catalog refer to Air Preparation 14 21 4 O 4 Use clean air If the compressed air supply is contaminated with chemicals cynthetic materials corrosive gas etc it may lead to break down or malfunction Operating Environment Warning 1 Do not use in environments where the product is directly exposed to corrosive gases chemicals salt water water or steam 2 Do not expose the product to direct sunlight for an extended period of time
128. tset and inset inflation pressure and accessory part numbers Alcoa provides training live or on video on proper wheel installation and maintenance practices free of charge Contact Alcoa Wheel and Forged Products at 1 800 242 9898 option 4 Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 Not all Alcoa wheels are available with the Dura Bright surface treatment Note The Dura Bright surface treatment and the Dura Flange options are not currently available together on the same wheel Dura Bright is available in all polishing finishes Dura Flange is only available in satin finish Inspection Inspect thoroughly and frequently 3 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 have been in service need to be inspected at regular intervals to assure proper and safe performance It isn t always possible to predict exactly when the useful life of a wheel will end Wheels will eventu ally wear out But generally older wheels and wheels operating in extreme conditions should be exam ined more frequently for obvious signs that they should be removed from service Examine all exposed areas frequently Clean wheels and look for cracks or other damage Also check the inner dualed wheel when the outer whee
129. um 19 5 nonsymmetrical wheels require tires to be mounted and demounted over the disc side of the wheel only Lubricate the second tire bead Start second bead into Place tire wheel assembly inside safety cage or other NOTICE Refer to tire manufacturers well holding it in position with the clamp to the suitable restraint refer to OSHA rule 1910 177 recommendation for proper tire rim flange Lubricate bead half way around With paragraph b see Section 7 Refer to tire manufacturer s pressure curved end of tool between tire bead and flange and recommendation for proper tire pressure Using a clip the stop towards the wheel push tool outward to work on air chuck or a self locking straight chuck with remote tire over flange Continue to pry bead over flange valve and pressure gauge inflate the tire wheel assembly using the tool until remaining bead is over flange Seat to proper pressure If air escapes roll tire or use bead the tire bead using an air ring or other mechanical expander to force tire beads against rim Be sure to bead seating aid stay out of the path of potential exploding parts or air blasts 21 22 Mounting tubeless tires continued WARNING NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tires CAUTION NOTICE Do not exceed maximum wheel load Customer must
130. ure 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 41 OSH A Re 1 Each restraining device or barrier shall have capacity to withstand 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 continued 1 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 corro
131. uts DiscMate 014000 Lug nut covers 181 Hub covers N A Rear inner cap nuts N A 10 22 5x7 50 15 DC 7300 53 628 544 120 TR545D 873400 2225 39874 0 1 2 ODF 11 22282515906 7400 50 666 582 130 1785440 883440 8864 39874 12 225x1400 15DC 1280 7 20 130 TR543Eoutset 841400 0 2 39874 13 24 5x8 25 15 DC 7300 62 66 577 120 18509 983400 0 12 2245 39874 Continued on the next TUBELESS WHEELS round hand holes ENGLISH UNITS continued Maximum Maximum wheelload Wheel Outset Inset inflation Valve Part Available Front outer Rear outer no Wheel description in 105 Ibs inches inches PSI cold stem number Finishes Stabilizer cap nuts cap nuts 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hole diameter use two piece flange nuts 011000 Lug nut covers 181 Hub covers Front 076018 or 0760851 Rear 077018 077085 Rear inner cap nuts 0 1 2 3 008 14 22 5x7 50 15 DC 7300 53 628 5 44 120 5450 873600 108 208 308 2225 39874 0 1 2 3 008 108 208 308 15 22 5 8 25 1520 7400 48 6 66 5 81 130 544 883640 ODF 1DF 20 8864 39874 0 1 2 ODF 16 22 5 8 25 15206 8000 55 6 66 5 69 130 TR543C 885600 1DF 20 39874 0 1 2 3 17 22 5x9 00 15 DC 9000 60 6 94 6 04 130 544 893640 008 108 8964 39874 208 308 18 22 5 9 00 150 1
132. without charge Individuals establishments and other organizations desiring single or multiple copies of these charts may order them from the OSHA Publications Office U S Department of Labor Room N 3101 Washington DC 20210 Telephone 202 219 4667 49 FR 4350 Feb 3 1984 as amended at 52 FR 36026 Sept 25 1987 53 FR 34737 Sept 8 1988 61 FR 9239 Mar 7 1996 6 Glossary of Common Terms Glossary of 1 2 DUAL SPACING One half the distance between the two center lines of dualed wheels The dimension is the same as the OUTSET dimension Common Terms 1 PIECE FLANGE NUT A one piece washer and nut combination not recommended for use on any Aloca wheel application 2 PIECE FLANGE NUT A two piece washer and nut combination used to secure hub piloted wheels S 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 dimen sions stated in diameter inches or millimeters BOLT HOLE Hole found in the disc of the wheel through which the bolt stud passes BORE See CENTER BORE See HUB BORE CONE LOCK CAP NUT See 2 PIECE FLANGE DC Abbreviation for drop center DISC AREA The vertical wheel face which supports the rim DISC WHEEL A one piece forged or two piece

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