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WHEEL SERVICE MANUAL

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1. ALCOA WHEEL SERVICE ange MANUAL m IMRBORTANIRSAKERYARRE CAVUM ONSJEORIRRUCKERTIMSFANDEWHIE ETIES JANUARY 2012 SUPERSEDES APRIL 2011 IMPORTANT Federal OSHA Regulations require all employers to make sure their employees who service rims wheels understand the safety information contained in this manual Do not let your employees service rims wheels unless they are thoroughly trained and completely understand this safety information If you are a service technician do not service rims wheels unless you are thoroughly trained and completely understand this safety information ALCOA LIMITED WARRANTY FOR HEAVY DUTY TRUCKS TRUCK TRAILERS BUSES RV and MOTORHOME WHEELS This limited warranty applies to Alcoa forged aluminum wheels with bead seat diameters measured in 5 inch increments Wheels and the surface of rim flange treatments applied to the Wheels Transit Wheels means Wheels used on transit vehicles such as buses and vans whose primary purpose is to transport people Alcoa warrants to the original purchaser from Alcoa or its authorized distributor that a new Alcoa truck truck trailer bus RV or motorhome Wheel is free from defects in material and workmanship for the applicable time period set below a Except as stated in b of this section Wheels are warranted for 60 months from the date of manufacture as shown on the Wheel b Transit Wheels and RV and motorhome Wheels are warranted for 120 months fro
2. ii Information to be used in the training program shall include at a minimum the applicable data contained in the charts rim manuals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts or rim manual the employer shall assure that the employee is instructed concerning the contents of the charts and rim manual in a manner which the employee is able to understand 2 The employer shall assure that each employee demonstrates and maintains the ability to service rim wheels safely including performance of the following tasks 1 Demounting of tires including deflation i Inspection and identification of the rim wheel components ii 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 vill 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 necess
3. HUB PILOTS Pads on the hub to locate the center hole of a hub piloted wheel in Abbreviation for inches INNER CAP NUT The ball seat nut used to install the inner stud piloted dual wheel to a vehicle see Double Cap Nut INSET The distance from the wheel mounting surface to the rim centerline when the centerline is placed inboard of the mounting surface kg Abbreviation for kilogram weight measurement equal to 1000 grams kPa Abbreviation for kilo Pascals pressure measurement Glossary of Common Terms continued LOCK RING The third piece of a 3 piece rim assembly which locks the side ring to the rim base MAXIMUM INFLATION The highest amount of air pressure allowed measured at normal ambient temperatures mm Abbreviation for millimeters MULTI PIECE WHEEL A wheel assembly in which the rim portion of the wheel consists of two or more separate parts N m Abbreviation for Newton meters OFFSET See OUTSET OPEN SIDE The side of the wheel opposite the disc face OSHA Abbreviation for the U S Department of Labor Occupational Safety and Health Administration OUTER CAP NUT The ball seat nut used to install the outer wheel of a stud piloted dual assembly or a single stud piloted wheel to a vehicle The outer nut screws onto the inner cap in a dual assembly See Double Cap Nut OUTSET The distance from the mounting surface of the wheel to the rim centerline when the rim cente
4. Dimension checks 2 4 Best Inspection Method Photo to the right shows the TRA Ball Tape 2nd Best Inspection Method If a ball tape is unavailable Non Dual wheel 3rd Best Inspection Method Rolling wheel as described on this page Open Side Circumference Check WARNING Wheels that have been subjected to high pressure tire and rim separation or excessive heat damage may no longer have sufficient dimension and contour to retain the tire bead while under pressure Exploding wheel tire assembly can cause serious injury or death WARNING Immediately and permanently remove from service any wheel that has been exposed to high pressure tire and rim separation or excessive heat WARNING Wheels that have been run flat or have other physical damage may no longer have sufficient dimension and contour to retain the tire bead while under pressure Rims that lack proper dimension and contour can lead to explosive separation of the tire and rim causing serious injury or death WARNING Any wheel that has been in service must be inspected prior to mounting Follow dimension check procedures described in this section during each wheel inspection Measure the circumference of the bead seat on the open side see illustration to left with a ball tape The circumference of the bead seat on the open side of the wheel should be checked at each tire change The open side is the side opposite the disc f
5. 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 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 This space x must be 2mm less than the thickness of the Alcoa wheel to be accomodated Determine this space when the nut is bottomed out at the stud without a wheel mounted Tightening hub piloted mounting two piece flange nuts 4 10 Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of flange nuts should be done in recommended sequences WARNING Undertorqued flange nuts can 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 s causing serious i
6. matter of life Unsafe handling or failure to follow approved mounting and demounting procedures and death WARNING 22 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 Under U S federal law any individual handling tire wheel assemblies must be trained in OSHA regulations as mentioned in section 6 Safety is everybody s business Do not attempt to service any wheel assembly without proper training Proper equipment is important Be sure you have the recommended tools and equipment on hand and use them according to manufacturer s instructions Tubeless wheels and tires require equal care Even though tubeless assemblies have fewer parts than multi piece wheels they still require respect and proper handling Pay particular attention during crucial steps e Removal of tire and wheel assemblies from vehicles e Demounting tire from wheel e Wheel inspections e Inflation of tire e Handling and storing of inflated assembly Safety and service information is readily available Wheel tire and service equipment manufacturers offer service manuals and other training materials Stay up to date on proper procedures and keep current instructional materials handy in the shop Study safety and service information and use it on Statistics show that in most industries at w
7. 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 Rim flange wear continued Edge Removal Procedures There are many tools available to remove the sharp edge on the wheel caused by rim flange wear Here are some examples of commonly used tools File A file can be used very effectively to remove the edge photo 4 Photo 4 Removing sharp edge by hand with Photo 5 Air or electric power sander a metal file Air or Electric Powered Sander This provides a very quick and effective method of removing the edge Operators should use all care to keep a uniform edge when using these tools photo 5 Air or Electric Grinder This is 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 Grinder Photo 7 Grinder 13 Rim flange 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 wear continued metal as uniformly as possible and not to gouge the wheel photo 7 on previous page filings and sparks Many power tools have edges that are sharp or may become hot during use Some power
8. OSHA Area and Regional Offices The address and telephone number of the nearest OSHA office can be obtained by looking in the local telephone directory under U S Government U S Department of Labor Occupational Safety and Health Administration Single copies are available without charge Individuals establishments and other organizations desiring single or multiple copies of these charts may order them from the OSHA Publications Office U S Department of Labor Room N 3101 Washington DC 20210 Telephone 202 219 4667 49 FR 4350 Feb 3 1984 as amended at 52 FR 36026 Sept 25 1987 53 FR 34737 Sept 8 1988 61 FR 9239 Mar 7 1996 41 42 Glossary of Common Terms Glossary of Common Terms 7 1 AIR CHAMBER The area in a mounted tire and rim assembly that contains the air BEAD SEAT The tire seating surface of the rim BOLT CIRCLE The circle defined by the centers of the bolt holes stud holes of a wheel dimensions stated in diameter inches or millimeters BOLT HOLE A hole in a disc wheel for attachment fasteners BORE See CENTER HOLE CENTER BORE See CENTER HOLE DISC The center member of a disc wheel DISC FACE The flat central portion of a disc wheel in which the bolt holes are located and which contacts the drum hub or mating wheel DISC WHEEL A rim combined with a center disc which has bolt holes for attaching to a vehicle DISC WHEEL HALF DUAL SPACING The distan
9. 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 3 5 for recommendations and instructions for demounting tubeless tires Adequately lubricate the bead seats and properly re seat the tire beads Reinflate the wheel in a safety cage or other suitable restraint refer to OSHA rule 1910 177 paragraph b see Section 6 WARNING Cracked or damaged wheels may fail or come off the vehicle Wheels that fail or come off the vehicle while it is moving can cause serious injury or death WARNING Immediately and permanently remove cracked or damaged wheels from service Visually inspect wheels for cracks or damage Remove wheels from service with known or suspected damage Mounting area Stud hole cracks are usually caused by improper torquing see Sections 4 8 and 5 2 excessive loading or insufficient mounting flange support by the hub or brake drum Remove wheel from service 2 6 Shown below are stud hole cracks emanating from bolt hole to bolt hole Causes are undersized diameter of wheel support surface see specifications on next page support surface not flat incorrect attachment parts see Section 4 2 and insufficient torque see Sections 4 8 4 11 5 2 Remove wheel from service Support surface should be flat to the diameter recommended on
10. or i Damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline Alcoa s liability and purchasers exclusive remedy for a Wheel or surface or rim treatment on such Wheel that does not comply with the foregoing warranties is limited to repair or replacement of the Wheel ALCOA SHALL NOT BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL INDIRECT OR SPECIAL DAMAGES FOR ANY BREACH OF WARRANTY THERE IS NO WARRANTY THAT A WHEEL OR SURFACE OR RIM TREATMENT OF SUCH WHEEL SHALL BE MERCHANTABLE OR FIT FOR ANY PARTICULAR PURPOSE NOR IS THERE ANY OTHER WARRANTY EXPRESS OR IMPLIED EXCEPT SUCH AS IS EXPRESSLY SET FORTH IN THIS LIMITED WARRANTY Notes 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 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 This limited warranty should be used in conjunction with the Service Manual and the Alcoa Dura Bright Wheel Finish Care and Maintenance manual The Service Manual contains important safety information and warnings and failure to read and understand that
11. 75 10 5 11 75 12 25 11 75 12 25 11 75 12 25 13 00 12 25 13 00 13 00 14 00 14 00 14 00 13 00 14 00 7 50 8 25 1 30 8 25 8 25 8 25 9 00 There may be additional rim to tire matches not shown above Contact the tire manufacturer or your Alcoa wheel representative for additional information Recommendations for demounting tubeless tires WARNING An aluminum wheel can be structurally weakened by excessive heat Tire wheel assemblies using wheels that have been exposed to excessive heat may experience a sudden and unpredictable tire wheel separation causing serious injury or death Immediately and permanently remove any wheel from service that has been subjected to excessive heat such as a tire fire wheel bearing failure or braking system drag seize 3 _ 5 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 cause serious injury or death Inspect tires and wheels for damage before removing from vehicle If damage is found tire must be completely deflated before loosening cap nuts Immediately and permanently remove damaged tires or wheels from service WARNING 20 Recommendations for demounting tubeless tires continued Demounting of tubeless tires 3 6 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your particular machi
12. Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced under the CAUTION Alcoa limited warranty Severely corroded wheels are unsuitable for service Bolt holes If wheels are run loose both stud located wheels and hub piloted wheels can be damaged Look for wallowed out or elongated ball seats on stud located wheels On hub piloted wheels look for elongated stud holes Over torquing can lead to damaged ball seats on stud located wheels and can damage the disc surface of hub piloted wheels Remove damaged wheels from service For hub piloted normally if you see For hub piloted normally if you see a Damaged ball seat contact area Pounding thread marks on the inside diameter of wallowed out bolt hole this would of nut on ball seat contact area identified the bolt holes this would indicate the indicate the wheel ran loose by arrows wheel ran loose Disc area Inspect both sides of disc area for hand hole cracks If cracks are found remove the wheel from service Rim area Check the entire rim area for nicks gouges and cracks Loss of air may be caused by cracks in areas around the valve stem hole Remove the wheel from service 2 10 Drop center crack Valve hole crack Bead Seat area Loss of air may be caused by cracks in the bead seat areas around the rim Remove the wheel from service if damaged 2 11 Bead seat cracks are normally caused by overloading of the wheels If you have
13. CICS ssc cciscccctinesescarvecicdnssuravanienninesaadindeasuciadbersslendaadunecss 20 J0 Demountng G0 TIDE CRS ANS sisri iaso a e E A A E eNi 21 a o E o i PA A E A O E E AE EEA E A EEN 22 4 1 Recommendations for proper installation Of Wheels ccccccssssseecceeeseneceeeeeeneeeecceseaeeceeeesnaeeeeeesas 2A d2 Whicel tap TO iieiea e nE ae nsec deep NEEE EEE EAEOI 23 4 3 How to measure stud SAO sap 5 cpa ascites at cs saps cat ceeacicaa ssc see tee setae seseina ie aie ei ata meee iua E iiaae 24 4 4 Stud located ball seats are spherical csscascseccancanescdeversdeonscnnccsassevetedcedasceenisvsepeamessdnsualeceatitioaevacepeilindectaces 24 4 5 Stud Piloted Mounting System Single and wide base wheel stud located ball seat mounting 24 4 6 Dualed wheels stud located ball seat MOUNTING c ce ccesessscceeceecesessennaeeeeeeecessesseaaeeeeeeeeeeesaas 25 4 7 Dualed wheels steel inner aluminum outer stud located ball seat mounting eee eeeeeeeeees 27 4 8 Tightening stud located ball seat cap NUES ce eeeeescccecsssseceeceseeaeeccesesnneceesesseeeeecsseeaeeceeeesaeeeeeeeeas 28 4 9 Hub Piloted Mounting System Single dualed and wide base wheels hub piloted mounting two piece Tonge TUNG 2 cass cies secede crcacaen cate epice sal peta a cainse E sake ica dap NE EN E EE 30 4 10 Tightening hub piloted mounting two piece flange MUS Lcccccccssscascccncessacasscaccessecaneeanscesecensseacecssasauceds 31 A L VOC PREC EAS MA
14. See Section 4 2 pg 23 for proper hardware assemblies 4 11 Stud located ball seat ra aluminum wheel Two piece ra flange nut 4 The following are examples of incorrect wheel assemblies Insufficient contact area Do not use two piece flange nuts with stud located ball seat wheels Hub piloted Alcoa DA Pd aluminum wheel eNA Ball seat cap nut ai ji te Insufficient contact area NOTICE All of the different Incorrect use of ball seat cap nut on hub piloted system variations of mounting Do not use ball seat cap nuts with hub piloted wheels wheels incorrectly on hubs Incorrect use of ball seat Incorrect use of ball seat Incorrect use of ball seat Incorrect use of a hub wheels on hub piloted wheel on hub piloted system wheel on hub piloted system piloted wheel as an inner system Do not use ball Do not use ball seat wheels as Do not use ball seat wheels Do not use hub piloted seat wheels as inner and inner dual with a hub piloted as outer duals with a hub wheels with stud piloted outer duals with a hub wheel system piloted mounting system mounting systems Note piloted wheel system the lack of contact between duals 33 Proper Torque Wheel Identification and Valves Avoid abuse Abuse can shorten the 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
15. appears between the short leg and the rim flange the wheel should be removed from service and scrapped If a ball tape or carpenter square is unavailable roll the unmounted wheel without a tire a minimum of 10 feet over a smooth flat level clean surface such as asphalt or concrete pavement Any deviation from rolling in a straight line is an indication of a potential lack of proper dimension and contour Remove the wheel from service until it can be properly checked with a ball tape IF YOU DO NOT FULLY UNDERSTAND ANY OF THESE INSPECTION METHODS AS DESCRIBED IN THIS SECTION CONTACT ALCOA AT 800 242 9898 FOR CLARIFICATION oe ESE foe Ks ES Eo i Dimension checks continued Cracked or damaged wheel checks Tire Wear or Ride Problems If you experience tire wear or ride problems it may be helpful to check radial run out Remove the wheel from the vehicle deflate and remove the tire see Section 3 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 indicator reading of 030 inches or less is acceptable
16. are recommended to be replaced when the tire wheel assemblies are removed and reinstalled WARNING Wheels that are not properly installed or maintained may not be safe Failure to follow proper wheel installation or maintenance practices may result in serious injury or death Follow the proper wheel installation and maintenance practices as contained in this Alcoa Wheel Service Manual For training on proper installation and maintenance available free of charge from Alcoa or for the most recent updates contact Alcoa Wheel and Transportation Products at 1 800 242 9898 or on the web at www alcoawheels com Wheel cap nuts amp Wheel mounting tool 4 2 NOTICE One piece flange nuts are not approved for use on any Alcoa wheel application WARNING Use of chrome plated cap nuts which have chrome plating on the surfaces that contact the wheel can cause reduced and inconsistent wheel clamping This condition can cause wheels to loosen and disengage from the vehicle causing serious injury or death WARNING 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 standardized The R and L on cap nut part numbers indicate right and left hand threads respectively Alcoa recommends the following cap nuts for use with Alcoa aluminum truck wheels Cap Nuts and Sleeve
17. damaged wheels can lead to an explosive separation of tires and wheels or wheel failure on the vehicle Explosive separations of tires and wheels or wheel failure on the vehicle could cause WARNING serious injuries or death Never attempt to weld braze or heat any surface of an Alcoa aluminum wheel Heat damage WARNING Excessive heat from fire brake malfunction wheel bearing failure tire failure or other sources may weaken the metal and cause the wheel tire assembly to 2 3 separate explosively Exploding wheel tire assembly can cause serious injury or death WARNING Immediately and permanently remove from service any wheel that has been exposed to excessive heat Inspect for exposure to excessive heat A wheel that has been subjected to excessive heat may appear charred or burned A wheel that has been exposed to excessive heat may appear to be in good condition if it has been cleaned Do not use any wheel that has been overheated regardless of appearance Even if a wheel does not appear to be obviously burned inspect the labels tire bead brake drum and high temperature nylon spacer for evidence of charring melting blistering or burning A wheel may discolor from excessive heat It can appear a dull grayish color and will not polish to a bright finish as a typical wheel would Any wheel run with a flat tire longer than the time necessary to immediately pull off the road should be checked for excessive heat dama
18. fully tightened 7 Tires shall not be inflated when any flat solid surface is in the trajectory and within one foot of the sidewall 8 Employees shall stay out of the trajectory when inflating a tire 9 Tires shall not be inflated to more than the inflation pressure stamped in the sidewall unless a higher pressure is recommended by the manufacturer 10 Tires shall not be inflated above the maximum pressure recommended by the manufacturer to seat the tire bead firmly against the rim flange 11 No heat shall be applied to a single piece wheel 12 Cracked broken bent or otherwise damaged wheels shall not be reworked welded brazed or otherwise heated 39 FR 23502 June 27 1974 as amended at 52 FR 36026 Sept 25 1987 53 FR 34736 Sept 8 1988 OSHA Regulations continued Appendix A Trajectory APPENDIX A TRAJECTORY WARNING STAY OUT OF THE TRAJECTORY AS INDICATED BY SHADED AREA Note Under some circumstances the trajectory may deviate from its expected path FIGURE 3 oo ee FIGURE 2 Appendix B Ordering Information for NHTSA Charts OSHA has printed two charts entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi piece Rim Matching Chart as part of a continuing campaign to reduce accidents among employees who service large vehicle rim wheels Reprints of the charts are available through the Occupational Safety and Health Administration
19. of vehicle WARNING control can result which can cause serious injury or death Only use approved mechanical or pneumatic bead seating devices WARNING A pressurized tire wheel assembly can explode and separate violently This violent separation can cause serious injury or death WARNING Lubricate wheel and tire bead using approved lubricant Tire beads should be mounted over the rim flange closest to the wheel well Push bead over flange as far as possible Lubricate the second tire bead Start second bead into the well holding it in position with the clamp to the rim flange Lubricate bead half way around With curved end of tool between tire bead and flange and the stop towards the wheel push tool outward to work tire over flange Continue to pry bead over flange using the tool until remaining bead is over flange Seat the tire bead using an air ring or other mechanical bead seating aid Always contain the tire wheel assembly in an inflation cage during inflation i oll EE Insert curved end of tool between bead and wheel flange with tool stop against flange In circular motion use short successive bites to work the bead over the flange Push down on tool as bead is worked over flange Place tire wheel assembly inside safety cage or other suitable restraint refer to OSHA rule 1910 177 paragraph b see Section 6 Refer to tire manufacturer s recommendation for proper tire pressure Using a clip o
20. on free training on proper installation and maintenance procedures contact Alcoa Wheel and Transportation Products at 800 242 9898 or on the web at www alcoawheels com Determining Rim Flange Wear STEP 1 Remove the wheel tire assembly from the vehicle Remove the valve core to deflate the tire completely Remove the tire from the wheel according to OSHA regulations TMC recommended practices for tire and rim safety procedures and or the Alcoa Wheel Service Manual Photo la Photo 1b 11 Rim flange wear continued NOTICE Examine the tire for cuts in the bead area and side wall If no damage occurred to these areas return the tire to service Cut tires should be removed from service The tire should be inspected at this time for any other damage and be treated per normal tire procedures recommended by the tire manufacturer NOTICE Check the wheel at every tire change or ONCE PER YEAR for rim flange wear and any sharp edges If you follow this practice you will significantly reduce the possibility of a rim flange cutting into the tire 12 STEP 2 After the wheel is separated from the tire verify that the circumference of the bead seat on the open side is acceptable see Section 2 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 photos la and 1b on previous page See Rim Flange Wear Gauge Instructions on the i
21. or wheel component which is bent out of shape pitted from corrosion broken or cracked shall not be used and shall be marked or tagged unserviceable and removed from the service area Damaged or leaky valves shall be replaced 3 Rim flanges rim gutters rings bead seating surfaces and the bead areas of tires shall be free of any dirt surface rust scale or loose or flaked rubber build up prior to mounting and inflation 4 The size bead diameter and tire wheel widths and type of both the tire and the wheel shall be checked for compatibility prior to assembly of the rim wheel f Safe Operating Procedure Multi Piece Rim Wheels The employer shall establish a safe operating procedure for servicing multi piece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at least the following elements 1 Tires shall be completely deflated before demounting by removal of the valve core 2 Tires shall be completely deflated by removing the valve core before a rim wheel is removed from the axle in either of the following situations 1 When the tire has been driven underinflated at 80 or less of its recommended pressure or ji When there is obvious or suspected damage to the tire or wheel components 3 Rubber lubricant shall be applied to bead and rim mating surfaces during assembly of the wheel and inflation of the tire unless the tire or wheel manufacturer recommen
22. page Tightening stud located ball seat cap nuts Inner Cap Nut Inner Cap Nut left hand threads Inner Cap Nut right hand threads Note The top of the inner cap nut Note This should have the letter L Note This should have the letter R will have thread direction identified on the end of the cap nut on the end of the cap nut on the end of the nut 28 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 Stud Located Ball Seat Mounting System It is recommended to torque to between 450 and 500 foot pounds If lubricated with motor oil torque should be between 350 and 400 foot pounds Note when dualing steel wheels with Alcoa aluminum wheels follow the steel wheel manufacturer s recommendations regarding the proper torque and use of thread lubricants to mount the wheel WARNING Application of lubricant to the ball seats can cause excessive torque Over torque can stretch studs causing them to fail Overtorquing can lead to wheel disengagement causing serious injury or death WARNING Do not allow oil to contact ball seats or mounting surfaces of the wheel hub or drum Do not use aerosol cans for lubrication of stud threads On vehicles eq
23. s recommendation never use the detergent straight and maintenance without diluting with water In the mixed diluted state the cleaner acidity should be at pH equal or greater than 5 avoid cleaners that contain any hydrofloric acid In the mixed diluted state the cleaner alkalinity basicity should be at pH equal or lower than 9 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 3 1 9 1 5 When tires are removed the entire rim must be cleaned and inspected see Section 2 With a 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 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 high temperature nylon spacers is highly recommended Note pH value can be found in chemical MSDS Material Safety Data Sheet If the cleaner is in concentrated form contact your cleaning chemical supplier to determine pH levels Only Alcoa s Warranty Center can authorize warranty claims and determine justified warranty returns Dura Bright and Dura Flange cla
24. scratches and other surface blemishes resulting from improper maintenance cleaning road debris curbing accident h Rim flange wear unless the rim has been treated with Dura Flange or i Damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline Alcoa s liability and purchasers exclusive remedy for a Wheel or surface or rim treatment on such Wheel that does not comply with the foregoing warranties is limited to repair of replacement of the Wheel Alcoa shall not be liable for any incidental consequential indirect or special damages for any breach of warranty There is no warranty that a Wheel or surface or rim treatment of such Wheel shall be merchantable or fit for any particular purpose Nor is there any other warranty express or implied except such as is expressly set forth in this limited warranty This limited warranty should be used in conjunction with the Service Manual and the Alcoa Dura Bright Wheel Finish Care and Maintenance manual The Service Manual contains important safety information and warnings and failure to read and understand this information may result in serious injury or death WARNING Wheels that are not properly installed or maintained may not be safe Failure to follow proper wheel installation or maintenance practices may result in injury or WARNING death Follow the proper wheel installation and maintenance practices as
25. sharp angle can damage wheels 5 l Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures roll stamped on the wheel Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions Keep wheel Wheel cap nuts must be kept tight see Section 4 8 When checking the cap nuts on dual disc nuts ti ght wheels utilizing the stud located ball seat mounting system loosen every other outer cap nut and then check the torque of the inner cap nuts Retorque the loosened outer cap nuts Repeat procedure with the rest of the nuts Check all cap nuts for proper torque after the first use or any removal Inspect wheels see Section 2 and check wheel nuts during service stops Dirt streaks from cap nuts may indicate looseness 5 2 Flange nuts must be kept tight and studs and nuts should be checked frequently At tire changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed For proper nut torque refer to the chart below Torque Level Ft Lb Torque Level Ft Lb Lubricated Dry 11 16 16 300 400 7 8 14 350 400 M20 x 1 5 280 330 M22 x 1 5 450 500 Hub piloted using two piece flange nut Stud piloted double cap nut standard type 7 8 radius 3 4 16 450 500 1 1 8 16 450 500 Stud pi
26. should be put on the vehicles with the valve stems 180 apart Alcoa Aluminum Wheels Outer Cap Nut P N 5996R or L 3 4 Stud See 4 2 page 23 Inner Cap Nut P N 5978R or L or P N 5988R or L See 4 2 page 23 gt 1 31 to 1 44 k stud standout Correct mounting for dual aluminum stud located ball seat mount wheels WARNING Incorrect inner cap nuts used with dualed aluminum wheels can bottom out on the unthreaded portion of the stud before the wheels are properly seated Improperly seated wheels can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running wheels can lead to stud breakage WARNING Use only cap nut 5978R or L 5988R or L or their equivalent when mounting dual aluminum wheels On occasion Alcoa aluminum truck wheels are operated dualed with a steel inner wheel When this application occurs it is recommended to use a high temperature nylon spacer because of corrosion issues In the event a steel inner wheel is used extreme care must be exercised to properly seat it to the hub or drum prior to mounting the outer aluminum wheel Selection of an inner cap nut capable of fixing the steel inner wheel and providing adequate external thread length to secure the outer aluminum dualed wheel is critical to a safe assembly Alcoa recommends the use of inner cap nuts 7896R and L Grade 8 or equivalent for this purpose Dualed wheels ste
27. this type of wheel breakage it would be recommended to use SEVERE SERVICE WHEELS Please see Alcoa Wheels Product Spec Guide for part numbers and wheel descrtptions of the Severe Service Wheels 10 Rim flange wear 2 12 Rim flange wear is not a warrantable issue Only Dura Flange wheels have a warranty on rim flange wear against sharp edges for a 24 month warranty period Irregular wear on the surface of the rim flange is caused by abrasion from the tire chafer and sidewall Rim flange wear happens most often in applications with heavy or shifting loads If you are experiencing excessive rim flange wear in your operation consider using Alcoa Dura Flange aluminum wheels These wheels have been specially treated to significantly reduce rim flange wear Remove wheels from service when rim flange wear is excessive Excessive wear can be determined using an Alcoa approved wear gauge and procedures detailed below If rim flange wear becomes sharp and or cuts the tire contact Alcoa for recommended maintenance procedures THESE GAUGES ARE TO BE USED FOR RIM FLANGE WEAR ONLY THEY ARE NOT A BEAD SEAT ANGLE OR DIAMETER TOOL Rim Acceptable Rim NOT Acceptable Rim Gauge Rim Gauge Alcoa P N 000700 Alcoa P N 000700 No daylight in i Daylight in this this area area indicates indicates acceptable rim Wheel rim EXCESSIVE wear Wheel rim Remove from service immediately To obtain a gauge s at no charge and information
28. DEF 7 07 mme ose ra 3 ane oss 738 ae oss eas UL cs 392 G7 T 12162 TET Cay FEF Aa 11 41 ISS 0453 11 51 B14 as oes ns Cage i240 az oso 12 70 15 45 15 88 ley Oi CLF 4 oja HE 2 21 03 Pa R e 21 at nn m iar Da f i plep in 3a ba a JE y 45 Conversion Factors Inches to Millimeters Inches x 25 4 Millimeters 8 2 Millimeters to Inches Millimeters x 0 03937 Inches PSI to kPa PSI x 6 8948 kPa kPa to PSI kPa x 0 145 PSI Pounds to Kilograms Pounds x 0 4536 kg Kilograms to Pounds kg x 2 2046 Pounds Foot pounds to Newton Meters Ftlbs x 1 35582 N m Newton Meters to Foot pounds N m x 37561 Ft Ibs 46 Alcoa Wheel Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2012 Alcoa Wheel Products All Rights Reserved Form E37 13584 Printed in USA 02 12 30M
29. I aro cce seta ceee sas iiinn EEE EEEE EE EE EE iT 33 5 Proper Torque Wheel Identification and Valves cccccccccceecccceccccceceeeeeeeeeeeeeeeeeeeneaeaaas 34 JA AVO ADUNE essere settee ces an toe sacs ares tne st nes ween vee ees 34 WC E E arse A AE sta A N A OA N T E AAI A AA 34 39 Balance Welo hiS coser iee rn E Te E ee eer eee carr eer ere 35 54 Ownerin service identi lication ac decrnecesssecevissynrcesesaisiorcamasstccnenadbaseet aces hetiyscaieaau nausea sdopamusenieuantnasiaces 35 a acces cree eine tc eases nnn ease a ecg Sete a a R a0 Ma eect ea aes scene fects wae yeep eaten oe anion nce tas paca ace ease AE A 36 IS PT SOS sce cichonnsienncsinns scoss scioscac ane er iira ensi aenieei a irei ea ieai eia 37 C OSA RE o E nent tea ase T E T O ATS 37 T Glossary Ole Common LOE asee a a 42 7 1 Glossary of Common TT sects eas nthe tennessee nt getetees eeena tenikan serr na hs te ccndcceumecavonce tered vacaute 42 T2 Whieelmeas a Nts gets ca E E T TOTEE EEE OTIS EN FS e E ae acess E EE A N E 45 8 1 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 Inch esneeseesseessseesesssesreesssee 45 8 2 Conversion Factors asec ssscanictecd sluudan dcdaasusnausaieubssseadedeningatieasvniaciasveduiesaansnspesseigalit sedis txivastaeapebancdosedsncaseies 46 Ea N Py ma ES et Go Safety Safe SSIVICE WARNING An inflated wheel and tire assembly contains enough air pressure to cause practices are a an explosive separation
30. ace In the case of center flange wide base wheels or wheels with insets less than 3 inches both rim flanges should be checked Any wheel should be inspected prior to mounting If the circumference of the bead seat does not match the required dimension as indicated by the TRA certified ball tape immediately and permanently remove the wheel from service Ball tapes used for measuring wheel circumference can be purchased from the Tire and Rim Association Inc 175 Montrose West Avenue Copley Ohio 44321 330 666 8121 or at www rma org For instructions on proper use of ball tape reference the current Tire and Rim Association yearbook ea is E os tie a p a i i pmpa E Se oi pee i ie k 7 l EAA seth E Photo above shows carpenter square even on both bead seats Photo above shows an undersized wheel that you can clearly place a credit card approximately 030in or 76mm between the square and the wheel THIS INSPECTION TECHNIQUE ONLY APPLIES TO DUAL OR DISC FACED WHEELS Check all wheels at each tire change for proper contour of the open side of the rim Place the long leg of a carpenter square across the center of the disc side of the wheel Extend the short leg across both rim flanges of the wheel as shown above Repeat this process at four equidistant points around the wheel The short leg should touch both rim flanges at each point If a distance greater than the thickness of a credit card or 030 in or 76mm feeler gauge
31. amp on Dura Bright surface treated wheels can affect the appearance and performance of the Dura Bright surface treatment local to the stamp Valves Alcoa drop center wheels for tubeless tires come from the factory with air valves installed If it becomes necessary to replace an air valve install it using 9 to 11 ft lbs 12 to 15 Nm 110 to 130 in lbs of torque Replacement valves may be obtained from your authorized Alcoa Wheel Distributor Always use 5 _ 5 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 or grommet with a non water based tire lubricant When metal valve stem extensions are used it is recommended that valve stem stabilizers be used or use a plastic valve stem extension 35 Identification Alcoa Wheel Identification 5 _ 6 Since 1977 all Alcoa aluminum disc wheels have been identified with a stamp that shows the wheel load rating maximum inflation pressure date of manufacture part number wheel description and DOT marking designation Prior to June 1996 all Alcoa heavy duty truck wheels had the Alcoa identification symbol on the outside of the disc near the hand hole in line with the valve location This marking was phased out on heavy duty truck whe
32. anges nuts and studs should be inspected for cracks and stripped 9 or damaged threads After each wheel mounting cap nut torque should be checked with a torque cap nuts wrench Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of cap nuts should be done in recommended sequences 4 K Some states have laws which dictate full thread engagement or thread engagement past the nut 7 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 seat or to the cap nut to wheel contact surface Oiled seats can lead to over torquing which can stretch studs causing failure of studs Failed studs can cause the wheel to disengage from the vehicle causing serious injury or death Lubricants must be completely removed from the cap nut seats and contact surfaces if applied accidentally WARNING Undertorqued cap nuts allow wheels to run loose pounding out deforming the ball seats fatiguing studs or losing nuts Overtorquing can stretch studs causing them to fail Both under and overtorquing can lead to wheels coming off causing serious injury or death Check all parts including wheels studs and cap nuts Check mounting faces of wheels hubs and drums Check for dirt corrosion or damage Remove dirt and rust replace damaged parts Follow correct tightening sequences and torque levels Continued on next
33. ary to assure that each employee maintains his or her proficiency d Tire Servicing Equipment 1 The employer shall furnish a restraining device for inflating tires on multi piece wheels 2 The employer shall provide a restraining device or barrier for inflating tires on single piece wheels unless the rim wheel will be bolted onto a vehicle during inflation 3 Restraining devices and barriers shall comply with the following requirements G Each restraining device or barrier shall have the capacity to withstand the maximum force that would be transferred to it during a rim wheel separation occurring at 150 percent of the maximum tire specification pressure for the type of rim wheel being serviced ii Restraining devices and barriers shall be capable of preventing the rim wheel components from being thrown outside or beyond the device or barrier for any rim wheel positioned within or behind the device iii Restraining devices and barriers shall be visually inspected prior to each day s use and after any separation of the rim wheel components or sudden release of contained air Any restraining device or barrier exhibiting damage such as the following defects shall be immediately removed from Service A Cracks at welds B Cracked or broken components C Bent or sprung components caused by mishandling abuse tire explosion or rim wheel separation 38 OSHA Regulations continued D Pitting of components due t
34. ce Stud 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 Hub 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 30 Single dualed and wide base wheels hub piloted mounting two piece flange nuts continued Two pieced sleeved flange nuts Sleeved flange nuts serve two purposes l pa Increase thread engagement Reduce indexing of wheels When using sleeved flange nuts There are two kinds of sleeved flange nuts single mount and dual mount as shown All threads in the sleeve do not need to be engaged with the wheel bolt for proper installation Sleeved flange nut should have enough length to engage both wheels in a dual application DO NOT USE single wheel nuts in a dual wheel application Always use wheels and hardware that are designed for use with sleeved flange nuts e f Lubricate here Single mounted wheels require sleeved flange nuts with a short sleeve o e Le hi Fy Lubricate here L Dual mounted wheels require sleeved flange nuts with long sleeve nuts
35. ce from the outside disc face surface between the wheels as a dual assembly to the center of the rim DOUBLE CAP NUTS Two wheel nuts used in stud piloted wheel systems They include inner cap nuts used to fasten inner wheels to a vehicle and outer cap nuts used to fasten single wheels and outer wheels to a vehicle These nuts have both right and left hand threads and have ball seats that fit into the wheel ball and ball seat bolt holes to center and clamp the wheels on the hub DROP CENTER The well or center portion of the wheel rim DUAL WHEEL Any wheel that can be mated disc side to disc side with another wheel resulting in an inner and outer dual wheel assembly FLANGE NUT A nut with a flat face or flange that bears against the wheel can be one piece or multi piece construction 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 CENTER HOLE Hub Hole Hub Bore Center Bore Bore The large hole in the middle of a disc wheel HUB PILOTED MOUNTING A wheel mounting system in which location of the wheel is accomplished by positioning the wheel center hole on a machined pilot continuous of interrupted on the hub Fastening is accomplished by flange nuts bearing against the flat face of the wheel disc
36. ce where an employee services rim wheels Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components Single piece wheel means a vehicle wheel consisting of one part designed to hold the tire on the wheel when the tire is 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 ai OSHA Wheel means that portion of a rim wheel which provides the method of attachment of the assembly to the R ti axle of a vehicle and also provides the means to contain the inflated portion of the assembly e the tire egu auons and or tube continued 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 G 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
37. contained in this Alcoa Service Manual For additional copies of the manual and other useful items listed below available free of charge or for the most recent updates contact Alcoa Wheel and Transportation Products at 1 800 242 9898 or on the web at www alcoawheels com To obtain information on free training on proper installation and maintenance procedures contact Alcoa Wheel Products at 800 242 9898 or on the web at www alcoawheels com Important information available free from Alcoa Alcoa Wheel Service Manuals Disc Wheel Service Manual Videos CD 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 Disc Wheel Inspection CD published by the TIA 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 by OSHA Mounting Demounting Instructions for Alcoa Aluminum 19 5 RW Published by Alcoa Wheel and Transportation Products Wheels and Steel Disc 19 5 Wheels Published by Alcoa Wheel and Transportation Products Alcoa Rim Flange Safety Material Maintaining Alcoa Aluminum Wheels Rim Flange Wear Instructions Rim Flange Wear Gauge Technical Bullet
38. d below with motor oil This will minimize corrosion between the mating surfaces Lubrication is not necessary with new hardware Position one of the hub s pilot pads at the twelve o clock position After positioning wheels on the pilot pads hand tighten all two piece flange nuts then tighten to the recommended torque following the proper sequence shown below for your type wheel After 5 50 miles of operation torque should be rechecked unless your documented fleet practices determine otherwise Check torque frequently from then on If nuts require frequent 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 O to environmental conditions 6 O O 3 multiple re installations improper torquing and other factors Consult with your hub and stud manufacturer for 4 ON O 5 maintenance and replacement C recommendations Six Stud Eight Stud 1 10 8 09o 30 Os gO OF Ten Stud Incorrect as semblies WARNING Use of two piece flange nuts on ball seat wheels ball seat cap nuts on hub piloted wheels or single piece flange nuts in place of 2 piece flange nuts is dangerous Using the wrong wheel nuts can cause loss of torque broken studs and cracked wheels conditions which can lead to serious injury or death WARNING Use only hardware designed specifically for each wheel type
39. d to serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 7896R or L or its equivalent when mounting steel inner duals WARNING Inadequate wheel support surface can lead to stud hole to stud hole fracture resulting in separation of the outer disc and rim from the vehicle Separation of the wheel from the vehicle can cause serious injury or death Alcoa aluminum wheels with 11 1 4 diameter bolt circle require a support surface at least 13 3 16 in diameter Check the outer support surface of the inner steel wheel for flatness and adequate diameter before installing the outer wheel When the wheels are serviced check the mounting surfaces of both wheels for stud hole to stud hole cracks If cracks are found immediately and permanently remove the wheel from service For the support surface diameter required by other bolt circle sizes ask your Alcoa representative WARNING Use of two piece flange nuts on ball seat wheels or ball seat cap nuts on hub piloted wheels is dangerous Using the wrong cap nuts can cause loss of torque broken studs and cracked wheels conditions which can lead to serious injury or death Use only hardware designed specifically for each wheel type See Section 4 2 pg 23 for proper hardware assemblies 21 Tightening stud Cap nuts must be kept tight and studs and nuts should be checked frequently Nuts should be located ball seat retorqued if necessary At tire ch
40. detergent will speed the cleaning process Use no harsh alkaline cleaners When tires are removed the entire wheel must be cleaned and inspected See Section 2 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 2 l 4 tire is removed see Section 3 1 To maintain the original appearance of your Alcoa wheels the following procedures are recommended a After installing new wheels and prior to operating your vehicle use a sponge cloth or soft fiber brush to wash exposed wheel surfaces with a mild detergent and warm water solution Rinse thoroughly with clean water Wipe dry to avoid water spots Wax the cleaned surface with any automotive polish Clean your Alcoa truck wheels as frequently as required to maintain their appearance Dura Br ight The Dura Bright surface treatment is designed to be easy to clean and generally only requires water If soils attached to the surface do not come off with cold water try warm water and wipe surface treated with a soft towel or chamois material If soils remain use warm water and a mild detergent wheels cleaning with assistance of a commercial high pressure power washer if available Always dilute the detergent according to the manufacturer
41. ds against it 4 Ifatire ona vehicle is underinflated but has more than 80 of the recommended pressure the tire may be inflated while the rim wheel is on the vehicle provided remote control inflation equipment is used and no employees remain in the trajectory during inflation 5 Tires shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead 6 Whenever a rim wheel is in a restraining device the employee shall not rest or lean any part of his body or equipment on or against the restraining device 7 After tire inflation the tire and wheel components shall be inspected while still within the restraining device to make sure that they are properly seated and locked If further adjustment to the tire or wheel components is necessary the tire shall be deflated by removal of the valve core before the adjustment is made 39 40 OSHA Regulations continued 8 No attempt shall be made to correct the seating of side and lock rings by hammering striking or forcing the components while the tire is pressurized 9 Cracked broken bent or otherwise damaged rim components shall not be reworked welded brazed or otherwise heated 10 Whenever multi piece rim wheels are being handled employees shall stay out of the trajectory unless the employer can demonstrate that performance of the servicing makes the employee s pr
42. e mounted as singles and require 1 8 45 7mm minimum stud standout Most vehicles have 1 1 8 studs on the front hubs Alcoa single cap nuts P Ns 5996R and 5996L or equivalents should be used Some front hubs have 3 4 studs On these hubs use Alcoa single cap nuts P Ns 5995R and 5995L or equivalents High temperature nylon spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring High temperature nylon spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum Single Alcoa Aluminum Wheel Outer Cap Nut P N 5996R or L See 4 2 page 23 Correct single mounting with 1 1 8 stud located ball seat mount 1 8 minimum stud standout Continued on the next page Single and wide base wheel stud located ball seat mounting continued NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to 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
43. el inner aluminum outer stud located ball seat mounting continued 4 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 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 WARNING WARNING WARNING Inner Steel Wheel 4 Alcoa Aluminum Wheel f Outer Cap Nut P N 5996R or L See 4 2 page 23 Hub p gt Inner Cap Nut P N 7896R or L See 4 2 page 23 gt Correct dual mounting for steel inner aluminum outer stud located ball seat mount 1 31 to 1 44 stud standout 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 lea
44. els manufactured after June 1996 Wheel Load Rating Maximum Pounds Inflation Pressure ALCOA FORGED MAX LOAD 7300 LB MAX PSI 120 ae USA 042711 PART NO 883671 22 5X8 2515 DC T DOT ee Requirements Origin of Date of Manufacture Wheel Description FMVSS 120 Manufactor Month Day Year Designation prior to 2000 some wheels may have only Month Year All Dura Bright surface treated wheels are designated by the letters DB following the part number such as 883671DB Note Dura Bright wheels produced after November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 with bead seat diameters measured in 0 5 inch increments Not all Alcoa wheels are available with the Dura Bright surface treatment All Dura Flange wheels are designated by the letters DF following the part number such as 883677DE All Dura Bright Dura Flange wheels are designated by the letters DD following the part number such as 883673DD As of January 2009 Alcoa introduced a new logo label Usage requirements include warnings spindle recommendations recommended torque levers and customer service number 36 OSHA Regulations OSHA Regulations 6 1 29 C F R Section 1910 177 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 machine
45. esence 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 with the lug nuts
46. f 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 pla
47. fails in normal use or service see the qualifications section below to meet the foregoing warranties on any Wheel Alcoa agrees without charge to replace the Wheel Qualifications Alcoa does not warrant and will not repair or replace or make adjustment with respect to any Wheel or surface or rim flange treatment on such Wheel that has been subjected to misuse or abuse or any of the following a Using a tire which is oversized according to standards recommended by the Tire and Rim Association Inc or other recognized tire and rim agencies such as ETRTO Europe b Loading the Wheel beyond the applicable maximum wheel load as specified by Alcoa c Inflating tires beyond the applicable maximum as specified by Alcoa d Changing the original condition of the Wheel by alteration or by subjecting it to any processing such as welding or straightening e Accidents or abnormal or severe operating conditions including without limitation tire fires brake fires severe brake system drags or seizures or running with a flat tire f Failure to follow maintenance instructions or warnings set forth in the Alcoa Wheel Service Manual Service Manual Alcoa Technical Bulletins or other Alcoa literature Recommended maintenance includes without limitation using proper torque periodic cleaning polishing valve replacement periodic inspection for damage and loose lug nuts and rim flange wear inspections and procedures g Nicks
48. g a tire always use a clip on air chuck or threaded straight chuck and a remote valve with pressure gauge Stay out of trajectory of wheel 17 18 Recommendations for mounting tubeless tires continued Mounting tubeless tires 3 2 NOTICE Not all tire mounting demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tires NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions NOTICE When match mounting tires on Alcoa wheels locate valve stem adjacent to low point mark on the tire NOTICE Alcoa aluminum 19 5 non symmetrical wheels require tires to be mounted and demounted over the disc side of the wheel only NOTICE Refer to tire manufacturers recommendation for proper tire pressure WARNING Never use a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel Such use can lead to an uncontrolled pressure build up in the tire and may result in an explosion Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire on or off the vehicle or later on the road Loss
49. ge After January 2009 the new Alcoa Logo may not show heat damage A blistered charred blackened or cracked looking logo decal on an Alcoa wheel may indicate that the wheel has been exposed to excessive heat as shown in picture to the left or discoloration as shown in picture to the right Inspect all axle end components for signs of exposure to excessive heat Pay particular attention to brake drums or discs high temperature nylon spacer wheel liners and tire beads If these components show signs of over heating the entire assembly including the wheel should be replaced Charred High Temperature Nylon Spacer Charred Rubber Charred Heat Indicator Drop Center 2009 and after Wheels manufactured starting in January 2009 will have a 1 inch clear round heat indicator located next to the roll stamp on the inside shown on the left and right along with the same 1 inch clear round heat indicator located on the tire side drop well as shown in the photo above If either of these round labels show signs of blistering or have a charred blackened or cracked look this may indicate that wheel has been exposed to excessive heat Charred Heat Indicator 2009 and after Charred Heat Indicator 2009 and after IF ANY OF THE ABOVE CONDITIONS ARE SEEN REMOVE THE WHEEL FROM SERVICE IMMEDIATELY THIS INCLUDES ANY HEAT DAMAGE TO THE TIRE DISCOLORATION TO THE WHEEL AND OR BRAKE DRUM AND ANY BURNT OR CHARRED LABELS
50. he wheel is loose the holes will pound out deform if stud piloted or elongate if hub piloted see Section 2 8 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 2 On ball seat wheels be sure the end of the socket is smooth or cover the wheel mounting surface with a protective shield prior to tightening the cap nuts The end of the socket will mar the wheel around the cap nuts if it is not smooth 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 Do not introduce any foreign objects such as spacers or top hats into the contact surface areas of the mounting system unless approved by Alcoa Do not paint Alcoa forged aluminum wheels Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 2 15 for specific cautions care and maintenance procedures High temperature nylon spacers are a protection gasket designed to be placed between the wheels and also the brake drum wheel contact surfaces see Sections 4 2 4 6 4 7 4 9 High temperature nylon spacers
51. ims can only be authorized and determined by Alcoa s Warranty Center Mounting Alcoa wheels with Tubeless Tires Recommendations for mounting WARNING Damaged tires or wheels can lead to an explosive separation of tires tubeless tires anu Explosive separation can cause serious injury or death Inspect tires and wheels for damage before removing from vehicle If damage is WARNING found the tire must be completely deflated before loosening cap nuts Immediately 3 l and permanently remove damaged tires or wheels from service hs nee if 4 mi sian i WARNING Use of inner tubes in tubeless wheels will hide slow leaks Slow leaks 3 may indicate cracked see Section 2 10 2 11 or damaged wheels which lead to Alcoa at 800 242 9898 E failures i j Option 1 Wheel failures can cause accidents which may result in serious injury or death a Never use an inner tube on an Alcoa tubeless wheel Immediately and permanently remove cracked or damaged wheels from service NOTICE Alcoa aluminum 1 Do not gouge or nick the wheel Place aluminum wheels on clean floor and use a protective mat non symmetrical wheels _ when hand mounting tires Additional care should be used when mounting Alcoa Dura Bright require special tire mounting surface treated wheels since minor nicks and scratches cannot be polished out see Section 2 15 techniques see Section 3 3 pages 16 for specific cautions care and maintenance procedures 2 Always use a
52. information may result in serious injury or death If you do not have copies of the Service Manual you may obtain copies free of charge at www alcoawheels com or by contacting Alcoa Wheel Products Australia at Phone 03 9311 5800 email awp sales alcoa com au or the address below Alcoa Wheel Products Australia 18 Law Court Sunshine West 3020 September 2012 How to use this manual This manual is written in a style called structured text Throughout the manual you will find numbers which look like this See Section 3 1 These numbers are cross references to other sections of the manual The numbers 3 1 refer to section 3 subtopic 1 You will find the section number and subtopic number under the heading in each section Table of Contents Section Number Page Number Foa E E E E E E 2 2 Tnspection and Maintenant e css ac node cas sana di aasntnavstevensednnueunsbotiatatanctiesteseseresbepiutieetanunaeriwinones 3 2 1 Inspect thoroughly and fregucntly css saswsdsnnesiesanisucconsuyatewtackauiesaneiivsenetpsonssdeneexasinditenetneaiacd deans REDER 3 VV a A E taiaraatemaghas 3 23 TM UU ecean e EE E E E E E E E E 4 2 Dimension NSN a3 corps ote rinira iaeoa AAA AAA EAEAN 2 5 Cracked or damaged Wie SCC CIS si cacsasa ects dncanisnata Ss hetigenantihed snelyannt baasensiagabayae nes neausealonatonsastheladnaatbetons 6 PC Mme COIVUL NEG aes cts eer enna eee er aceon nme nt he Sree ne S Senet errr EEA ene erate ener roreerr 7 2a
53. ins available at www alcoawheels com Welding Rim Flange or otherwise heating Alcoa Aluminum Wheels Altering Alcoa Wheels from original design and use of adaptor plates Tire Balancers Sealants Wheel balancing weights Mounting demounting tires on Alcoa 22 5 non symmetrical wide base wheels Rim Flange Wear 6 Alcoa Wheel Products Australia Limited Warranty ALCOA WHEEL PRODUCTS Limited Warranty Service Manual This limited warranty applies to Alcoa forged aluminum wheels with bead seat diameters measured in 5 inch increments Wheels and the surface or rim flange treatments applied to the Wheels Transit Wheels means Wheels used on transit vehicles such as buses and vans whose primary purpose is to transport people Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure The warranties set forth in this document apply to all Wheels sold or manufactured by Alcoa Wheel Products Australia Pty Ltd Alcoa 18 Law Court Sunshine Victoria 3020 Phone 03 9311 5800 email awp sales alcoa com au In addition to the rights and remedies to which you may be entitled and which cannot be excluded unde
54. ire manufacturers recommended pressure but under no circumstances exceed cold tire pressures as listed in Alcoa Wheels Product Spec Guide 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 enlargement and elongation which can occur if the cap nuts are not kept tight see Section 2 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 2 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 is not approved on Alcoa wheels Wheels should not be painted or otherwise coated in any way that may interfere with the mounting surfaces Any wheels that show signs of alteration should be removed from service and scrapped Wheel identification must be legible Wheels should be taken out of service if such identification does not meet federal requirements WARNING Welding brazing or otherwise heating any area of an Alcoa aluminum wheel will weaken the wheel Weakened or
55. k To determine if the Alcoa aluminum dual wheel assembly has adequate 7 P 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 manufacturers recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel in Alcoa s Wheel Product Spec Guide Both inset and outset wheels are measured from the mounting surface of the wheel to the center line of the rim Maintaining proper tire inflation and load ratings are essential to maintaining proper minimum dual spacing 1 a Dual spacing L__ l Vehicle i clearance i i Tire i clearance a Tire section width r hy j z TA a pe D2 fg fate KAS d LITT WF ee a oa A f a a p m Pe a r 7 lt P a EP A 1 a gre ee a Bi iamm A Bolt R Center circle dia hole dia T K a E E _ 7 aS OEE ei Lal E e Oe 1 a L RE Zz E L Zz 8 _ Wheel lt _ gt i Wheel outset Inset same as offset gt 7 or half dual spacing lt t Backspace t Tire center line Tire center line _f O Conversion Tables ae apes ecimal an H wea ome oa Millimeter Oo oa Equivalents Chart TE Up to 1 inch O7 1 13 EEST 1 59 s e 0 625 ama om as AJEA
56. l weights if there is inadequate rim to properly hold a clip on style weight Improperly installed weights could fly off during use and damage the vehicle or cause personal injury Always follow the recommended procedures in this manual or from the wheel weight manufacturer Adhesive weights should be applied only to a clean surface on the brake side of the wheel rim These weights should be installed only in a location where they will not contact the brake components during vehicle operation POSTIONING Both sides of the wheel have a designed area where the adhesive weights must be applied For wheels with the 2nd generation of Alcoa wheel rim flange design only the weights should always be applied against the small hump wedge i e as close as possible to the rim flange Closed Side Open Side Closed Side Open Side Outside Inside Owner in service Some fleets wish to specially identify wheels as to OWNERSHIP and IN SERVICE dates Alcoa identific ation permits the practice of permanently stamping wheels with the date they are first placed into service 1 Use Lo Stress stamps or equivalent 2 Location of stamped areas on outside disc should be in space outward from a line between hand 5 4 hole centers and a minimum of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impression st
57. l COMOSON emer nee RE ner ere enna et er eer een ee eee ree eee ere erry kere eee mere eee eres 8 De MONI TRG errata ce csc ec nina chs eeign GE sch acco EEE E 9 NR A circa a cect asset E ee tcc sown see dene oe cd aaa dean eee ane ene 9 210 RM AS oa cot cesar E EE E E E E EE EE E 10 2 11 Bead eye gle sco errors aos re E EE E EEE R TEE E cea E EE EEE REEE R 10 2 12 Rimflange Weal iciirniisriniuiiinroetekeiuri niiina ikidir ienirt ia iroi iinan eri taaduatnon eres 11 2 13 Dura Flange TREAT TN eree e E E E EE E E E EE ES 16 2 14 Maintenance against corrosion non Dura Bright Surlace treated wheels csisscsisrsniissnsiiissds 16 2 15 Dura Bright surface treated wheels cleaning and maintenance sssssesssssssesssssrssssressseessseessseessene 16 3 Mounting Alcoa Wheels with Tubeless Tires c cccccceeseeseeeceececeeeeeeceeeeceeeeeeeeeeeaaenaaas 17 3 1 Recommendations for mounting tubeless TiS desis cccsscrccsrscrascaracdsaesiiaadwarvacnsdsesaetvdawscuninedeaatasdacnadnninds 17 3 2 M u nt ne t beless TNS arse suen sa tnccrwsnwihunasunraninceamelindsd foltduucnesuasebladicdeashatuasibunbbeadateaeueiuneindiuedsatdaaiylenis 18 3 3 Mounting tires on non symmetricial drop Well wheels cccsscccesssssecceeeeseeeeeceeseneeeccesesneeeeeeeeanees 19 3 4 Rim width to tire ATA IN Sos stats caietopssaceenemoucsated ade tees caieeicaceuabatonen edad fieenanseenabecduade gasuumeamasuatgndondedoans 20 3 5 Recommendations for demounting tubeless
58. llustrations on previous page to make this determination If you do not have an Alcoa Rim Flange Wear Gauge contact Alcoa Wheel and Transportation Products to obtain a gauge s at no charge by calling 800 242 9898 or on the web at www alcoawheels com STEP 3 If the wheel is deemed to be serviceable by the rim flange gauge examine the wheel flange edge for sharpness by using a rubber sharpness gauge These gauges are constructed by having a section of tire side wall or a suitable piece of rubber attached to a block of wood photo 2 By running the sharpness indicator gauge along the wheel in the area of the wear determine if the wear is sharp enough to cut or damage the rubber on the sharpness indicator photo 3 If the rubber is cut then follow the edge removal instructions below Photo 2 A rubber sharpness gauge 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 on the following page If the rubber is not cut then the wheel can be returned to service without further work for rim flange wear CAUTION Do not run unprotected hands or fingers across worn rim flange areas of used wheels
59. loted double cap 15 16 12 750 900 nut heavy duty type 1 1 8 16 750 900 1 3 16 radius 1 5 16 12 750 900 For nuts used on hub piloted wheels apply two drops of motor 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 4 10 For nuts used on stud piloted wheels apply two drops of motor oil to the first two or three threads at the tip of each stud only see Section 4 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 results in loose wheels which can damage wheels studs and hubs and can result in wheel loss Overtightening can damage studs nuts and wheels and results in loose wheels as well 3 All torque wrenches air wrenches and any other tools should be calibrated periodically to ensure the proper torque is applied 34 Balance wei ghts Balance weights for Alcoa wheels are available from your Alcoa Wheel Distributor With radial tires it may be necessary to temporarily reduce the tire pressure when installing clip on weights to allow clearance of the weight clamp over the rim flange Use of coated balance weights is recommended to avoid staining and corrosion of the aluminum wheel surface 5 3 Excessive rim flange wear see Section 2 12 could dictate the use of stick on or adhesive whee
60. m the date of manufacture as shown on the Wheel Alcoa agrees without charge to repair or replace a Wheel that fails in normal use see the qualifications section below because of defects in material and workmanship Alcoa warrants to the original purchaser from Alcoa or its authorized distributor the Dura Flange rim flange treatment against sharp edges for 24 months from the date of manufacture as shown on the Wheel Alcoa warrants to the original purchaser from Alcoa or its authorized distributor the Dura Bright surface treatment against 1 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 the mounting hardware or wheel weights ii blistering due to loss of adhesion of the surface treatment and iii lift off of the surface treatment due to physical damage nicks scratches gouges The foregoing Dura Bright surface treatment warranty is applied for the application period of time set forth below a Except as stated in b of this section Dura Bright surface treatment on Wheels is warranted for 60 months from the date of manufacture as shown on the Wheel b Dura Bright surface treatment for RV and motorhome Wheels is warranted for 120 months from the date of manufacture as shown on the Wheel If the Dura Flange rim flange treatment or Dura Bright surface treatment
61. 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 Alcoa Aluminum Wide Base Wheel Outer Cap Nut P N 5996R or L A See 4 2 page 23 Correct wide base wheel mounting with 1 1 8 stud located ball seat mount 1 8 minimum stud standout Single Alcoa Aluminum Wheel Drum lt 7 Outer Cap Nut P N 5995R or L See 4 2 page 23 3 4 Stud Hub gt Correct single mounting with 3 4 stud located ball 1 8 es minimum seat mount stud standout 4 Alcoa Aluminum Wide Base Wheel Z Drum gt X_ Z Outer Cap Nut P N 5995R or L 3 4 Stud 4 See 4 2 page 23 Correct wide base wheel mounting with 3 4 stud located ball seat mount 1 8 minimum stud standout Dualed wheels Rear wheels are most frequently mounted as duals Each inner aluminum wheel is attached by 10 inner stud located ball cap nuts Alcoa recommends use of inner cap nuts 5978R 5978L or 5988R 5988L see 4 2 page 23 9 Cap nuts recommended by Alcoa are compatible with Alcoa wheels Hardware of equal dimensions and strength may be used seat mounting 4 6 Continued on next page 25 26 Dualed wheels stud located ball seat mounting continued NOTICE Do not exceed maximum wheel load Customer must com
62. medies available with respect to Wheels Alcoa does not warrant and will not repair or replace or make adjustment with respect to any Wheel or surface or rim flange treatment on such Wheel that has been subjected to misuse or abuse or any of the following a Using a tyre which is oversized according to standards recommended by the Tire and Rim Association of Australia b Loading the Wheel beyond the applicable maximum Wheel load as specified by Alcoa c Inflating tyres beyond the applicable maximum as specified by Alcoa d Changing the original condition of the wheel by alteration or by subjecting it to any processing such as welding or straightening e Accidents or abnormal or severe operating conditions including without limitation tyre fires brake fires severe brake system drags or seizures or running with a flat tyre f Failure to follow maintenance instructions or warnings set forth in the Alcoa Wheel Service Manual Service Manual Alcoa Technical Bulletins or other Alcoa literature Recommended maintenance includes without limitation using proper torque periodic cleaning polishing valve replacement periodic inspection for damage and loose wheel 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 h Rim flange wear unless the rim flange has been treated with Dura Flange
63. n air chuck or a self locking straight chuck with remote valve and pressure gauge inflate the tire wheel assembly to proper pressure Be sure to stay out of the trajectory of potential exploding parts or air blasts Mounting tubeless tires continued Mounting tires on non symmetrical drop well wheels 3 3 cause extremely rapid corrosion of the wheel rim surface Alcoa wheels corroded by the use of liquid tire balancers or sealants will not be replaced under the Alcoa limited warranty CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may CAUTION Severely corroded wheels are unsuitable for service Heavy duty truck tires have a guide rib or ring molded into the sidewall next to the tire bead When the tire is inflated this ring should be evenly spaced from the wheel rim all the way around the wheel Check the position of the ring before removing the assembly from the inflation cage If the ring and wheel are not concentric deflate the assembly in the cage re lube and remount the tire Alcoa wheels usually have a symmetrical drop well with a narrow ledge on both sides of the rim This feature allows mounting of the tire from either side of the wheel However some Alcoa wheels are non symmetrical and contain a narrow ledge on only one side of the wheel Reduced well wheels as well as some other wheel designs feature an increased underwell diameter and also have a non symmeterical sloping rim profile which p
64. ndout 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 Wheel Mounting Tool The Alcoa Wheel Mounting Tools are designed to align wheel bolt holes seat brake drums that have 980 diameter bolt holes and prevent thread damage to M22x1 5 studs P N 000426 23 24 How to measure stud standout Stud located ball seats are spherical 4 4 Stud Piloted Mounting System Single and wide base wheel stud located ball seat mounting 4 5 Stud standout is measured from the axle end mounting surface the hub for inboard mounted drums and the drum for outboard mounted drums to the first complete thread at the outside end of the stud Exposed shoulder 4 NY d First full thread Stud Standout 4 bp First full thread Stud Standout NN Mounting Mounting surface surface Inboard mounted drum Outboard mounted drum The nut seat for the stud located ball seat mounting system is a precision machined spherical surface Cap nuts must be properly manufactured to assure correct seating Never use one or two piece flange nuts on a wheel designed with ball seats see Section 4 11 Ball seat cap nuts may be obtained from your Alcoa Wheel Distributor Front wheels ar
65. ne before attempting to mount or demount tires Remove valve core air from tire wheel assembly prior to removal from vehicle When hand demounting tires from wheels placing aluminum wheels on a clean floor and protective mat is recommended Additional care should be used when demounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 2 15 for specific cautions care and maintenance procedures Always use a rubber leather faced or plastic mallet Keep tire tools smooth Use them with care Rim gouges or nicks may cause cracks If using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel Remove the valve core from the valve stem to ensure complete tire deflation Place wheel on machine lubricate tire and wheel bead area before demounting then position tool so flat end can be driven between tire bead and rim flange Straighten tool to a vertical position until bead is separated from wheel Insert curved end of tire tools between tire and wheel approximately 10 inches apart Pull one tool toward center of wheel then pull second tool in the same manner To free bead leave one tool in position take out and reinsert the other tool curved end between bead and flange a short distance from the spanned area Pry bead free of rim repeating process until entire bead is free from wheel Repeat procedure at inter
66. 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 at the bottom of the previous page again shows how this gauge is used Be sure to move the gauge all around the wheel s circumference and make sure that no area of the flange is below what the gauge indicates is acceptable If the entire wheel flange is within the limits of the rim flange wear gauge the wheel may be returned to service STEP 7 Always inspect the wheel for any other conditions that would warrant removal from service Consult the Alcoa Wheel Service Manual or the TMC User s Guide to Wheels and Rims WARNING WARNING WARNING 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 Explosive separations of tires and wheels or wheel failure on the vehicle could cause serious injury or death Never attempt to weld or braze any surface of an Alcoa aluminum wheel WARNING Returning wheels to service with inadequate flange height as determined by the Alcoa Rim Flange Wear Gauge can lead to an explosive separation of tires and wheels Explosive separations of tires and wheels on the vehicle could cause serious injury or death Wheels with flange height
67. njury 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 Section 4 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 hex head design and other designs have different torque requirements Contact the manufacturer for the proper torque values See section 5 2 Wheel studs on both the right and left side hubs of vehicles utilizing the hub piloted wheel system have right hand threads Prior to mounting hub piloted wheels generously coat the wheel pilot or hub pads with a non water based lubricant to minimize corrosion product build up between the wheel and hub pilot Excessive corrosion build up between the wheel and hub pilots can make wheel removal difficult Do not lubricate the face of the wheel hub or brake drum see illustration on the next page Continued on the next page 31 32 Tightening hub piloted mounting two piece flange nuts continued Lubricate the hub pads or the wheel hub bore generously with a non water based lubricant Before installing two piece flange nuts lightly lubricate the stud threads and the contact surfaces between the cap nut and the washer as illustrate
68. o corrosion or E Other structural damage which would decrease its effectiveness iv Restraining devices or barriers removed from service shall not be returned to service until they are repaired and reinspected Restraining devices or barriers requiring structural repair such as component replacement or rewelding shall not be returned to service until they are certified by either the manufacturer or a Registered Professional Engineer as meeting the strength requirements of paragraph d 3 4 of this section 4 The employer shall furnish and assure that an air line assembly consisting of the following components be used for inflating tires i A clip on chuck i An in line valve with a pressure gauge or a presettable regulator and iii A sufficient length of hose between the clip on chuck and the in line valve if one is used to allow the employee to stand outside the trajectory 5 Current charts or rim manuals containing instructions for the type of wheels being serviced shall be available in the service area 6 The employer shall furnish and assure that only tools recommended in the rim manual 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
69. orst only one in 1000 serious accidents results in a fatality But when the accident involves tires and wheels statistically one ie the job in every 10 serious accidents is a fatality That s 100 times more offen than in most 1 in 1000 other industries lin10 TYPICAL INDUSTRY TIRE SERVICE INDUSTRY Inspect thoroughly and frequently 2 1 Wheel alteration 2 2 Inspection and Maintenance 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 is not always possible to predict the useful life of a wheel Wheels will eventually wear out But generally older wheels and wheels operating in extreme conditions should be examined more frequently for obvious signs that they should be removed from service Examine all exposed areas frequently Clean wheels and look for cracks corrosion wear or other damage Also check the inner dualed wheel when the outer wheel is removed During tire changes thoroughly examine the entire wheel Pay 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 maximum wheel load rating and inflation pressure which is roll stamped onto wheel per Section 5 6 Do not overinflate Use the t
70. pare 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 1 5 16 to 1 44 1 7 16 stud standout Some vehicles use studs longer than standard up to 1 88 1 7 8 standout When changing types of brake drums be sure to check for excessive stud standout greater than 1 88 1 7 8 All states and provinces have their own standards for fastener engagement Most of these consist of at least 1 to 2 threads past full thread engagement Excessive stud standout may cause the inner cap nut to bottom out on the longer stud preventing proper seating of the wheel Each outer dual wheel is attached by 10 single cap nuts which thread on the inner cap nuts Use Alcoa outer cap nuts P Ns 5996R 5996L or equivalents Match mounted dual wheels
71. quire wheel studs and cap nuts with metric threads Most frequently these Mounting System are M22x1 5 Generally the same diameter stud is used to mount either single or dualed wheels Single dualed Studs on both sides of the vehicle are right hand threads thereby eliminating the need for flange nuts and wide base peculiar to either the right or left side of the vehicle The same flange nut is used to mount dualed or single wheels wheels hub Most states have laws which dictate full thread engagement or thread engagement past the nut body piloted Make sure you know the laws for the states in which you operate and comply mounting Note Some stud located ball seat wheels have the same number of holes and bolt circle diameter two piece as hub piloted wheels They should not be mixed flange nuts Drum 4 9 a 33mm hex head E 2 piece flange nut P N 39874 M22x1 gt NOTICE Do not exceed ee maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s f 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 33mm hex head replacing broken studs always 2 piece flange nut replace the studs on each side P N 39874 of the broken stud If two or M22x1 5 more studs are broken repla
72. r the Australian Consumer Law or any other relevant legislation Alcoa warrants to the original purchaser from Alcoa or its authorised distributor that a new Alcoa truck trailer bus RV or motorhome Wheel is free from defects in material and workmanship for the applicable time period set forth below a Except as stated in b of this section Wheels are warranted for 60 months from the date of manufacture as shown on the Wheel b Transit Wheels and RV and motorhome Wheels are warranted for 120 months from the date of manufacture as shown on the Wheel Alcoa agrees without charge to repair or replace a Wheel that fails in normal use or service see the qualifications section below because of defects in material and workmanship If you believe that a Wheel is defective at any time during the described warranty period return the Wheel along with the original receipt and a brief description of the defect to Alcoa Wheel Products Australia Pty Ltd 18 Law Court Sunshine Victoria 3020 If Alcoa determines that the Wheel is defective Alcoa at its option shall repair or replace the defective Wheel Alcoa will also refund your reasonable costs of returning the defective Wheel to Alcoa if you forward to the address set out above a copy of the receipt for the reasonable costs that you have incurred in returning the Wheel to Alcoa Alcoa warrants to the original purchaser from Alcoa or its authorised distributor the Dura Flange rim flange trea
73. rline is mounted outboard of the hub face This dimension is the same as the 1 2 DUAL SPACING dimension PILOT PAD See HUB PILOTS PSI Abbreviation for pounds per square inch REVERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tire centerline RIM That portion of the wheel which supports the tire RIM CENTERLINE A line to the radial axis of the wheel running through the mid point between the rim flanges RIM FLANGE The edge of a rim that has a larger diameter than the tire bead designed to support the tire SIDE RING One removable component of a multi piece rim 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 that is used with wheel nuts to fasten wheels or rims to a vehicle STUD PILOTED MOUNTING A wheel mounting system in which location and fastening of the wheel are both accomplished by nuts which fit corresponding studs at each wheel bolt hole TIRE BEAD That surface of the tire which contacts the angled surface of the wheel rim TORQUE The measure of tightness WHEEL MOUNTING FACE See DISC FACE wt Abbreviation for weight 43 44 Wheel measurement How to measure minimum dual spacing Minimum dual spacing measurement is determined by the tire manufacturer and may be obtained from the tire manufacturers handboo
74. rovides additional brake clearance In order to minimize the possibility of tire bead damage all mounting and dismounting of the tire should be performed only from the narrow ledge side of the wheel in accordance with OSHA regulation Tires should be mounted demounted only across the disc side of the wheel r e Mount from this side Do not mount from this side Mount from this side Do not mount from this side he a if 19 Rim width to tire matching Rim to Tire Matching Chart for Medium and Heavy Trucks Tire Size Tire Size for both radial Approved for both radial Approved and bias tires Rim Widths and bias tires Rim Widths 3 4 8R17 5 9R17 5 10R17 5 11R17 5 8R19 5 225 70R19 5 245 70R19 5 265 70R19 5 445 65R19 5 5 25 6 00 6 00 6 75 6 75 7 50 7 50 8 25 25 0 00 6 75 6 00 6 75 6 75 7 50 150 825 13 00 14 00 8R22 5 9R22 5 235 80R22 5 245 75R22 5 10R22 5 255 70R22 5 255 80R22 5 275 80R22 5 11R22 5 265 75R22 5 12R22 5 295 60R22 5 295 75R22 5 305 75R22 5 305 85R22 5 315 80R22 5 335 65R22 5 15R22 5 385 65R22 5 425 65R22 5 16 5R22 5 18R22 5 445 S50R22 5 445 55R22 5 445 65R22 5 11R24 5 275 80R24 5 285 75R24 5 12R24 5 5 25 6 00 6 75 6 00 6 75 7 50 6 75 7 50 6 75 7 50 073 30 6 23 7 50 8 25 1T 30 6 23 7 50 8 25 1 30 8 25 T30 8 2 8 25 9 00 8 25 9 00 8 25 9 00 8 25 9 00 8 25 9 00 9 00 9 75 9 00 9
75. rubber leather faced or plastic mallet Inspect the wheel for damage Do not use a damaged or severely corroded wheel see Section 2 Clean the wheel disc face and the tire bead seat areas Be sure the wheel is dry before applying tire lubricant 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 2 2 7 Lubricate the rim and tire bead immediately before mounting the tire Do not use any lubricant which contains water Water based lubricants can promote corrosion attack on the rim surface The use of non water based lubricants is especially important when mounting tubeless tires as the air in the tire is contained by the seal between the bead and tire rim 8 Never lubricate the rim or tire bead with a flammable solution This can lead to an explosion during airing of the tire or in subsequent operation of the vehicle see Warning on next page 9 If using a tire mounting demounting machine on aluminum wheels care should be taken to prevent gouging the wheel 10 Use only dry air for tire inflation The use of moisture traps in the air compressor feed line is recommended 11 Do not overinflate Use the tire manufacturer s recommended pressure but under no circumstances exceed cold tire pressures roll stamped on the wheel 12 When inflatin
76. s 2 piece 26 25 mm height 33mm hex head flange nut Mounts single and dualed wheels to wheel centering hubs Right hand threads used on both sides of vehicle P N 39874 supersedes P Ns 39701 and 39691 M22 1 5 RH threads 2 piece 78 5 mm height 33mm hex head flange nut Mounts dualed wheels with 32mm bolt holes to wheel centering hubs Right hand threads used on both sides of vehicle P N 430732 M22x1 5 RH threads Available in Dacromet corrosion resistant coating P N 578732 1 1 8 X 16 cap nut Mounts standard single wheels and wide base wheels to 1 1 8 studs Also mounts outer dualed wheel to 1 1 8 inner cap nut P N 5996R 5996L replaces P N 5552R 5552L 3 4 X 16 cap nut Mounts standard single wheels and wide base wheels to 3 4 studs Do not use on steel wheels P N 5995R 5995L replaces P N 5554R 5554L 2 piece 50mm height 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 430632 M22x1 5 RH threads Available in Dacromet corrosion resistant coating P N 578632 Inner cap nut inner thread 3 4 X 16 outer thread 1 1 8 X 16 For use with steel inner dual wheel and aluminum outer dual wheel with 1 31 1 5 16 to 1 44 1 7 16 stud standout P N 7896R 7896L Grade 8 Inner cap nut for use with standard length studs 1 31 1 5 16 to 1 44 1 7 16 stud sta
77. s It does not apply to the servicing of rim wheels used on automobiles or on pickup trucks and vans utilizing automobile tires or truck tires designated LT 2 This section does not apply to employers and places of employment regulated under the Longshoring Standards 29 CFR part 1918 Construction Safety Standards 29 CFR part 1926 or Agriculture Standards 29 CFR part 1928 3 All provisions of this section apply to the servicing of both single piece rim wheels and multi piece rim wheels unless designated otherwise b Definitions Barrier means a fence wall or other structure or object placed between a single piece rim wheel and an employee during tire inflation to contain the rim wheel components in the event of the sudden release of the contained air of the single piece rim wheel Charts means the U S Department of Labor Occupational Safety and Health Administration publications entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi Piece Rim Wheel Matching Chart the National Highway Traffic Safety Administration NHTSA publications entitled Demounting and Mounting Procedures for Truck Bus Tires and Multi Piece Rim Wheel Matching Chart or any other poster which contains at least the same instructions safety precautions and other information contained in the charts that is applicable to the types of wheels being serviced Installing a rim wheel means the transfer and attachment o
78. that falls below the Alcoa gauge have inadequate rim flange height to support the tire on the rim Immediately and permanently remove any wheel from service that has inadequate rim flange height WARNING Excessive heat from fire brake malfunction wheel bearing failure tire failure or other sources may weaken the metal and cause the wheel tire assembly to separate explosively Exploding wheel tire assembly can cause serious injury or death 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 15 Dur a Flange Dura Flange has a 24 month warranty against wear which creates a sharp edge that would maintenance require maintenance per section 2 12 Minor wear or minor pitting is not a warrantable condition Edge re conditioning cannot be performed on Dura Flange wheels including those methods 2 1 3 as described in Section 2 12 Maintenance The following information is for standard Alcoa forged aluminum wheels without the Dura Bright against corrosion surface treatment See Section 2 15 for specific instructions on the care and cleaning of Alcoa Dura Bright surface treated wheels non Dura Bright surface treated wheels Clean frequently with high pressure water from a hose The use of a mild
79. the chart on the following page Ea N Py ma ES ce th Go Inspect the hub drum contact area thoroughly or cracks or other damage Mounting area continued Corrosion 2 1 Support Surface Diameters Support surface should be flat to the diameter recommended per SAE J694 Number of Backup BOE Connell Mounting Type icc Thread Size I 125inch inch U U S Stud pilot Stud US Stud pilot 13 2 13 13 2135 in 13 2135 in 750 1 125 in 1 1251 750 1 125 in e ee T mem T see T mm p e e a ars Sobi 2426n 20mm Certain environments can lead to corrosion Some of the more common corrosive materials are salt magnesium chloride and calcium chloride compounds used for snow removal and highly alkaline materials If the air used to fill tubeless tires or the tire itself is not dry the areas of the wheel under the tire can corrode severely Bead seat and valve stem corrosion often are caused by entrapped moisture Mild corrosion as shown in pictures to left should be removed thoroughly by wire brush and the rim protected with non water based tire lubricant see Section 3 1 Remove any severely corroded 0 125 inches deep wheel from service Hub bore gauge does not fit Hub bore gauge with severe corrosion Remove any severely corroded wheel from service CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface
80. tment against sharp edges for 24 months from the date of manufacture as shown on the Wheel Alcoa warrants to the original purchaser from Alcoa or its authorised distributor the Dura Bright surface treatment against i filiform corrosion worm or hair like lines generally milky in appearance underneath surface protective treatment and emanating from damage to the surface treatment such as nicks scratches or damage from mounting hardware or wheel weights ii blistering due to loss of adhesion of the surface treatment and iii lift off of the surface treatment due to physical damage nicks scratches gouges The foregoing Dura Bright surface treatment warranty is for the applicable period of time set forth below a Except as stated in b of this section Dura Bright surface treatment on Wheels is warranted for a period of 60 months from the date of manufacture as shown on the Wheel b Dura Bright surface treatment for RV and motorhome Wheels is warranted for 120 months from the date of manufacture as shown on the Wheel If the Dura Flange rim flange treatment or Dura Bright surface treatment fail in normal use or service see the qualifications section below to meet the foregoing warranties on any Wheel Alcoa agrees without charge to replace the Wheel September 2012 Alcoa Wheel Products Australia Limited Warranty D Qualifications Except as stated above this document describes all of the warranties given and re
81. tools produce excessive noise when used f CAUTION Removing sharp edges with hand or power tools produces metal 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 eye wear gloves protective clothing and hearing protection when using hand or power tools Photo 8 Severe rim flange wear Photo 9 Sharp edge removed STEP 4 These photographs show the results 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 which you choose the objective is to remove only the sharp edge photo 9 Remove just enough metal to smooth the edge Take care to make sure the edge removal is as uniform as possible Avoid gouging the wheel 14 Rim flange wear continued STEP 5 After the edge is removed run the sharpness indicator gauge along the area of edge removal to check for any remaining sharpness If the rubber is still cut perform the steps again to remove the sharp edge Always remove the minimum amount of material
82. uipped to accept wheels manufactured for use with the stud located ball seat mounting system wheel studs on the right side of the vehicle have right hand threads and those on the left have left hand threads The R and L on the studs and nuts indicate right and left hand threads respectively see Section 4 2 and previous page 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 2 Six Stud 1 10 8 Gap 30 os 50 Oa 7 0 2 Fight Stud Ten Stud Continued on the next page 29 Tightening stud After 5 50 miles of operation torque should be rechecked unless your documented fleet practices determine lo cate d b all seat otherwise Loosen outer cap nuts on every other stud to check the torque on inner cap nuts then retorque 9 outer cap nuts Repeat steps on remaining studs Check torque frequently from then on If nuts require cap nuts frequent tightening studs break frequently or wheel nut seats are pounding out hardware and mounting practices should be reviewed Note whenever the outer cap nut is loosened ALWAYS retorque the inner cap continued nut before retorquing the outer cap nut Hub Piloted Most U S manufacturers of highway trucks tractors and trailers which incorporate the hub piloted wheel mounting system re
83. vals until bead is totally separated from wheel Repeat procedure on other side of tire Tire is now ready for demounting Lubricate the tire bead Insert straight end of tire tool between beads and both rim flanges hooking stop on the tool over second flange Position inserted tool at 90 angle to tire assembly at top of wheel and lubricate bead areas on both sides of tool Lean tire assembly toward tool and rock or bounce to pry off the tire 21 22 4 Wheel Installation Recommendations for proper installation of wheels 4 1 NOTICE Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to insure proper clearance from any obstructions NOTICE Check for and replace bent broken cracked or damaged studs When replacing broken studs always replace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs WARNING Make sure all wheel cap nuts are properly torqued check them often see Section 4 8 If t

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