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Alcoa Wheel Service Manual

1. 7 AN ER u ma ya N WHEELS Alcoa Wheel Service Manual Europe January 2010 Supersedes all previous manuals Technical Data Valve Application Chart Balancing Manual ALgrease brochure Rim Flange Wear Instructions Contents DUA VGA ee ee ee ee ee ne 4 2 Limited WANNE A Be SU EN cine E E est ott escent ested is trou E A E a eat aay NEE DT BEIN E A IE ENUERKEIIE BEINE 6 4 AN NEE SVC HOT ee Eee aan wee RM eRe amacaNaaee 7 Bc Alc a Wheel Specification SNEEU een nee een ee 7 C Genaral haraoc on II See ee en euere ee 7 D DISC Oa cguipped CS ee ee nee 7 d Alcoa wheel identification nennen men een en EEE 8 amp Table matching BIETE 9 Wheel measurement sera RE na E EE E 10 g Mixed application of Alcoa and steel wheels unse ee 11 h Owner in service identification sssssssssseseesesssssssssseeeesessssssssssteeesosnsssssseetereoosssssseeeereresssssssseettersssssssssstrrrososssssssserrrrossssssseeeerreesssss 12 5 Puting wheels N S erv een een 13 a Putting wheels in service hidden damage ss ssssssssssesessssseceessssssseeesssssseeeessssssseeesssssseeeeosssssseresssssseereossssseeeessssssereeosssseeeresssssss 13 b Putting wheels in service wheel alteration ssssssssessssssseeeessssssseeesssssseeeesnsnssseeeesnsssecerossssseeresssssseeeeosssssseeeensssseeerossssssseeessssseeees 14 c Mounting area support surface diameterS eccessssssssessesscsscssessessessessesseessssessussscssesscssc
2. For proper nut torque refer to the chart below Hub piloted using two piece flange nuts Nut Thread Torque Level Nm Metric M18 x 1 5 340 400 Metric M20x 1 5 380 450 Metric 1 M22x1 5 610 675 Scania 7 8 11 BSF 540 660 Volvo 2 7 8 14 UNF 640 700 47 48 For proper installation of two piece flange nuts two drops of motor oil should be applied to the point between the nut and flange and two drops to the first two or three threads at the tip of each stud see Section 5 n ii 1 Including Volvo from 2005 2 Volvo up to 2004 5 n iv Dualing with steel wheels When dualing steel wheels with Alcoa aluminium wheels follow the steel wheel manufacturer s recommendations regarding the proper torque and use of thread lubricants to mount the wheel See Section 4 g NOTICE I If using specialty fasteners cap nuts consult the manufacturer for recommended torque values Tightening wheel nuts to their specified torque is extremely important Under tightening which results in loose wheels can damage wheels studs and hubs and can result in wheel loss Over tightening can damage studs nuts and wheels and results in loose wheels as well All torque wrenches air wrenches and any other tools should be calibrated periodically to ensure the proper torque is applied When mounting painted steel inner dual wheels with outer aluminium wheels be cautious of excessive paint build up on the inner steel wheel
3. ACCEPTABLE Photo above shows carpenter square even on both bead seats Pose E 4 0 5 5 so f 19 ln UNACCEPTABLE Photo above shows an undersized wheel where you can clearly place a credit card approximately 0 030 in or 0 76 mm between the square and the wheel THIS INSPECTION TECHNIQUE ONLY APPLIES TO DUAL OR DISC FACED WHEELS Check all wheels at each tyre 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 on page 54 Repeat this process at four equidis tant 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 0 76 mm or 0 030 in feeler gauge appears between the short leg and the rim flange the wheel should be perma nently removed from service and scrapped Dimension checks 3rd best inspection method rolling wheel as described below If a ball tape or carpenter square is unavailable roll the wheel without a tyre a minimum of 10 feet or 3 meters 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
4. Excessive paint can reduce the clamping force and allow the wheels to become loose which can lead to serious injury or death 5 n v Incorrect assemblies The following are examples of incorrect wheel assemblies u _ EB Nfl ER 1 hub piloted Alcoa aluminium wheel 1 Stud located ball seat aluminum wheel 2 ball seat cap nut 2 two piece flange nut 3 insufficient contact area 3 little if any contact area e Do not use sleeved cap nuts on wheels designed for use with extended studs Do not use two piece flange nuts on wheels designed for use with sleeved cap nuts e Do not use Volvo OE sleeved cap nuts on any other Usi h heci f Eurheel sing the wrong wheel nuts can cause loss o wpe or nn l torque broken studs and cracked wheels condi e Do not use two piece flange nuts with stud located ball l re tions which can lead to serious injury or death conical seat wheels Ee not use ball seat or conical seat cap nuts with hub Use only hardware designed specifically for each piloted wheels wheel type See Section 5 m and 5 n for proper hardware assemblies 49 6 Wheels in service 50 6 a Avoid abuse Abuse can shorten the life of a wheel Lack of care in changing a tyre heavy pounding of the wheel rim over loading exposure to excessive heat or hitting curbs at high speed or a sharp angle can damage wheels 6 b Inspect thoroughly and frequently Sa
5. Do not use flexible extension tubes without a proper clamping installation attached to the outer wheel Loose extension tubes may cause damage to the wheel and valve with air loss as a result REPLACING VALVES The best occasion to check the valve is when tyres are replaced It is recommended to fit a new valve every time when a new tyre is mounted Before mounting the new valve check if the valve cor responds with the wheel Use the preceding tables for reference Always use silicone or EPDM O rings T shape grommets not rubber when replacing the sealants Clean the valve seat and valve hole thoroughly after removal of the valve Remove all dirt grease and oxidation Make sure all contact areas are dry Avoid using sharp tools and or excessive force that could cause scratches or dents in the surface Uneven or damaged surfaces can lead to leakage Fine sandpaper steel wool or a soft wire brush will help you to clean the area without harming the surface For valves with O rings only Apply a layer of ALgrease in the valve hole and the outer and inner side wheel surface up to 1 inch or 2 centime ters in diameter around the valve hole Before installing the valve apply some Algrease on the shaft and base where the O ring is located Do not use any other lubri cants that are water based or contain metals Upon installing hold the valve in its position an check the alignment to be able to host a valve extension for du
6. Some trailer axle manufacturers offer axles with combined or extra long stud lengths suitable for both thinner steel wheels and thicker aluminium wheels In some cases Alcoa wheels can be mounted without replacing studs or purchase of sleeved nuts To determine correct amp safe fitting follow the procedure as described in this section 5 m iii Section B mounting Alcoa wheels with standard studs amp Alcoa sleeved nuts The standard wheel stud length can accommodate Alcoa wheels with more disc thickness when a special sleeved nut is used The shank or sleeve of these nuts extends into the mounting holes and compensates the standard stud length securing sufficient thread engagement Only use the Alcoa wheels with an appropriate mounting hole diameter to allow the sleeve of the nut to easily pass through it Sleeved nuts are available for 32 0 mm mounting hole diameter for mounting with sleeved nut e M22 x 1 5 Metric Volvo 2005 gt 7 8 11 BSF Scania 7 8 14 UNF Volvo gt 2004 30 0 mm mounting hole diameter for mounting with sleeved nut e M20x 1 5 Metric 26 5 mm mounting hole diameter for mounting with sleeved nut e M18x 1 5 Metric For reference see Alcoa Wheel Specification Sheet for bolthole diameters If in doubt consult your Alcoa dealer distributor or Alcoa Wheel Products Belgium To ensure correct mounting with sleeved nuts there must be enough thread engagement The recommend
7. REVERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tyre centerline RIM CENTERLINE A line to the radial axis of the wheel running through the midpoint between the rim flanges 8 b Conversion Factors Inches to Millimeters Inches x 25 4 Millimeters Millimeters to Inches Millimeters x 0 03937 Inches PSI to kPa PSI x 6 8948 kPa kPa to PSI kPa x 0 145 PSI RIM FLANGE That portion of the rim which extends above the rim surface which retains the tyre bead RIM That portion of the wheel which supports the tyre SHORT CAP NUT A retrofit cap nut with a short extension sleeve used to secure single wheels See also LONG CAP NUT STUD A threaded bolt extending from the hub surface to which the wheels are secured by the cap nuts STUD LOCATED BALL SEAT MOUNTING A wheel mounting system which uses the studs and spherical ball seat cap nuts to center and secure the wheel not appli cable for EU type Alcoa wheels TYRE BEAD That surface of the tyre which contacts the angled surface of the wheel rim TORQUE The amount of force used to tighten cap nuts Usually stated in Foot pounds or Newton meters and measured with a torque wrench WHEEL MOUNTING FACE Mounting area support surface diameter that portion of the wheel face which contacts the hub or brake drum Pounds to Kilograms Pounds x 0 4536 kg Kilograms to Pounds kg x 2 2046 Pou
8. diameter inches or millimeters EU BOLT HOLE Hole found in the disc of the wheel through which the bolt stud passes BORE See HUB BORE CENTER BORE See HUB BORE CLOSED SIDE the disc face side of the wheel DC Abbreviation for drop center DISC AREA The vertical wheel face which supports the rim DISCMATE wheel gasket A nylon 6 6 gasket that goes between the hub or brake drum and wheel and or between two wheels to protect against corrosion DISC WHEEL A one piece forged or two piece welded assembly of a disc and a rim DROP CENTER The well or center portion of the wheel rim that enables the fitment of tubeless tyres 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 FOOT POUNDS NEWTON METERS The measure of the amount of torque applied to a cap nut or other part May be measured with a torque wrench Ft Ibs abbreviation for Foot pounds torque measure ment HUB BORE The center hole of a disc wheel dimensions stated in inches or millimeters EU HUB PILOTED MOUNTING A wheel mounting system which uses the hub to center the wheel and two piece flange nuts to secure it in Abbreviation for inches INNER CAP NUT Cap nut used to mount the inner wheel in a dualed stud located wheel system not applicable for EU type Alcoa wheels INSET The distance from the wheel mounti
9. right and left hand threads respectively GAX578032 M22 x 1 5 Metric Volvo 2005 gt Short Single GAX57803201 M22 x 1 5 Metric LH thread Short Single GAX578132 M22 x 1 5 Metric Volvo 2005 gt Long Dual GAX57813201 M22 x 1 5 Metric LH thread Long Dual GAX614230 M20 x 1 5 Metric Short Single GAX614330 M20 x 1 5 Metric Long Dual GAX542026 M18 x 1 5 Metric Short Single GAX542126 M18 x 1 5 Metric Long Dual GAX578432 7 8 11 BSF Scania Short Single GAX578532 7 8 11 BSF Scania Long Dual GAX578232 7 8 14 UNF Volvo gt 2004 Short Single GAX578332 7 8 14 UNF Volvo gt 2004 Long Dual The extension 01 on cap nut part numbers indicate left hand thread versions NOTICE e Though sleeved nuts are designed to compensate stud length sufficiently a minimal stud standout i e thread engage ment is required see section 5 m iii and 5 m iv 45 46 5 n ii Tightening nuts Two piece flange nuts M22 x1 5 M20 x 1 5 M 18 x 1 5 or 7 8 11 BSF or 7 8 14 UNF may be subject to different torque requirements Inquire at the manufacturer of the vehicle or axle for proper torque values or refer to the owner s manual of the vehicle 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 8 80 kilometer of operat
10. Alcoa Wheel Products Europe at 32 11 45 84 60 Limited warranty For medium amp heavy duty truck trailer and bus wheels Alcoa warrants to the original purchaser from Alcoa or its authorized distributor that a new Alcoa aluminium medium amp heavy duty truck trailer and bus wheel is free from defects in material and workmanship Alcoa agrees without charge to repair or replace a wheel that fails in normal use and service because of defects in material and workmanship Truck trailer bus wheels and the Dura Bright surface treatment are warranted for 60 months from the date of manufacture as shown on the wheel except the Dura Flange rim flange treatment which is warranted for a period of 24 months against wear which creates a sharp edge that would require mainte nance Alcoa does not warrant and will not repair or replace or make adjustment with respect to any wheel that has been subjected to misuse or abuse including the following a using a tyre that is oversized according to standards recommended by the Tire and Rim Association Inc or other recognized tyre and rim agencies such as ETRTO Europe or others b loading the wheel beyond the applicable maximum wheel load as specified by Alcoa c inflating beyond the applicable maximum as specified on the Alcoa wheels d changing the original condition of the wheel by alter ation or by subjecting it to any processing such as welding or straightening e acci
11. Excessive heat from fire brake malfunction wheel bearing failure tyre failure or other sources may weaken the metal and cause the wheel tyre assembly to separate explosively Exploding wheel tyre assembly can cause serious injury or death Immediately and permanently remove from service any wheel that has been exposed to excessive heat Welding or brazing the rim flange or any area of an Alcoa aluminium wheel will weaken the wheel Weakened or damaged wheels can lead to an explosive separation of tyres and wheels or wheel failure on the vehicle Explosive separations of tyres 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 aluminium wheel Returning wheels to service with inadequate flange height as determined by the Alcoa Rim Flange Wear Gauge can lead to an explosive separation of tyres and wheels Explosive separation can cause serious injury or death Wheels with flange height that falls below the Alcoa gauge have inadequate rim flange height to support the tyre on the rim Immediately and permanently remove any wheel from service that has inadequate rim flange height NOTICE Excessive rim flange wear see Section 6 f could dictate the use of stick on or adhesive wheel weights if there is inadequate rim to properly hold a clip on style weight 61 6 f iv Dura Flange If you are experiencing excessive rim fla
12. OF THESE INSPECTION METHODS AS DESCRIBED IN THIS SECTION CONTACT ALCOA AT 32 0 11 458 460 FOR CLARIFICA TION duable wheel single wheel 55 56 6 e Tyre wear or ride problems If you experience tyre wear or ride problems it may be helpful to check radial run out Remove the wheel from the vehicle deflate and remove the tyre see Section 5 g v for recommendations and instructions for demounting tubeless tyres Remount the wheel on the vehicle without the tyre Be sure to follow proper mounting procedures to assure the wheel is well centered on the hub Place a dial indicator as illustrated in this picture to trace the bead seats of the wheel Rotate the wheel noting the amount of variation shown on the dial indicator Alcoa aluminium wheels should be tested for radial run out only at the bead seat surface A total indicator reading of 1 0 mm or 0 04 inch or less is acceptable Tyre wear can also be caused by improperly seated tyres Inspect the tyre for proper seating on the wheel The tyre beads may not be seated properly If so remove the wheel from the vehicle deflate and break the bead seats see Section 5 g v for recommendations and instructions for demounting tubeless tyres Adequately lubricate the bead seats and properly reseat the tyre beads Re inflate the wheel in a safety cage or other suitable restraint 6 f Rim Flange Wear It is recommended to read this and following sections before putting
13. WorkHorse wheel offset 135 81352X GAX40MSOON 81353X GAX40MSOON 81354X GAX40MSOON 81355X GAX40MS00N 81356X GAX40MS00N Use extension GAX85 for wheels manufactured gt 06 2000 81455X GAX40MSOON Use extension GAX85 for wheels manufactured gt 06 2000 8145XX GAX40MSOON 8155XX GAX40MSOON 8165XX GAX40MSOON 81751X GAX40MSOON 81752X GAX40MSOON 817570 GAX40MSOON WorkHorse wheel offset 120 817580 GAX40MSOON WorkHorse wheel offset 120 x 13 00 83352X GAX40MS00N 83353X GAX40MS00N x 14 00 84151X GAX40MSOON x 15 00 85052X GAX40MSOON 172 007 8405XX GAX70MS07N2 22 5x17 00 offset 67 mm 8425XX GAX40MSOON 22 5x17 00 offset 50 mm VALVES PART NR GAX40MSOON straight Replaces BTR542 BTR552 GAX54MSOON straight GAX70MSO7N2 7 Replaces B7OMS 07N GAX70MS27N 27 Replaces B7OMS 27N B60MS 27N BV3 20 5 GAX70MSA4S5N 45 Replaces B7OMS 45N BTR543C GAX70MS60N 60 Replaces B70MS 60N BTR543D GAX83MS OON straight Replaces BTR544SP Extension valve for DUAL mounting WHEEL PART NR 7434XX 81151X 81152X 81251X 81252X 81354X 81355X 81356X 8145XX 8155XX 8165XX 8175XX 83353X 84151X 22 5 x 14 00 8425XX 22 5 x 17 00 offset 50 mm Use extension valve GAX85 for 81356X amp 81455X gt 06 2000 77345X 01 2008 gt 77346X 01 2008 gt 77347X 01 2008 gt 78345X 01 2008 gt 78346X 01 2008 gt 78347X 01 2008 gt 8405XX 22 5 x 17 00 offset 67 mm 87451
14. can cause reduced and inconsistent wheel clamping This condition can cause wheels to loosen and disengage from the vehicle causing serious injury or death Never use cap nuts with chrome plated contact surfaces Use only recommended hardware on Alcoa aluminium wheels 5 n i Two piece hex head nuts Design and specifications of nuts used for Alcoa wheels comply with DIN standard 74361 European Alcoa wheels are used with two piece hex head nuts that have following threading M22 x 1 5 M20 x 1 5 M18 x 1 5 7 8 11 BSF 7 8 14 UNF NOTICE One piece nuts are not approved for use on any Alcoa wheel application Only two piece nuts or two piece sleeved nuts with an integral freely turning washer designed for hub centering mounting systems must be used for fastening European Alcoa wheels for heavy duty vehicles Regular nuts that come with truck or trailer axles with steel wheels can also be used with Alcoa wheels with corresponding bolt hole diameters given the thread engagement is sufficient see section 5 l and 5 m Following 2 piece hex head sleeved nut types are available from Alcoa M22 x 1 5 Metric Volvo 2005 gt M20 x 1 5 M18 x 1 5 7 8 11 BSF Scania 7 8 14 UNF Volvo gt 2004 Some vehicles come equipped with right hand and left hand threads These vehicles have on the right side right hand threads and on the left have left hand threads The R and L on the studs and nuts indicate
15. conical or spherical nuts never use any kind of this type of hardware on European type Alcoa heavy duty wheels Hubs designed for steel hub piloted wheels may not have enough pilot tab length to locate dualled aluminium wheels Pay close attention to pilot tab length particularly when converting from steel to aluminium duals Make certain the outer wheel is engaged and centered by the hub pilot pads Before purchasing Alcoa wheels always consult your truck trailer or axle OEM the pilot tab length for sufficient centering must be 5 mm or more for single mounting and 1x disc thickness 5mm for dual mounting In both cases dimensions are excluding bevelled edges Longer spigots make mounting easier 5 1 Disc thickness amp thread engagement The mounting flange of Alcoa wheels is thicker 19 0 to 28 5 mm than the mounting flange of steel wheels 10 to 13 mm and therefore requires different mounting hardware Insufficient engagement of threading between stud and nut may cause cracking or breaking of the stud For correct mounting of Alcoa wheels use e Longer replacement studs with standard nuts as described in Section A hereafter or e Sleeved nuts available from Alcoa with standard length studs as described in Section B hereafter Insufficient engagement of threading between stud and nut could cause loss of the wheel For FEIELENLE see the latest Alcoa wines Specification Failure to follow proper wheel installatio
16. discs If one of these components show signs of overheating the entire assembly including the wheel should be replaced Heat Indicator Wheels manufactured as from February 2009 will have a 1 in or 2 5 cm clear round heat indicator sticker 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 sticker located on the tyre side drop well as shown in the photo above If either of these round labels show signs of blistering charred blackened or cracked look this may indicate that the wheel has been exposed to excessive heat IF ANY OF THE CONDITIONS AS DESCRIBED ON PAGE 52 ARE SEEN REMOVE THE WHEEL FROM SERVICE IMMEDIATELY THIS INCLUDES ANY HEAT DAMAGE TO THE TYRE DISCOLORATION TO THE WHEEL AND OR BRAKE PARTS AS WELL AS ANY BURNT OR CHARRED LABELS 6 d Dimension checks Open side circumference check Wheels that have been subjected to high pressure tyre and rim separation or excessive heat damage may no longer have sufficient dimension and contour to retain the tyre bead while under pressure Exploding wheel tyre assembly can cause serious injury or death Immediately and permanently remove from service any wheel that has been exposed to high pressure tyre and rim separation or excessive heat Wheels that have been run flat or have other physical damage may no longer have sufficient dimension and contour to retain the tyre bead w
17. is used extreme care must be exercised to properly fix both wheels to the hub The selection of correct hardware i e nuts sleeved cap nuts amp studs are crucial to obtain a safe fixation as well as enough pilot tab length on the hub to properly center the outer aluminium wheel HUB ENGAGEMENT 1 Stud standout and thread engagement hardware For use with 2 piece flange nuts and replacing studs the minimal stud standout must be e 1x disc thickness steel wheel 1x disc thickness Alcoa wheel height of nut 3 mm for use with M22 M20 or M 18 x 1 5 threads or 2 full threads in case of other type of threading such as BSF or UNF e Example the disc thickness of 1x steel wheel and 1x Alcoa wheel added with a regular 2 piece flange nut M22 x 1 5 result in a stud standout of 12 22 27 3 64mm Wheels Both wheels steel and Alcoa must match wheel size and offset wheel load index as well as being fitted with matching tyres and tread of the same depth A mixed dual fitment is subject to all recommendations and guide lines that apply for safe and proper fitment of a steel dual and aluminium dual fitment referring to manuals of steel wheel OEM and the Alcoa Wheel Service Manual Note When mounting painted steel inner dual wheels with outer Alcoa 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 For use with
18. must be completely removed from the cap nut s washer i e nut to wheel contact surface if applied accidentally Do not allow oil to contact mounting surfaces of the wheel hub or drum Do not use aerosol cans for lubrication of stud threads See section 5 i Lubrication ALgrease 5 n iii Keep wheel nuts tight Wheel cap nuts must be kept tight Check all cap nuts for proper torque after the first use or any removal Inspect wheels and check wheel nuts during service stops Dirt streaks from cap nuts may indicate looseness Flange nuts must be kept tight and studs and nuts should be checked frequently At tyre changes nuts and studs should be inspected to be sure they are in good condition If nuts require frequent tightening or studs break fre quently hardware and mounting practices should be reviewed UNDER amp OVER TORQUE Undertorqued nuts allow wheels to run loose pounding out deforming the bolt holes fatiguing studs or losing nuts as well as cause cracks in the bolt hole area Over torquing can stretch studs causing them to fail with loss to torque and may cause pre mature fatigue Both under and over torquing can lead to wheel dis engagement causing serious injury or death Check all parts including wheels studs and 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
19. 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 rec ommendations when replacing studs NOTICES e Perform a wheel fitment check to insure proper clearance from any obstructions e Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating e Refer to tyre manufacturer s recommendation for proper tyre pressure Before mounting the tyre Wheels that are not properly installed or main tained may not be safe or work properly Failure to follow proper wheel installation or maintenance practices may result in injury or death Follow the proper wheel installation and mainte nance practices as described in this section Make sure all wheel nuts are properly torqued check them often see Section 5 n ii If the wheel is loose the holes will pound out deform If some cap nuts are tight and others are loose the wheel may develop cracks or studs may break This condition may cause wheels to loosen and disengage from the vehicle Dirt streaks or rust radiating from stud holes can indicate loose nuts see Section 5 Be sure the end of the wheel wrench is smooth or cover the wheel mounting surfac
20. smooth transition surface from drop center to bead seat for this and older wheel generations For easy fixation of these valves a 4 5 mm hex key can be used All new valves and nuts are nickel plated and come with a nickel plated dome type dust cap that includes a seal for 100 air tightness Metal valve stem caps are recom mended over plastic caps Valve nuts and torque Alcoa valves have 14 and 16 mm hex nuts Older US made wheels used 5 8 hex nuts for the valves The recom mended torque is 12 to 15 Nm 9 to 11 Ft Lb DON Ts Do not fit valves for steel wheels Valves for steel wheels may have different diameters different bends angle and or insufficient thread length e Do not use brass valves Aluminium and brass cause accelerated corrosion Corrosion may result in leakage e Do not bend the Alcoa standard valve to another shape e Do not inflate the tyre with air coming from an air system using automatic lubrication for power tools e Do not use balancing liquids or balancing powder These products may cause oxidation of the wheel s bead seat and drop center as well as malfunctioning of the valve core with air loss as a result e Do not use metal or brass valve extensions without a solid support Unsupported steel extensions accelerate fatigue to the valve base or valve hole area due to cen trifugal forces As a result cracks can occur in the valve base and or the wheel s valve hole area causing air loss
21. the weight and the surface of the wheel In this way cleaning deter gents that contain silicon can destroy the glue and cause the balancing weight to come loose from the wheel The weights must be applied with some force 5 kg thumb pressure against the small hump at the designated areas 4 Time Hofmann weights with blue tape type 551 5 have a relatively low initial glue force The weight can be relocated immediately after sticking when balancing The glue will reach its maximum holding force after 24 hours at room temperature At the closed side only Hofmann type 551 of 50 75 amp 100 grams can be used If more than 100 grams are needed at this side the weights should be put behind each other The open side allows the use of Hofmann 551 types ranging from 50 to 225 grams Relocating wheels from a cold place to a warmer place causes condensation on wheel surfaces which will affect the adhesion negatively This condition leads to insufficient contact between wheel and adhesive weight It may cause the weights to fly off during use and damage the vehicle or cause personal injury DON TS e Do not use 125 to 225 gram weights on the closed side the width of these weights exceeds the available surface on this side e Do not use 250 and 300 gram weights at all they are too wide for the closed side and too high for the open side They may foul brake parts Alternatively use more weights of smaller sizes
22. without damaging the valve seat Once this valve has been loosened it cannot be used anymore and has to be replaced by a new one or change to the same valve of the 2nd generation GAX70MS 07N2 Valves with black T shape grommet with one piece nut GAX40MSOON GAX54MSOON GAX70MSO7N2 GAX83MSOON original equipment valves GAX70MS27N GAX70MS45N GAX70MS60N replace ment valves gt gt gt 19 20 gt gt gt Current versions These valves come with a one piece nut with enlarged contact surface that evenly distrib utes the forces in the valve hole area It also significantly reduces the chance of damaging this area when applying too much torque When checked for proper functioning this type of valve can be used again These valves do not necessarily need lubrication or greasing when checking or replacing The 4 original equipment valves cover the entire range of currently produced wheels These valves have slotted heads and a hex base which offer more grip and enable easy replacement with the use of a screwdriver or wrench GENERAL RECOMMENDATIONS DO s To avoid loss of air by improper fitment or corrosion Alcoa wheels should be fitted with chrome or nickel plated valves that meet high standards and that are specially designed for Alcoa wheels e When inflating the tyre use dry air Valve stem dust caps with an air seal are recommended The valve base of the 3 replacement valves is flat which enables a
23. 2 piece sleeved cap nuts the minimal number of thread engagement between stud amp nut must be e 14 full turns for M22 x 1 5 Metric Volvo from 2005 e 13 full turns for M20 x 1 5 Metric e 12 full turns for M18 x 1 5 Metric e 10 full turns for 7 8 11 BSF Scania e 12 full turns for 7 8 14 UNF Volvo up to 2004 11 2 Piloting Hubs designed for steel hub piloted wheels may not have enough pilot length to locate Alcoa dualled aluminium wheels or with an Alcoa at the outer position and a steel wheel at the inner position Pay close attention to the pilot tab length particularly when converting from steel to aluminium duals Measure the hub pilot to make sure the hub has a minimum pilot length that allows no less than 5 mm for the outer wheel excluding the bevelled edges The horizontal part of the pilot therefore should be at least 27 mm in case the inner aluminium wheel s disc thickness is 22 mm The horizontal part of the pilot must be at least 17 mm for a mixed dual in case the inner steel wheel s disc thickness is 12 mm 3 Torque When dualing steel wheels with Alcoa aluminium wheels follow the vehicle manufacturer s recommendations regarding the proper torque and use of thread lubricants to mount the wheel 4 h Owner in service identification Some fleets wish to specially identify wheels as to OWNERSHIP and IN SERVICE dates Alcoa recommends that fleets and owner operators adopt the practice of perma
24. 66340X GAX70MS45N X675 66082X GAX70MS45N 66347X GAX70MS45N 66382X GAX70MS45N 19 5 x 6 75 76347X GAX70MS45N 76348X GAX70MS45N 76448X GAX70MS45N 76449X GAX70MS45N x7 50 77340X GAX70MS45N 77345X GAX70MS27N gt 12 2007 GAX54MSOON 01 2008 gt 77346X GAX70MS27N gt 12 2007 GAX54MSOON 01 2008 gt 77347X GAX70MS27N gt 12 2007 GAX54MSOON 01 2008 gt X 825 78340X GAX70MS45N 78342X GAX70MS45N 78345X GAX70MS27N gt 12 2007 GAX54MSOON 01 2008 gt 78346X GAX70MS27N gt 12 2007 GAX54MS00N 01 2008 gt 78347X GAX70MS27N gt 12 2007 GAX54MSOON 01 2008 gt x 14 00 7434XX GAX40MSOON 225 x 7 50 87352X GAX70MS60N 87357X GAX70MS60N For Volvo including extension GAX09070 87450X GAX70MS27N 87451X GAX70MS07N2 87452X GAX70MSO7N2 87453X GAX70MSO7N2 87455X GAX70MS27N 16 225 x 8 25 88354X GAX70MS60N 88355X GAX70MS45N 88356X GAX70MS45N 8845 XX GAX70MS27N 8855XX GAX70MS27N 88650X GAX70MS27N 8865 1X GAX70MS07N2 88652X GAX70MS07N2 88653X GAX70MS07N2 88655X GAX70MS27N 886570 GAX83MSOON WorkHorse wheel 886580 GAX83MSOON WorkHorse wheel x 9 00 89352X GAX70MS60N 89353X GAX70MS45N 89355X GAX70MS45N 8945XX GAX70MS27N 8955XX GAX70MS27N 89651X GAX70MS07N2 89652X GAX70MS07N2 89653X GAX70MS07N2 896570 GAX83MSOON WorkHorse wheel 896580 GAX83MSOON WorkHorse wheel XI 8105XX GAX40MSOON 81151X GAX40MSOON 81152X GAX40MSOON 81251X GAX40MSOON 81252X GAX40MS00N 812570 GAX40MSOON WorkHorse wheel offset 135 812580 GAX40MSOON
25. ALgrease foreign matter accumulate around the wheel and hub before mounting the wheel to the hub If sticking area Water and road salt can then lead to oxidation in the occurred once the wheel has been removed center bore of the wheel The centering spigots and espe cially the uninterrupted centering edges of the hubs are thereby causing the wheels to stick to the hubs so that it becomes difficult to remove them Clean the faces of the disc of the wheel and the hub that are in contact Clean spigots or centering edges of the hub as well as the inner side of the hub bore of the wheel thoroughly Use a wire brush to remove traces of rust oxides and dust Apply a thin layer of ALgrease on the inner side of the hub bore of the wheel and or at the spigots or centering edge of the hub 37 ALgrease is safe to use on aluminium and steel It resists Do not apply ALgrease to the mating surfaces in the high and low temperatures Parts and surfaces treated mounting area of the hub or the disc of the wheel with ALgrease are protected from corrosion It is recom mended to use ALgrease each time wheels are fitted Do not use any other lubricants that are water based or contain heavy metals Such products can lead to accelerated corrosion 38 5 j Wheel installation to the hub Recommendations for proper installation of wheels Check for and replace bent broken cracked or damaged studs When replacing broken studs always
26. Alcoa wheels are fully machined they do not require balancing The tyre wheel combination however may need corrective weighting Liquid or powder balancing is not recommended Preferably use coated balancing weights Regulations banned use of lead for balancing of cars and vans up to 3 5 T GVW At the moment of writing balancing weights used for commercial vehicles over this GVW may still contain lead The past two decades Alcoa wheels came with different rim flange designs There are 3 types of designs that can be distinguished This section indicates how to properly balance wheels produced as from the early 90 s 1st generation of Alcoa wheel rim flange design Clip on weights Below listed wheels can be balanced with clip on weights from Hofmann known as type 555 and 556 Exceptions included Improperly installed weights could fly off during use and damage the vehicle or cause personal injury Always follow the recommended procedures in this manual or the balancing weight manufac turer some wheels continued to be able to host this type of balancing weights till today For reference see part numbers Wheel size 1st gen Alcoa P N 17 5 x 6 00 66320X 66340X 125x675 66082X 66347X 66382X 195675 76347X 76348X 76448X 76449X 19 5 x 7 50 77340X 19 5 x 8 25 78340X 19 5 x 14 00 7434XX 225x750 8735XX 225x825 8835XX 225X825 8845XX 22 5 x 9 00 8935XX 225X900 8945XX 22 5 x 11 75 off
27. Alcoa wheels in service Rim Flange wear is not a warrantable condition Only Dura Flange wheels have a 24 month warranty period against wear which creates a sharp edge that would require maintenance Irregular wear on the surface of the rim flange is caused by abrasion from the tyre bead 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 aluminium wheels These wheels have been specially treated to significantly reduce rim flange wear For infomation consult www alcoa com alcoawheels europe en info_page duraflange asp Remove wheels from service when rim flange wear is excessive Excessive wear can be determined using an Alcoa approved wear gauge and procedures detailed under section 6 f ii If rim flange wear creates sharp edges and or cuts the tyre see Edge Removal Procedures detailed under section 6 f iii or contact Alcoa for recom mended maintenance procedures 6 f i Alcoa Rim Flange Wear Gauge instructions THESE GAUGES ARE TO BE USED FOR RIM FLANGE WEAR ONLY THEY ARE NOT A BEAD SEAT ANGLE OR DIAMETER TOOL rim NOT acceptable rim gauge wheel rim rim acceptable rim acceptable rim gauge rim gauge wheel rim wheel rim daylight in this area indicates daylight in this area indicates acceptable rim acceptable rim 6 f ii Determining Rim Flange We
28. DESCRIPTION GAX85 GAX09070 Replaces B2412 and B2412N B2414 and B2414N GAX09150 19 mm nickel plated valve extension 24 mm overall length 54 mm plastic valve extension including dust cap 72 mm overall length 133 mm plastic valve extension including dust cap 151 mm overall length VALVES FOR ALCOA WHEELS The past two decades Alcoa wheels have been equipped with different types of valves There are 3 types of designs that can be distinguished This section allows one to replace nearly all valves found in wheels as from the early 90 s with the latest version see preceding tables Valves with orange or black O ring BTR542 BTR543C BTR543D BTR543E BTR544 all BTR 545 all B60MS 27N BV 3 20 5 Early versions Nickel plated or chrome plated valves with O ring These valves do need lubrication or greasing when checking or replacing Valves with black T shape grommet and two piece nut GAX70MSO7N B7OMS 07N B70MS 27N B70MS 45N B70MS 60N Previous version To have a better sealing on the inside the O ring is replaced by a larger T shape rubber grommet This also reduces the risk for galvanic corrosion between the valve and the inside of the valve seat These valves do not necessarily need lubrication or greasing when checking or replacing The 14 mm hexagonal nut of this valve is equipped with an integral plastic washer that also prevents galvanic corrosion on the outside It also allows torquing the nut
29. Pa 130 PSI cold Nuts Two piece nut or two piece sleeved nut according to DIN 74361 standards Mounting Hub centered according to DIN 74361 standards Valve torque 12 to 15 Nm 9 to 11 Ft Lb Wheel nut torque Availability wheels Recommended by truck or axle manufacturer Through all vehicle manufacturers or authorized Alcoa distributors 4 d Alcoa wheel identification Since 1977 all Alcoa aluminium disc wheels have been All Dura Bright surface treated wheels are designated identified with a stamp that shows the wheel load rating by the letters DB following the part number such as maximum inflation pressure date of manufacture part 896513DB number wheel description and DOT marking designation All Dura Flange wheels are designated by the letters DF Prior to June 1996 all Alcoa heavy duty truck wheels had following the part number such as 896510DF the Alcoa identification Symbol gt lt on the outside of the disc near the hand hole in line with the valve location If you cannot identify the size or load rating of the wheel it This marking was phased out on heavy duty truck wheels should not be used manufactured after June 1996 Wheels made between 1996 and 2009 e ALCOA FORGED MAX LOAD 3550 kg wheel load rating MAX KPa 952 T DOT maximum inflation pressure T DOT FMVSS 120 designation e JWL T symbol Japanese impact test MADE IN HUNGARY can also be JAPAN MEXICO U S A 021703 da
30. X 87452X 87453X 88651X 88652X 88653X 89651X 89652X 89653X 77345X gt 12 2007 77346X gt 12 2007 77347X gt 12 2007 78345X gt 12 2007 78346X gt 12 2007 78347X gt 12 2007 87450X 87455X 8845XX 8855XX 8945 XX 8955XX 66340X 66347X 76347X 76348X 76448X 76449X 77340X 78340X 78342X 88355X 88356X 89353X 89355X Wheels in this section are designed for drum brakes only Extension valve GAX09070 is optional when single mounted 66320X 10 2001 gt 87352X 88354X 89352X Wheels in this section are designed for drum brakes only Extension valve GAX09070 is optional when single mounted 88657X 88658X 89657X 89658X Wheels in this section are Workhorse wheels Use extension valve GAX09150 for all valves when dual mounted VALVES PART NR OBSOLETE BTR544D 60 WHEEL PART NR amp REPLACEMENT VALVES 66320X gt 09 2001 can be replaced with GAX70MS60N Wheels in this section are designed for drum brakes only Extension valve GAX09070 is optional when single mounted BF8437 BH 8437 60 Can be replaced with GAX70MS 60N For Volvo with 87357X use extension GAX09070 Check clearance Wheels in this section are designed for drum brakes only Extension valve GAX09070 is optional when single mounted BTR543E 75 81352X 81353X can be replaced with GAX40MSOON straight 83352X can be replaced with GAX40MSOON straight EXTENSION VALVES PART NR
31. acturer s recom mendation never use the detergent straight without diluting with water In the mixed diluted state the cleaner acidity alkalinity should have a pH between 5 and 9 Avoid cleaners that contain hydro chloric sulfuric nitric or hydrofluoric acid The latter hydrofluoric acid often used in car truck wash pre treatment routines for wheels should never be used on Dura Bright treated wheels When tyres are removed the entire rim must be cleaned and inspected see Section 6 b With a soft brush remove any foreign products from the rim portion of the wheel that supports the tyre Generously coat the entire air chamber surface with an approved surface protection and lubricate each time the tyre is removed see Section 5 g ii 7 c Maintenance Dura Flange wheels 1 Edge re conditioning cannot be performed on Dura Flange wheels Dura Flange has a 24 month warranty against wear which creates a sharp edge that would require main tenance Minor wear or minor pitting is not a warrantable condition 3 Once in service Dura Bright wheels can become nicked or scratched by road debris and or mechanical damage If this occurs continue to follow the normal washing and cleaning instructions provided above 4 Even as durable as Dura Bright wheels are the mounting area can become scratched marred or dis colored when mounted against another wheel hub or drum The use of a wheel mounting surface gua
32. al mounting applications Install the valve with care and do not over torque the rec ommended torque is 12 to 15 Nm 9 to 11 Ft Lb 21 22 VALVES AVAILABILITY Two types of valves cover most common Alcoa wheels Valves GAX70MSO7N2 for current 8 25 amp 9 00 truck and bus wheels and GAX40MSOON for most super single wheels 5 f Valve extensions Alcoa distributors offer different valve extensions A quality extension of 150 mm will enable tyre pressure checks and adjustment of the inner tyre of a regular dual fitment Metal valve extensions for dual mounting may be used in conjunction with a support or valve stem stabilizer only The mass of metal valve extensions and rotation may cause forces that can lead to cracks in the valve hole area of the wheel or the valve stem 5 g Mounting tyres European Alcoa wheels have a 15 bead seat angle and accommodate tubeless tyres with a 15 bead only Never use tube type tyres or tyres with different angled beads on European Alcoa wheels e Do not use a wheel that has been exposed to excessive heat from tyre fires brake fires severe brake system drags or seizures or other causes e Do not use a damaged tyre or damaged wheel Inspect them carefully before mounting e Use only the appropriate tyre size matching the rim width according to ETRTO and or tyre manufacturer s recommendations e Check if the valve is mounted in the right way with proper torque e Appl
33. angle to tyre assembly at top of wheel and lubricate bead areas on both sides of tool Lean tyre assembly toward tool and rock or bounce to pry off the tyre 29 30 5 g vi Use ALgrease when changing tyres Frequent changing of tyres in undesirable conditions use of water based lubricants for tyre fitting as well as neglecting to clean the surface of the bead seat un doubtedly lead to loss of air caused by corrosion oxidiza tion of the aluminium and dirt build up Certain types of rubber can fuse to the bead seat of the wheel If this rubber amp other residues are not removed before the fitment of a new tyre the uneven surface can lead to loss of air Remove the valves core when cleaning the bead seats to avoid dirt build up in the valve shaft which could cause malfunctioning of the valve Before mounting a new tyre clean the bead seats thoroughly with a wire brush or an appropriate power tool until a smooth and clean surface is reached Avoid using strong abrasive tools and or excessive force that could cause dents in the surface Uneven or damaged surfaces can lead to leakage Apply a film of ALgrease to both bead seats rim flanges humps and curved sides of the rim well Also apply ALgrease to both beads of the tyre Proceed with mounting of the tyre according to mounting procedures and safety guidelines provided by the tyre manufacturers 5 h Balancing Supersedes Balancing Manual 2005 Since
34. ar STEP 1 Remove the wheel tyre assembly from the vehicle Remove the valve core to deflate the tyre completely Remove the tyre from the wheel according to the section Mounting Alcoa wheels with Tubeless Tyres Section 5 g iii STEP 2 After the wheel is separated from the tyre verify if the cir cumference of the bead seat on the open side is accept able see Section 6 d 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 right photo unacceptable See rim flange wear gauge instructions on the illus trations above to make this determination If you do not have an Alcoa rim flange wear gauge contact Alcoa Wheel Products Europe to obtain a gauge s at no charge by calling 32 11 45 84 60 or emailing info wheels alcoa com acceptable unacceptable no daylight in this area indicates excessive wear 57 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 made by attaching a section of tyre side wall or a suitable piece of rubber to a block of wood 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 If the rubber is cut then follow these edge removal instruction
35. bsequent operation of the vehicle see below warning If using a tyre mounting demounting machine on aluminium wheels care should be taken to prevent gouging the wheel 10 Use only dry air for tyre inflation The use of moisture traps in the air compressor feed line is recommended 11 Do not overinflate Use the tyre manufacturer s recom mended pressure but under no circumstances exceed cold maximum inflation pressure 12 When inflating a tyre always use a clip on air chuck or threaded straight chuck and a remote valve with pressure gauge Never use a volatile or flammable material such as ether or gasoline as an aid to seating the tyre beads on the wheel can lead to an uncontrolled pressure buildup in the tyre and may result in an explosion Explosive separation of the tyre and wheel can occur while seating beads in this manner while adding air to the tyre on or off the vehicle or later on the road Loss of vehicle control can result which can cause serious injury or death Only use approved mechanical or pneumatic bead seating devices A pressurized tyre wheel assembly can explode and separate violently This violent separation can cause serious injury or death Always contain the tyre wheel assembly in an inflation cage during inflation 5 g ii Mounting tyres on non symmetrical drop well wheels Alcoa wheels often contain a symmetrical drop well with In order to minimize the possibility of tyre b
36. cid cleaners Use ALclean and ALpolish Alcoa Brushed amp Mirror Polished wheels are uncoated The highly corrosion resistant alloy that is used for Alcoa wheels reduces oxidation to a minimum Maintaining the original luster of the wheels is easy with ALclean and ALpolish Regular and frequent maintenance will keep your wheels bright and shiny for years Alcoa Dura Bright wheels only need soap and water washing to stay bright These wheels should not be polished with standard polishes such as ALpolish Corrosion Due to aluminium s natural resistance to corrosion Alcoa forged aluminium wheels do not need to be painted Certain environments such as livestock hauling can lead to corrosion Other potentially corrosive materials include salt highly alkaline substances and chloride compounds Using ALprotect reduces corrosion and improves the pro tection of your wheels For information consult www alcoa com alcoawheels europe en info_page wheelcare asp 7 a Maintenance against corrosion Brushed and Polished wheels non Dura Bright surface treated wheels The following information is for standard Alcoa forged aluminium wheels without the Dura Bright surface treatment See Section 7 b for specific instructions on the care and cleaning of Alcoa Dura Bright surface treated wheels 1 Clean frequently with high pressure water from a hose The use of a mild detergent will soeed the cleaning process Do not use stron
37. contact the brake suspension steering or other compo nents during vehicle operation POSITIONING Both sides of the wheel have a designated area where the adhesive weights must be applied 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 Excessive rim flange wear see Section 6 f could dictate the use of stick on or adhesive wheel weights if there is inadequate rim flange to properly hold a clip on style weight closed side open side outside inside WY closed side open side 33 34 PROCEDURE amp DO S 1 Temperature The ambient temperature for sticking adhesive weights to wheels must be above 10 Celsius The tem perature of both wheel and adhesive weight must also be 10 Cor more Allow wheels to reach room temper ature at least 10 C before applying adhesive weights 2 Cleaning After determining how much weight must be applied and at which position the spots must be cleaned thoroughly and be completely free from dust grease and silicones This applies to both new and old wheels Use silicon remover or another appropriate cleaner that removes silicones and grease Silicones destroy the glue of the balancing weights and they will come loose 3 Sticking Important is to avoid air bubbles or insufficient contact between the adhesive tape of
38. cted 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 regard less of appearance Even if a wheel does not appear to be obviously burned check labels tyre bead brake compo nents and DiscMate for evidence of charring melting blistering or burning A wheel may discolor from excessive heat It can show a dull grayish color and will not polish to a bright finish as a typical wheel would Any wheel run with a flat tyre longer than the time necessary to immediately pull off the road should be checked for excessive heat damage A blistered 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 right or discoloration of the wheel as shown in picture below After January 2009 the new Alcoa logo may not show heat damage Excessive heat from fire brake malfunction wheel bearing failure tyre failure or other sources may weaken the metal and cause the wheel tyre assembly to separate explosively Exploding wheel tyre assembly can cause serious injury or death Immediately and permanently remove from service any wheel that has been exposed to excessive heat 51 52 Inspect all axle end components for signs of exposure to excessive heat Pay particular attention to brake drums or
39. d or otherwise coated in any way that may interfere with the mounting surfaces Explosive separations of tyres and wheels or wheel failure on the vehicle could cause serious Any wheels that shows signs of alteration should be injuries or death removed from service and scrapped Never attempt to weld braze or heat any surface of an Alcoa aluminium wheel 5 c Mounting area support surface diameters The support surface of the hub should be flat to the diameter recommended per SAE J694 below to properly accommo date the wheel disc area Applicable to hub pilot mounting type Alcoa wheels 381 M22x1 5 386 15 0152 335 10 7 8 11 BSF 381 386 150152 335 10 7 8 14 UNF 381 386 15071532 275 8 M22 x 1 5 335 343 Sl 275 8 M20 x 1 5 315 320 12 4 12 6 245 6 M18 x 1 5 284 290 11 2 11 4 225 10 M22 x 1 5 274 279 10 8 11 0 205 6 M18 x 1 5 246 249 Seo 5 d Before tyre mounting Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Refer to tyre manufacturer s recommendation for proper tyre pressure Before mounting the tyre perform a wheel fitment check to insure proper clearance from any obstruc tions Do not use a wheel that has been subjected to high pressure tyre amp rim separation run flat excessive heat or other physical damage A wheel subjected to any of these conditions may no longer have sufficient dimension and contour to retain th
40. dents 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 and other instructions and warnings set forth in the alcoa wheel service manual alcoa technical bulletins and other alcoa liter ature recommended maintenance includes without limitation using proper torque periodic cleaning polishing valve replacement periodic inspection for damage loose lug nuts and rim flange wear inspec tions and procedures g nicks scratches and other surface blemishes resulting from improper maintenance cleaning road debris curbing accident or operation are not warrantable h rim flange wear other than dura flange is not war rantable damage due to cleaning with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline Dura Bright surface treated wheels are warranted against 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 blistering or peeling due to loss of adhesion of the surface treatment lift off of the surface treatment due to physical damage nicks scratches gouges If nicks dings scratches or other damage does occur to the Dura Bright treatmen
41. dersized diameter of wheel support surface support surface not flat incorrect attachment parts see Section 5 c and insufficient torque see Sections 5 n il and 5 n iii Remove wheel from service Support surface should be flat to the diameter recom mended on the chart in section 5 c Inspect the hub drum contact area thoroughly for cracks or other damage 6 g ii Corrosion Certain environments can lead to corrosion Some of the more common corrosives are salt magnesium chloride and calcium chloride compounds used for snow removal and highly acid or alkaline materials If the air used to fill tubeless tyres or the tire itself is not dry the areas of the wheel under the tyre can corrode severely Remove wheels from service with severe hub bore corrosion Bead seat valve stem and hub bore corrosion often are caused by entrapped moisture Mild corrosion should be removed thoroughly by wire brush and the rim protected with non water based tyre lubricant see Section 5 Remove any severely corroded wheel from service The use of liquid tyre balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface Severely corroded wheels are unsuitable for service Alcoa wheels corroded by the use of liquid tyre balancers or sealants will not be replaced under the Alcoa limited warranty 63 64 6 g iii Bolt holes If wheels are run loose both stud located wheels and hub p
42. dge on the wheel caused by rim flange wear Here are some examples of commonly used tools File Air or electric power sander A file can be used very effectively to remove the sharp edge This provides a very quick and effective method of removing the sharp edge Operators should use all care to keep a uniform edge when using these tools Air or electric grinder Die grinder Another quick and effective method of removing the sharp Used with a sanding wheel cutting stone or grinding tool edge caused by rim flange wear Be careful as grinding pads this is a version of an electric grinder This tool is very quick may gum up from the aluminium that is removed Care and effective as well and care must be taken to remove must be used to avoid gouging the wheel metal as uniformly as possible and not to gouge the wheel 59 60 Removing sharp edges with hand or power tools produces metal filings and sparks Many power tools have edges that are sharp or may become hot during use Some power tools produce excessive noise when used Metal filings can be sharp and when 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 protec tion when using hand or powe
43. e Do not apply any adhesive weights in other areas than designated as they may cause a foul condition 5 h iii Balance liquid or powder Liquid or powder balancing is not recommended The policy of Alcoa Wheel Products is not to endorse any specific brand or entity of balancing powder The use of powder balancers in Alcoa wheels may cause clogged valves The use of a filtered valve core is recommended when using balancing powder Due to the design of Alcoa wheels and corresponding valves the installation of a long valve core or filtered valve core is not always possible The use of balancing powder will not void the warranty unless inspection of the wheel shows anomalies related to its use Liquid or powder balancers may harm the inner liner of tubeless tyres For information see tyre manufacturers recommendations For more information see Hofmann s web address www dionys hofmann de The use of liquid tyre balancers or sealants in Alcoa wheels may cause extremely rapid corrosion of the wheel rim surface Severely corroded wheels are unsuitable for service Alcoa wheels corroded by the use of liquid tyre balancers or sealants will not be replaced under the Alcoa limited warranty 35 36 lube here 5 i Lubrication ALgrease 5 i i Lubrication of the hub and or wheel hub bore Prior to mounting hub piloted wheels generously coat the wheel pilot or hub pads with a non water based lubricant to minim
44. e NUD een nee ee een 38 k PUDEN Renee 39 l Disc thickness amp thread CHgIgEMENT nennen een sinne nina 39 Me NUE SONS AEE A E E E E eer wants 40 i Section A mounting Alcoa wheels with standard nuts amp replacing Wheel studS sssssssesssssscesssssecssssseceesssseeesss 40 li Section A how to measure stud standout uassessssssssnssnssnssnsennensnnenunsunsnnsnnennsnnennennsnnensnneenennennennssnnsnnnnssnnennennsnnsnnennernennennne 41 iii Section B mounting Alcoa wheels with standard studs amp Alcoa sleeved nutS sssssesssssssesssssecesssssecessssecessssseeesss 42 iv Section B how to check sufficient thread ENGagGeMEeNt scsecsessessecsscssesssssssssscssesscescesessessessesseeseessssesseesesseescesceneeseeses 43 3 De WIENS en er ee ee TI een 44 i Two piece hex head nuts annehmen een ET 45 lie TO A E naar E E nis AAE E E E EE O I RENATE 46 ik Keep wheelnuts UON een Ee EAA 47 iv Dualng withsteelWwhee lsieni aa aeaa ea AOE era 48 w ENGST a NDO een EA A E een 49 Ge e IG ee A EEE IE 50 a ANO AOU G E A A 50 b Inspect thoroughly and frequently ernennen 50 C Pea aan Oe oaeen E IA EE E EE ators AE E AA EI REE E 51 de HEME TAS LOM CNES ee E E 53 e Tyre wearor ride PDrODIETIS aaa een rear eine 56 P RONGE WE ea a AENA ee ee 56 i Alcoa Rim Flange Wear Gauge instructions 57 ii Determining Rim Flange Weal ccssscsssssssssssssssssssssssssssssssssssssssssssassssssssscsssacsassnssscsucscsssassassus
45. e particular operating and e Ensure that both tyre beads are properly seated heavy instruction manual 5 9 i Recommendations for mounting tubeless tyres Damaged tyres or wheels can lead to an explosive separation of tyres and wheels Explosive separation can cause serious injury or death Inspect tyres and wheels for damage before removing from vehicle If damage is found the tyre must be completely deflated before loosening cap nuts Immediately and perma nently remove damaged tyres or wheels from service duty truck tyres have a guide rib molded into the sidewall next to the tyre bead When the tyre is inflated this guide rib or ring should be evenly spaced from parallel to the wheel rim all the way around the wheel Check the position of the ring before removing the assembly from the inflation cage If the ring and wheel are not concentric deflate the assembly in the cage and remount the tyre Use of inner tubes in tubeless wheels will hide Slow leaks Slow leaks may indicate cracked see Section 6 g or damaged wheels which lead to wheel failures Wheel failures can cause accidents which may result in serious injury or death Never use an inner tube on an Alcoa tubeless wheel Immediately and permanently remove cracked or damaged wheels from service 23 24 NOTICE Alcoa aluminium duable wheels require special tyre mounting techniques see Section 5 g iii 1 duable wheel Do not g
46. e stud s unthreaded part or exposed shoulder even before the wheels are clamped correctly Before mounting Alcoa wheels on hubs with such studs the space between the washer and the hubs mounting face must be determined _ TTT ls AAA Single mounted wheels require sleeved nuts with a short sleeve yA Ge gt eee N m er For dual mounting wheels must be mounted with long sleeve nuts ID This space x must be 2 mm less than the disc thickness of the Alcoa wheel to be accommodated Determine this space when the nut is bottomed out at the stud without a wheel mounted 43 44 Studs 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 regular mainte nance recommendations and stud replacement practices 5 n Wheel Nuts 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 All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs Use of chrome plated cap nuts which have chrome plating on the surfaces which contact the wheel
47. e tyre bead while under pressure A cracked or damaged wheel may cause the wheel to fail or come off the vehicle while the vehicle is moving Do not straighten the wheels Do not heat the wheels in an attempt to soften them for straightening or to repair other damage The special alloy used in these wheels is heat treated and uncontrolled heating will weaken the wheel Do not weld the wheels for any reason When tyres are removed the entire wheel must be cleaned and inspected With a brush remove any foreign products from the wheel s bead seats portions of the wheel that support the tyre Check the wheel s flanges for wear with Alcoa s Rim Flange Wear Gauge Remove sharp edges as explained in Section 6 f It is recommended to generously coat the entire air chamber surface with an approved surface protector and lubricate each time the tyre is removed See the recommendations in section 5 9 15 5 e Valves Supersedes Alcoa Valve Application Chart Manual 2005 The following information applies to the most common wheels From left to right used in Europe GAX40MSOON Originally wheels may have come with valves that have been GAX54MSOON replaced and improved meanwhile GAX70MS07N2 Therefore the table below lists replacement valves only GAX83MSOON e Includes Dura Bright wheels part numbers with extension DB e Includes Dura Flange wheels part numbers with extension DF 17 54 x 6 00 66320X GAX70MS60N
48. e with a protective shield prior to tightening the cap nuts The wrench end will mar the wheel around the cap nuts if it is not smooth Keep all component contact surfaces smooth and clean Dirt or projections on mounting surfaces may lead to lose 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 aluminium 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 7 b for specific cautions care and maintenance proce dures DiscMates are a protection gasket designed to be placed between the wheels and also between wheels and hub or brake drum contact surfaces see Sections 5 g i DiscMates are recommended to be replaced when the tyre wheel assemblies are removed and reinstalled 5 k Hub centering All European type Alcoa wheels for heavy duty com Always apply some ALgrease or non water based lubricant mercial vehicles are hub centered wheels European on the spigots to reduce corrosion and make it easier to type Alcoa wheels have cylindrical boltholes and are not remove wheels when replacing tyres or for service suitable for bolt centering with
49. ead damage a narrow ledge on both sides of the rim This feature all mounting and dismounting of the tyre should be allows mounting of the tyre from either side of the wheel performed only from the narrow ledge 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 under well diameter and also have a nonsymmetrical sloping rim profile which provides addi tional brake clearance mount from this side y Tyres should be mounted demounted only do not mount from this side across the disc side of the wheel 25 5 g iii Mounting tubeless tyres NOTICES Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Before mounting the tyre perform a wheel fitment check to insure proper clearance from any obstruc tions When match mounting tyres on Alcoa wheels locate valve stem adjacent to low point mark on the tyre e Not all tyre mounting demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tyres e Refer to tyre manufacturer s recommendation for proper tyre pressure Position wheel on machine Lubricate wheel entire air chamber surface and tyre bead using approved lubricant Tyre beads should be mounted over the rim flange closest
50. ed length of engagement between the threads of the stud and the sleeved nut is equivalent to 95 or more of the diameter of the stud The minimum recommended number of thread engage ment between stud amp nut is e 14 full turns for M22 x 1 5 Metric Volvo 2005 gt e 13 full turns for M20 x 1 5 Metric e 12 full turns for M18 x 1 5 Metric e 10 full turns for 7 8 11 BSF Scania e 12 full turns for 7 8 14 UNF Volvo gt 2004 5 m iv Section B how to check sufficient thread engagement Engage a single wheel or dualled wheels to the hub with at least two nuts securing the wheels Tighten one nut by hand and count the number of full turns till the nut sits snugly Do not center hub piloted type wheels with sleeved nuts The sleeves of the nut do NOT center the wheel s this mounting system still requires a hub piloting or hub centering axle The pilot tab length for sufficient centering must be 5 mm or more for single mounting or 1x disc thickness 5mm for dual mounting excluding bevelled edges both single and dual Short and long sleeved nuts are available from Alcoa in thread sizes for all European vehicles The torque to obtain the correct clamping force is recommended by your truck trailer or axle manufacturer Studs with unthreaded part bottom out Studs that have an unthreaded part or exposed shoulder can cause incorrect or no clamping of the wheel s at all Sleeved nuts may bottom out on th
51. esceseeseeseesecseeassaesaussuesscsscesseneaseeseeseeseeses 14 a Berore tre mouti Gear 15 NN en evs ssiees A susansis aay cots A E A A E ies eee reantustaeiaaeees 16 gt VAR POLE ASIONS nenne essen sea ARSTER TE E E 22 Oi UNM OS ee ee ee ee u ee er ee 22 i Recommendations for MOUNTING tubeless TYLeS cescssssssssssssssecsscssssssesesssssessssssssssssscsssssscsscsessscsscsssssscsscessesessessseseesses 23 li Mounting tyres on non symmetrical drop Well wheels csssssssssssessssssssssssssessscscsscsecsesssessssasssecsecsessecsecsecscssceecesssseeess 25 Il MOUNENG SMU SCS nenne N E E A re 26 iv Recommendations for demounting tubeless tyres from Alcoa wheels c sssssssssesssssessscsssssecsesssssessecssssssessessseneesses 28 v IDEMOUNENG Or tubeless CY FG een 29 vi Use ALgrease when changing tyFes scsscsscsscssssssssssssssssssssssesssssssssssssssscsssssssecsucsussussussessussusssseascascasesseasesscsucsucsecsucsassussaseesees 30 fi Balance NG wear Rena ee 31 i Balance weights clip on tYpe ee ee 33 ii Balance weights adhesive Dpe unnnae ee ne en 33 I Balance MUNI MOM OVS 2 een een 35 MEAP en een EHEN INITIIERTE 36 i Lubrication of the hub and or wheel hub BO nennen nenn anregen 36 ii Lubrication of the studs amp NUtS ssssssssseesssssssssssseecesesssssssssseeeesssossssssseteresoonssssseeeereesssssssseeeteroessssssssterrosonssssssserrerossssssseeetrerrsssss 36 IE ALO OO ae er 37 b Wheelimstallation to th
52. fe 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 Generally older wheels and wheels operating in extreme conditions should be examined more frequently for obvious signs that they should be removed from service Examine all exposed areas frequently Clean wheels and look for cracks or other damage Also check the inner dualled wheel when the outer wheel is removed During tyre changes thoroughly examine the entire wheel Pay particular attention to the rim contour and the surfaces of the rim Do not overinflate Use the tyre manufacturer s recom mended pressure but under no circumstances exceed cold inflation pressure Before mounting the tyre perform a wheel fitment check to insure proper clearance from any obstructions Damaged tyres or wheels can lead to an explosive separation of tyres and wheels Explosive separa tion can result in serious injury or death Inspect tyres and wheels for damage before removing from vehicle If damage is found tyre must be completely deflated before loosening wheel nuts Remove damaged tyres or wheels from service 6 c Heat damage Inspect for exposure to excessive heat A wheel that has been subje
53. g cleaners 2 When tyres are removed the entire wheel must be cleaned and inspected With a wire brush remove any foreign products from the tyre 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 protection and lubricant each time the tyre is removed see Section 5 i iii 3 To maintain the original appearance of your Alcoa wheels the following procedures are recommended a After installing new wheels and prior to operating your vehicle use a sponge cloth or soft fiber brush to wash exposed wheel surfaces with a mild detergent and warm water solution b Rinse thoroughly with clean water Wipe dry to avoid water spots d Clean your Alcoa truck wheels as frequently as required to maintain their appearance N For reference see the Wheel Care section on www alcoa com alcoawheels europe en info_page wheelcare asp 7 b Maintenance amp cleaning Dura Bright surface treated wheels 1 The Dura Bright surface treatment is designed to be easy to clean and generally only requires water If soils attached to the surface do not come off with cold water try warm water and wipe with a soft towel or chamois material If soils remain use warm water and a mild detergent with assistance of a commercial high pressure power washer if available Always dilute the detergent according to the manuf
54. he inflation cage If the ring and wheel are not concentric deflate the assembly in the cage and remount the tyre 27 28 5 g iv Recommendations for demounting tubeless tyres from Alcoa wheels 1 When hand demounting tyres from wheels placing aluminium wheels on a clean wooden floor or rubber mat is recommended Remove valve core air from tyre wheel assembly prior to removal from vehicle Addi tional care should be used when demounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 7 b for specific cautions care and maintenance proce dures Always use a rubber leather faced or plastic mallet Keep tyre tools smooth Use them with care Rim gouges or nicks may cause cracks If using a tyre mounting demounting machine on aluminium wheels care should be taken to prevent gouging the wheel An aluminium wheel can be structurally weakened by excessive heat Tyre wheel assemblies using wheels that have been exposed to excessive heat may experience a sudden and unpredictable tyre wheel separa tion causing serious injury or death Immediately and permanently remove any wheel from service that has been subjected to excessive heat such as a tyre fire wheel bearing failure or braking system drag seize or a high pressure tyre wheel separation Damaged tyres or wheels can lead to an explosive separation of tyres and wheels Explosive separation can cause se
55. heel tyre and service equipment manufacturers offer service manuals and other training materials Stay up to date on proper procedures and keep current instructional materials handy in the shop Study safety and service information and use it on the job An inflated wheel and tyre assembly contains enough air pressure to cause an explosive sepa ration Unsafe handling or failure to follow approved mounting and demounting procedures can lead to serious injury or death Study understand and follow the procedures contained in this manual Statistics show that in most industries at worst only one in 1000 serious accidents results in a fatality But when the accident involves tyres and wheels statistically one in every 10 serious accidents is a fatality That s 100 times more often than in most other industries 1 in 1000 TYPICAL INDUSTRY 1in 10 THE SERVICE INDUSTRY Wheel Selection 4 a Alcoa Wheel Specification Sheet Wheel specifications listed in the Specification Sheet are subject to change without prior notice To request a free copy of the current Alcoa Wheel Specification Sheet call Alcoa Wheel Products Europe or an authorized Alcoa Wheel distributor Contact Alcoa Wheel Products Europe at 32 11 45 84 60 To view online go to www alcoa com alcoawheels europe en info_page wheel_specs_technical asp The Alcoa Wheel Specification Sheet contains the current part number availability and complete spec
56. hile under pressure Rims that lack proper dimension and contour can lead to explosive separation of the tyre and rim causing serious injury or death 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 53 54 Dimension checks best inspection method with a wheel rim ball tape Photo shows a wheel rim ball tape Measure the circumference of the bead seat on the open side with a ball tape The circumference of the bead seat on the open side of the wheel should be checked at each tyre change The open side is the side opposite the disc face In the case of center flange wide base wheels or wheels with insets less than 76 mm or 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 wheel rim ball tape immediately and permanently remove the wheel from service Ball tapes used for measuring wheel circumference can be purchased from MAKRA Manfred Kratzmeier GmbH Werner von Siemens Stra e 15 76694 Forst Baden Germany Dimension checks 2nd best inspection method if a ball tape is unavailable use a carpenter square nail ee o J Pe 2 t ji 2 0 3 E s siis whl se s efis S rf 5 5 7 g 9 o Pg gt J aliases ahi PURNRAAANHA M N 7
57. ifications such as wheel dimensions offsets and load ratings 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 Most Alcoa wheels are available with the Dura Bright surface treatment Note Currently Dura Bright and Dura Flange options are not available together on the same wheel Dura Bright is available on most polished wheels Dura Flange is available on brushed finish only 4 c General characteristics Wheel material Approved by 4 b Disc brake equipped axles Most Alcoa wheels come with a protected valve design that reduce the risk that during rotation foreign parts like stones entered in the inner wheel area can be taken up by the valve Objects striking the fixed brake calliper of a disc brake system can lead to damages on the valve or brake calliper All current produced 22 5 and 19 5 Alcoa wheels for European vehicles have a protected valve design that can be mounted on axles with disc brakes Some 17 5 Alcoa wheels do not have a protected valve design and can be fitted on axles with drum brakes only See Alcoa Wheel Specification Sheet forged aluminium alloy 6061 T6 tempered LBF T V JWL T and all European vehicle manufacturers ISO certificates ISO 14001 2004 EMS Environmental Management System ISO TS 16949 2002 Tyre sizes All ETRTO approved sizes Max infl press 900 k
58. iloted 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 UNACCEPTABLE UNACCEPTABLE For hub piloted wheels normally if you see thread marks on For hub piloted wheels normally if you see a wallowed out the inside diameter of the bolt holes this would indicate the bolt hole this would indicate the wheel ran loose wheel ran loose 6 g iv Disc area Inspect both sides of disc area for hand hole cracks If cracks are found remove the wheel from service Hand hole cracks are normally caused by overloading of the wheels 6 g v 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 Cracks in areas around the valve stem hole are normally caused by overloading of the wheels 6 g vi Bead Seat area Loss of air may be caused by cracks in the bead seat areas around the rim Remove the wheel from service Bead seat cracks are normally caused by overloading of the wheels 65 7 Care and Maintenance 66 Regular cleaning Clean the wheels regularly with steam or high pressure water The use of a mild detergent is recommended Do not use harsh alkaline a
59. in General Characteristics see Section 4 c of this manual Before mounting the tyre perform a wheel fitment check to insure proper clearance from any obstructions Refer to tyre manufacturer s recommendation for proper tyre pressure Before mounting the tyre perform a wheel fitment check to ensure proper clearance from any obstruc tions Some forms of wheel damage can be hidden beneath the tyre so whenever a tyre is removed thoroughly examine the complete wheel Remove all grease and road dirt Use a wire brush or steel wool to remove rubber from the bead seats Check mounting holes for the enlargement and elonga tion which can occur if the cap nuts are not kept tight see Section 5 n iii Dirt streaks radiating from stud holes may indicate loose cap nuts 13 5 b Putting wheels in service wheel alteration Alcoa does not approve any form of alteration to wheels except minor cosmetic buffing for appearance purposes or light sanding for burrs in the rim flange area see Section 6 f iii Wheels should not be altered by welding brazing or other Welding brazing or otherwise heating any area heat application in an attempt to repair or straighten of an Alcoa aluminium wheel will weaken the a wheel Use of adapter plates or bead locks are not wheel Weakened or damaged wheels can lead approved on Alcoa wheels to an explosive separation of tyres and wheels or wheel failure on the vehicle Wheels should not be painte
60. ion of Alcoa wheel rim flange design 77345X 77346X 77347X 78345X 78346X 78347X 8745XX 8855XX 8865XX 8955XX 8965XX 81456X 81556X 81557X 81558X EU 81753X 81755X 81756X 81652X 81655X 8405XX 8425XX During 2009 and 2010 all Alcoa wheels are subject to a transition towards rim flange designs that can host both clip on and adhesive weights The new clip on weight however cannot be used at the 1st series of Alcoa wheels as listed above as the rim flange design is not the same Wheel size 3rd gen 22 5 x 11 75 offset 0 22 5 x 11 75 offset 120 22 5 x 11 75 offset 135 22 5 x 15 00 offset 120 Alcoa P N 8105XX 81251X 81252X 81751X 81752X 81151X 81152X 81257X 81258X 85052X 5 h i Balance weights clip on type Refers to 1st and 3rd generation of Alcoa wheel rim flange design Balance weights for Alcoa wheels are available from your hardware supplier for tyre dealers With radial tyres it may be necessary to temporarily reduce the tyre 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 aluminium wheel surface 5 h ii Balance weights adhesive type Refers to 2nd and 3rd generation of Alcoa wheel rim flange design Adhesive weights should be applied only to a clean surface on sides and areas as indicated These weights should be installed only in a location where they will not
61. ion torque should be rechecked unless your documented fleet practices determine otherwise Check torque frequently from then on Nuts must be kept tight and studs and nuts should be checked frequently Impact wrenches if used should be carefully adjusted to apply torques within the limits recommended Torquing of nuts should be done in recommended sequences After each wheel mounting nut torque should be checked with a torque wrench Nuts should be retorqued if necessary At tyre changes nuts and studs should be inspected to be sure they are in good condition If cracks and stripped or damaged threads are found remove these nuts from service Check wheel studs accordingly NOTICE If nuts require frequent tightening studs break fre quently wheel nut washers break or bolt holes are pounding out hardware and mounting practices should be reviewed Six Stud 1 2 O 709 O4 ns Os O O 3 8 Eight Stud 1 10 8 OOo 30 Os 50 O4 ne O Og 2 Ten Stud LUBRICATION Lubricants should not be applied to the cap nut s washer i e nut to wheel contact surface Application of excessive lubricant to the threads of the stud and or nut can cause excessive torque Over torque can stretch studs causing them to fail Oiled washers 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
62. ize 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 Lubricate the hub pads or the wheel hub bore generously with a non water based lubricant lube here AN lube here O Q Do NOT lubricate the face of the hub wheel face or brake drum 5 i ii Lubrication of the studs amp nuts For nuts used on hub piloted wheels apply two drops of motor oil to the point between the nut and the integrated washer and two drops to the first two or three threads at the tip of each stud This will minimize corrosion between the mating surfaces Lubrication is not necessary with new hardware lube here Algrease or equivalent lubricants are heat resistant and are safe for aluminium and tyres ALgrease can also be used for mounting tyres and valves Other lubri cants that are water based or contain heavy metals can accelerate corrosion and should not be used ALgrease can be ordered from your Alcoa distributor For more information on ALgrease see Alcoa Accessories Catalogue lubricate here lubricate here Do NOT lubricate the face of the hub wheel face or brake drum 5 1 1 ALgrease USE ALGREASE WHEN MOUNTING WHEELS During the time that wheels are in service dirt and other To prevent wheels from sticking to hubs use
63. n or Sheet with details about wheel sizes part numbers on fk l l l l maintenance practices may result in injury or dimensional properties such as disc thickness and appli eer cations 39 40 5 m Nuts amp studs 5 m i Section A mounting Alcoa wheels with standard nuts amp replacing wheel studs The Alcoa wheel version for this type of mounting requires longer studs than for steel wheels The stud standout must be long enough to cover the disc thickness of one or both wheels the height of the wheel nut and additional two threads For single mounting the minimum stud standout required disc thickness Alcoa wheel height of standard nut 3 mm M22 M20 or M18 x 1 5 NOTICE e If hex nuts with greater overall height are used more stud length is required The stud standout must be checked very carefully The stud standout is measured from the flat mounting surface of the hub which is in contact with the disc of the wheel to the outer end of the stud For dual mounting the minimum stud standout 2x disc thickness Alcoa wheel height of standard nut 3 mm M22 M20 or M18 x 1 5 2 full threads in case of 7 8 11 BSF or 7 8 14 UNF 5 m ii Section A how to measure stud standout Stud standout is measured from the axle end mounting surface i e the hub for disc brake operated axles and inboard mounted drums of drum brake operated axles to the first complete thread at the outside end
64. nds Foot pounds to Newton meters Ft Ibs x 1 35582 Nm Newton Meters to Foot pounds Nm x 0 737562 Ft Ibs 69 8 Contact 70 Alcoa Wheel Products Europe Industrieweg 135 Industrial Zone Ravenshout 7046 B 3583 Beringen Paal Belgium Tel 32 11 458 460 Fax 32 11 455 630 E mail info wheels alcoa com Web www alcoawheels com For specific territory contact consult www alcoa com alcoawheels europe en info_page contact_us_europe asp Disclaimer This brochure has been compiled with great care Nevertheless no guarantees can be made as to the com pleteness correctness or currentness of the information contained in this brochure Alcoa Wheel Products cannot be held liable for the content of this brochure or for the consequences of the use thereof Therefore no rights can be derived from the information as presented in this brochure Alcoa Wheel Products reserves the right to change the information in this brochure at any time without prior notice or without stating the reasons for doing so 71 ALCOA WHEEL PRODUCTS EUROPE ieweg 135 3 L Belgium 11 458460 englisch April 2010 is E
65. nently stamping wheels with the date they are first placed into service 1 Use Lo Stress stamps or equivalent 2 Location of stamped areas on outside disc should be in space outward from a line between hand hole centers and a minimum of 2 5 cm or 1 0 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 Due to different mechanical properties of steel wheels and forged aluminium wheels a mixed dual may decrease the lifetime of one or the other It is therefore recommended not to use mixed fitments in vocational heavy load hauling fleets and or off road applications Note Use of an impression stamp on Dura Bright surface treated wheels can affect the appearance and perfor mance of the Dura Bright surface treatment local to the stamp e Do not exceed maximum wheel load Customer must compare OEM vehicle and OEM tyre load rating to maximum wheel load rating Some wheels are not designed for use on axles with disc brake systems For reference see wheel part numbers on Alcoa Wheel Specification Sheet 5 a Putting wheels in service hidden damage Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Do not overinflate Use the tyre manufacturer s recom mended pressure but under no circumstances exceed cold inflation pressure listed
66. ng 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 measure ment LONG CAP NUT A retrofit cap nut with a long extension sleeve used to secure dualed wheels see also SHORT CAP NUT MAXIMUM INFLATION The highest amount of air pressure allowed measured at normal ambient tempera tures approx 20 C or 68 F mm Abbreviation for millimeters NEWTON METERS FOOT POUNDS The measure of the amount of torque applied to a cap nut or other part May be measured with a torque wrench Nm Abbreviation for Newton meters torque meaure ment OFFSET See OUTSET amp INSET The distance from either wheel mounting surface to the rim centerline OPEN SIDE The side of the wheel opposite the disc face OUTER CAP NUT A cap nut used to secure the outer stud located wheel in a dualed wheel pair and threaded onto the inner cap nut not applicable for EU type Alcoa wheels OUTSET The distance from the mounting surface of the wheel to the rim centerline when the rim centerline is mounted outboard of the hub face This dimension is the same as the 1 2 DUAL SPACING dimension PILOT TAB or PAD SPIGOT The raised surfaces parts on a hub used to center a hub piloted wheel PSI Abbreviation for pounds per square inch pressure measurement
67. nge wear in your operation consider using Alcoa Dura Flange aluminium wheels These wheels have been specially treated to sig nificantly reduce rim flange wear Only Dura Flange wheels have a warranty on rim flange wear against sharp edges for a 24 month warranty period Dura Flange has a 24 month warranty against wear which creates a sharp edge that would require mainte nance as per Section 6 f ili Rim flange maintenance 6 g Cracked or damaged wheel checks 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 Immediately and permanently remove cracked or damaged wheels from service 6 9 1 Mounting area Stud hole cracks are usually caused by improper torquing see Sections 5 n ii and 5 n iii excessive loading or insuf ficient mounting flange support by the hub or brake drum Remove wheel from service NOTICE Minor wear or minor pitting is not a warrantable condition Edge re conditioning cannot be performed on Dura Flange wheels including those described in the rim flange maintenance Section 6 f iii The Alcoa Dura Flange leaflet is available on www alcoa com alcoawheels europe en info_page downloads asp Visually inspect wheels for cracks or damage Remove wheels from service with known or suspected damage Shown right are stud hole cracks emanating from bolt hole to bolt hole Causes are un
68. of the stud i e the drum for outboard mounted drums of drum brake operated axles to the first complete thread at the outside end of the stud outboard mounted drum inboard mounted drum il hub exposed shoulder first full thread drum stud standout mounting surface wP u a For safe mounting with replacing wheel studs the stud standout must cover Single mounting For use with 2 piece flange nuts and replacing studs the minimal stud standout must be 1x disc thickness Alcoa wheel height of nut 3 mm for use with M22 M20 or M18 x 1 5 threads or 2 full threads in case of other type of threading such as BSF Dual mounting For use with 2 piece flange nuts and replacing studs the minimal stud standout must be 2x disc thickness Alcoa wheel height of nut 3 mm for use with M22 M20 or M18 x 1 5 threads or 2 full threads in case of other type of threading such as BSF or UNF Example 1x 22 5 x 9 00 Alcoa wheel with 22 mm disc thickness and a regular 2 piece flange nut M22 x 1 5 result in a stud standout of 22 27 3 52 mm or UNF Example 2x 22 5 x 9 00 Alcoa wheels with 22 mm disc thickness and a regular 2 piece flange nut M22 x 1 5 result in a stud standout of 2x 22 27 3 74 mm 41 42 Stud availability Consult your truck or trailer OEM for availability of longer replacement studs in case of 26 24 or 21 mm mounting system i e longer studs amp standard nuts Extra long studs
69. ouge or nick the wheel Place aluminium wheels on clean wooden floor or rubber mat when hand mounting tyres Additional care should be used when mounting Alcoa Dura Bright surface treated wheels since minor nicks and scratches cannot be polished out see Section 7 b DiscMate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the wheel contact surfaces from marring Always use a rubber leather faced or plastic mallet Inspect the wheel for damage Do not use a damaged or severely corroded wheel see Section 6 g ii Clean the tyre bead seat areas with a wire brush Be sure the bead seat and drop center are dry before applying tyre lubricant Inspect the tyre for damage Be sure the inside of the tyre is dry before it is mounted Use of a non water based lubricant is recommended as a rim surface protection and tyre mounting lubricant Coat the entire rim surface see Section 5 9 iii single wheel 7 Lubricate the rim and tyre bead immediately before mounting the tyre 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 tyres as the air in the tyre is contained by the seal between the bead and tyre rim Never lubricate the rim or tyre bead with a flammable solution This can lead to an explosion during airing of the tyre or in su
70. ould be used in conjunction with death this Alcoa Wheel Service Manual This manual contains important safety information and warnings and failure to read and understand this information may result in serious injury or death Follow the proper wheel installation and mainte nance practices as contained in this Alcoa Wheel Service Manual The limited warranty is included with the Alcoa Wheel Service Manual but may appear elsewhere If you do not have copies of the Alcoa Wheel Service Manual you may obtain copies free of charge from Alcoa Wheel Products Europe Paal Belgium tel 32 11 45 84 60 or on www alcoa com alcoawheels europe en info_page technical asp Safety 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 tyres require the same 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 tyre and wheel assemblies from vehicles e demounting tyre from wheel e wheel inspections e mounting of tyre to wheel e inflation of tyre e handling and storing of inflated assembly e mounting of the assembly to the vehicle Safety and service information is readily available W
71. r tools severe rim flange wear STEP 4 These photographs show the process of removing the edge Using whatever tool is selected work the tool around the wheel s circumference removing only enough material to eliminate the sharp edge This should only bea 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 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 sharp edge removed 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 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 tyre 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 See sections 6 b c d
72. rd such as DiscMates are 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 the proper dilution and pH value NOTICE For maintenance of Dura Bright wheels that were and are subject to damage erosion and discoloring of the Dura Bright treatment refer to the Dura Bright service bulletin of May 2009 This bulletin is available upon simple request from Alcoa Wheel Products Europe tel 32 11 45 84 60 67 8 Glossary of common terms and conversion factors 68 8 a Glossary of common terms 1 2 DUAL SPACING One half the distance between the two center lines of dualed wheels The dimension is the same as the OUTSET dimension 15 The angle of the tyre bead s surface as used for tubeless tyres and wheels for medium and heavy duty vehicles 1 PIECE FLANGE NUT A one piece washer and nut com bination not recommended for use on any Alcoa wheel application 2 PIECE FLANGE NUT A two piece washer and nut com bination used to secure hub piloted wheels AIR CHAMBER The space enclosed by a tyre and wheel rim or inner tube latter not applicable for EU type wheels BEAD SEAT The area along the outer edges of the rim where the mounted tyre and rim are in contact BOLT CIRCLE The circle defined by the centers of the bolt holes stud holes of a wheel dimensions stated in
73. rious injury or death Inspect tyres and wheels for damage before removing from vehicle If damage is found tyre must be completely deflated before loosening cap nuts Immediately and permanently remove damaged tyres or wheels from service 5 g v Demounting of tubeless tyres NOTICE Not all tyre mounting demounting machines work alike Be sure to read the operating or instruction manual for your particular machine before attempting to mount or demount tyres Remove the valve core from the valve stem to ensure complete deflation Place wheel on machine and position tool so flat end can be driven between tyre bead and rim flange Straighten tool to a vertical position until bead is separated from wheel Repeat procedure at intervals until bead is totally separated from wheel Repeat procedure on other side of tyre Tyre is now ready for demounting Lubricate the tyre bead Insert curved end of tyre tools between tyre and wheel approximately 10 inches 25 cm 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 Insert straight end of tyre tool between beads and both rim flanges hooking stop on the tool over second flange Position inserted tool at 90
74. s A rubber sharpness gauge or a suitable piece of rubber attached to a block of wood NOTICE 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 page 59 If the rubber is not cut then the wheel can be returned to service without further work for rim flange wear Examine the tyre for cuts in the bead area and side wall If no damage occurred to these areas return the tyre to service Cut tyres should be removed from service The tyre should be inspected at this time for any other damage and be treated per normal tyre procedures recommended by the tyre manufacturer Check the wheel at every tyre 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 tyre 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 Do not run unprotected hands or fingers across worn rim flange areas of used wheels Worn rim flange areas are sharp and can cut hands or fingers Cuts can lead to infection Always wear gloves when handling used wheels or when testing for edge sharpness 6 f iii Rim flange maintenance edge removal procedures There are many tools available to remove the sharp e
75. set 0 81352X 81353X 81354X 81355X 22 5 x 11 75 offset 120 81356X 81455X 22 5 x 13 00 83352X 83353X 22 5 x 14 00 2 84151X 31 32 1 Wheel sizes that use Hofmann type 555 for the closed side and 556 for the open side These wheels can host adhesive weights Hofmann type 551 5 on the open side 2 Wheel sizes that use Hofmann type 556 on both sides but are also able to host adhesive weights Hofmann type 551 5 on both sides except 8845XX 8855XX 8945XX and 8955XX 2nd generation of Alcoa wheel rim flange design Adhesive weights Below listed wheels can be balanced with adhesive weights only and do not host clip on weights of any other make or kind Instructions for balancing Alcoa wheels with Hofmann adhesive weights type 551 5 e Alcoa wheels with part numbers mentioned below are designed for balancing with adhesive weights type 551 5 from Hofmann Suffix 5 indicates blue taped adhesive weights with heat resistance up to 180 C These wheels cannot be balanced with clip on weights Hofmann type 555 or 556 e The weights should always be applied against the small hump wedge i e as close as possible to the rim flange See chapter 5 h ii for instructions about application of adhesive balancing weights Wheel size 2nd gen Alcoa P N 19 5 x 7 50 19 5 x 8 25 225X70 22 5 x 8 25 22 5 x 9 00 22 5 x 11 75 offset 120 22 5 x 11 75 offset 135 22 5 x 17 00 offset 67 22 5 x 17 00 offset 50 3rd generat
76. sucsucsesaeeassncsucsucsucaeesseacsasssesseasees 57 iii Rim flange maintenance edge removal PrOCCAULES sscsscssssessessessessessscssssscsscsecsscsscsscenceseesessessscseeaesaecsucaecsucescenceseeseeses 59 u Dua FONE opea AS R 62 g Grackedo rd amaged wheel Checks arena ar ET 62 L MOUNINO ANC A e EE E A nae ere nee ie 62 W EOS OUD sean E ee 63 ie BO VCS saranen E A EEE A E O EE E E ETE EAS 64 Ne LECIO ee A 64 Vs O ee ee ee een 65 Wl BES SC AO ea ren 65 TCA NO N AND a ee HE R 66 a Maintenance against corrosion Brushed and Polished wheels cssssssssssesssssssssssssscssssesssssssssssecsessssassecsssseeseeseeacssssseeeesee 66 b Maintenance amp cleaning Dura Bright surface treated wheels ssssessssssssssssssssscssesscsscssessesssssessessesssssessncsessscsscsscesceseeseenss 67 c Maintenance Dura Flange wheels uni 67 8 Glossary of common terms and conversion fact ts nn nennen 68 E E ELO ESL E ee nen 68 o Ea SI Fa S E E E E OE E ast EE EE E EE A E TE VAE RE RUN 69 Se E o iE a AEST EEEN NAN AAA E EIES A TN AA N AN EN AIE AEAN A NAAN SER NER FEEERUEGENS 70 Please read the following instructions carefully This manual should be retained for later use This manual gives detailed information and is available on line at www alcoa com alcoawheels europe en info_page technical asp Free hard copies are available from Alcoa Wheel Products Europe and authorized Alcoa Wheel distributors upon simple request Contact
77. t that exposes the aluminium underneath the metal exposed may naturally oxidize but any corrosion will be confined to the metal exposed and will not extend into or underneath the Dura Bright treatment Normally any washing materials or chemicals including mild acid washes that can safely be used on a vehicle its painted surfaces and components can safely be used on the Dura Bright surface treatment The Dura Bright treatment prevents corrosion of aluminium wheels and protects their shine So long as the treatment remains in place see comments g and h on page 4 and is maintained in accordance with section 7 b of this manual it is warranted against corrosion If corrosion does occur within the treatment warranty period subject to the limitations stated above Alcoa will replace any wheel exhibiting such corrosion There is no warranty that the wheel shall be merchantable or fit for any particular purpose nor is there any other warranty express or implied except such as is expressly set forth herein Alcoa shall not be liable for any incidental or consequential damages for any breach of warranty its liability and the purchaser s exclusive remedy being limited to repair or replacement of the wheel as stated in this limited warranty Wheels that are not properly installed or main tained may not be safe Failure to follow proper wheel installation or maintenance practices may result in injury or This limited warranty sh
78. te of manufacture month day year in this case February 17 2003 prior to 2000 wheels may have month year only PART NO 874503 part number 22 5 X 7 50 15 DC wheel size for tubeless heavy duty tyres 1 2 or 3 packing line Wheels made as from 2009 ALCOA FORGED MAX LOAD 4500 kg 9920 LB wheel load rating MAX PRESS 900 kPa 130 PSI maximum inflation pressure HUNGARY made in can also be JAPAN MEXICO U S A 112309 date of manufacture month day year in this case November 23 2009 PART NO 812522DB part number 22 5 X 11 75 0 wheel size and offset T DOT FMVSS 120 designation e JWL T symbol Japanese impact test 4 e Table matching tyre to rim Before mounting a tyre to a wheel check if tyre and wheel size match Rim width to tyre matching chart most common sizes for medium and heavy trucks according to ETRTO Tyre size section code Normal Section Sizes 7 525 8 and 8 5 5 25 6 00 6 75 9 and 9 5 6 00 6 75 10 6 75 7 50 11 7 50 8 25 12 8 25 9 00 13 9 00 9 75 60 Series 285 60 8 25 9 00 295 60 9 00 9 75 305 60 9 00 9 75 315 60 9 00 9 75 65 Series 385 65 11 75 2 25 425 65 13 00 14 00 445 65 14 00 70 75 80 and 90 Series 205 5 25 6 00 6073 215 6 00 6 75 225 6 00 6 75 235 6 75 7 50 245 6 75 7 50 255 6 75 7 50 8 25 265 675 7 50 8 25 275 7 50 8 25 285 7 50 8 25 9 00 295 8 25 9 00 305 8 25 9 00 315 9 00 9 75 There may be addi
79. tional rim to tyre matches not shown here Contact the manufacturer or the Alcoa wheel sales manager for additional information see contact page on www alcoa com alcoawheels europe en info_page contact_us asp Specific tyre manufacturers may have other recommendations 10 4 f Wheel measurement How to measure minimum dual spacing Minimum dual spacing measurement is determined by the tyre manufacturer and may be obtained from the tyre manufacturer s handbook To determine if the Alcoa aluminium dual wheel assembly has adequate minimum dual spacing for the selected tyres double the wheel outset measurement of the Alcoa wheel used If the doubled outset measurement is equal to or greater than dual spacing tyre clearance vehicle clearance tyre section width center hole diameter bolt circle diameter wheel outset wheel inset back space 0 tyre center line a eS Sa eS YS the tyre manufacturer s recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel on the Wheel Specification Sheet Both inset and outset wheels are measured from the mounting surface of the wheel to the center line of the rim Maintaining proper tyre inflation and load ratings are essential to maintaining proper minimum dual spacing 4 g Mixed application of Alcoa and steel wheels Alcoa aluminium truck wheels can be operated dualled with a steel inner wheel In the event a steel inner wheel
80. to the wheel well Push bead over flange as far as possible 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 Lubricate the second tyre 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 tyre bead and flange and the stop towards the wheel push tool outward to work tyre over flange Continue to pry bead over flange using the tool until remaining bead is over flange Seat the tyre bead using an air ring or other mechanical bead seating aid Place tyre wheel assembly inside safety cage or other suitable restraint Refer to tyre manufacturer s recommen dation for proper tyre pressure Using a clip on air chuck or a self locking straight chuck with remote valve and pressure gauge inflate the tyre wheel assembly to proper pressure If air escapes roll tyre or use bead expander to force tyre beads against rim Be sure to stay out of the path of potential exploding parts or air blasts Heavy duty truck tyres have a guide rib molded into the sidewall next to the tyre bead When the tyre is inflated this guide rib or 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 t
81. y ALgrease as rim protector and a tyre mounting lubricant which does not contain metals and is pH neutral gt gt gt Use original Alcoa valves only These valves are specially made to fit Alcoa wheels and are not available in the after market replacement market Alcoa has made all listed valves starting with part number GAX available to its complete dealer network in Europe For more info please contact your local dealer distributor or Alcoa Wheel Products Europe POM Polyoxymethylene valve stem extensions are rec ommended and can be obtained from your authorized Alcoa Wheel Distributor Check the status and torque of valves and valves exten sions frequently For further information consult the preceding tables and the Alcoa Wheel Specification Sheet Tyres that are not properly fitted or maintained may not work properly Failure to follow proper tyre fitment or mainte nance practices may result in injury or death Follow the proper tyre fitment and maintenance practices as contained in the tyre manufacturers manuals and sections 5 g and 5 g i to 5 g vi of this manual gt gt gt Not all tyre mounting demounting machines work alike e Refer to tyre manufacturers recommendation for Be sure to read the operating or instruction manual for proper tyre pressure Do not over inflate your particular machine before attempting to mount e Use a protective cage during inflation or demount tyres Follow th

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