Service Manual for Alcoa Wheels1 Edition 3 (2022)

Service Manual for Alcoa^®Wheels¹Edition 3

Europe, Latin America, Asia and Oceania, Edition 3

January 2022 | Supersedes March 2017

Manual

Limited warranty for Alcoa^®Wheels¹

Safety

Wheel selection

4.a.

Specifi

Sheet for Alcoa^®Wheels

4.b.

Disc brake equipped axles

4.c.

General characteristics

4.d.

Identifi

of Alcoa^®Wheels

4.e.

Table: matching tyre to rim according to ETRTO standard

4.f.

Wheel measurement

4.f.i. How to measure minimum dual spacing (for dual mounted wheels)

4.f.ii. How to measure off

(for single mounted wheels)

4.g.

Mixed application of Alcoa^®Wheels

4.h.

Mixed application of Alcoa^®Wheels and steel wheels

4.i.

Owner / in-service identifi

Putting wheels in service

5.a.

Putting wheels in service / hidden damage

5.b.

Putting wheels in service / wheel alteration

5.c.

Putting wheels in service / mounting area and support surface diameters

5.d.

Putting wheels in service / before tyre mounting / WHEEL FITMENT CHECK

5.e.

Valves for Alcoa^®Wheels

5.e.i. Valves with black / orange T-shape grommet with 1-piece nut

5.e.ii. Valve nuts and torque

5.e.iii. Valves, general recommendations

5.e.iv. Replacing valves

5.e.v. TPMS valves and modules

5.f.

Valve extensions

Before mounting tubeless tyres

6.a.

Safety and compliance

6.b.

Tools and machines

6.c.

Inspection

6.d.

Matching of tyre, wheel, and axle load

6.e.

Valve

6.f.

Lubricant

6.g.

Mounting tyres on symmetrical and non-symmetrical drop well wheels

6.h.

Symmetrical drop well wheels with safety hump

Mounting tubeless tyres on Alcoa^®Wheels

7.a.

Mounting tyre to rim

7.b.

Manual operation mounting and demounting tubeless tyres

7.c.

Infl

and bead seating check

Defl

and demounting tubeless tyres from Alcoa^®Wheels

8.a.

Before defl

and demounting

8.b.

Machines, tools, and lubricants

8.b.i. Machines

8.b.ii. Tools

8.b.iii. Lubricants

8.c.

Defl

and demounting

Balancing Alcoa^®Wheels with adhesive weights

10. Wheel installation

10.a. Wheel installation preparation

10.b. At wheel installation

10.c. Hub centring

10.d. Disc thickness and thread engagement

11. Mounting hardware

11.a. Mounting Alcoa^®Wheels with standard 2-piece fl

nuts and replacing wheel studs

11.a.i. How to measure stud standout (axles with drum brakes)

11.a.ii. Confi

proper stud standout

11.a.iii. Availability nuts

11.a.iv. Availability studs

11.a.v. Extra-long studs

11.b. Mounting Alcoa^®Wheels with standard length studs and sleeved nuts

11.b.i. How to check suffi

thread engagement

11.b.ii. Wheel studs with unthreaded part / 'bottom out' condition

11.b.iii. Wheel studs inspection

11.c.

2-piece hex head sleeved nuts for Alcoa^®Wheels

11.d. Mounting hardware for Alcoa^®Wheels specifi

made for Volvo

12. Wheel nuts

12.a. Tightening nuts

12.b. Keep wheel nuts tight

12.c. Dualling with steel wheels

12.d. Incorrect assemblies

13. Wheels in service

13.a. Inspect thoroughly and frequently

13.b. Hidden damage

13.c. Wheel alteration

13.d. Heat damage

13.e. Dimension checks

13.e.i. Dimension checks

13.e.ii. Dimension checks

13.e.iii. Dimension checks

13.f.

Tyre wear or vibrations

13.g. Rim fl

wear

13.g.i. Alcoa^® Wheels rim fl

wear gauge instructions

13.g.ii. Determining rim fl

wear

13.g.iii. Rim fl

maintenance / edge removal procedures

13.g.iv. Dura-Flange^®

13.h. Cracked or damaged wheel checks

13.h.i. Mounting area

13.h.ii. Bolt holes

13.h.iii. Vent - or hand holes and disc area

13.h.iv. Rim area (drop centre, valve hole area and bead seats)

13.i.

Corrosion

13.i.i. Corrosion at hub bore and wheel disc or mounting face

13.i.ii. Corrosion at drop centre

13.i.iii. Corrosion at valve hole area

13.j.

Regular inspection and removal of corrosion

14. Care and Maintenance

14.a. Maintenance against corrosion for Brushed, Mirror Polished and LvL ONE^®wheels (non-Dura-Bright^®surface treated wheels) ... 87

14.b. Maintenance and cleaning Dura-Bright^®XBR^®and Dura-Bright^®EVO surface treated wheels

14.b.i. Maintenance and cleaning Dura-Bright^®XBR^®and Dura-Bright^®EVO surface treated Alcoa^®Wheels in 5 steps

14.b.ii. Additional care and tips for Dura-Bright^®XBR^®and Dura-Bright^®EVO surface treated Alcoa^®Wheels

14.c. Maintenance Dura-Flange^®wheels

15. Out-of-Service Wheels

16. Glossary of common terms and conversion factors

16.a. Glossary of common terms

16.b. Common terms

16.c. Conversion factors

17. Links and references

100

18. Contact

101

1. Manual

Please read the following instructions carefully. This manual should be retained for later use. This manual gives detailed

information and is available online on our website.

This manual applies to Alcoa^®Wheels produced by Howmet-Köfém Kft. (“Company”) as listed in the current European

Specifi

Sheet for Alcoa^®Wheels or older generation wheels from previous Specifi

Sheet publications.

Hard copies are also available from HowmetWheel Systems and authorized distributors of Alcoa^®Wheels upon request. Contact your

regional Howmet Wheel Systems location.

2. Limited warranty for Alcoa^®Wheels¹

(April 2020)

Thislimited warranty applies to Alcoa^® Wheels,including forged

(a)

Using a tyre which is oversized according to standards

aluminium wheels for medium duty and heavy-duty trucks, truck

recommended by the Tyre and Rim Association, Inc. or other

trailers, bus,RV ormotorhomewheels (“Wheels”) and the Howmet

recognized tyre and rim agencies such as ETRTO (Europe);

surface or rim fl

treatments applied to the Wheels. The

(b)

Failure to install, use and maintain Wheels in strict conformity

warranties set forth in this document apply to all Alcoa^®Wheels

with all applicable laws, regulations, codes and industry

(“Wheel(s)”) manufactured by Howmet and sold by Howmet orits

standards;

authorized distributor to an original purchaser of the Wheel or the

(c)

Loading the Wheel beyond the applicable maximum Wheel

end user of the Wheel.

load as specifi by Howmet;

(d)

Infl

tyres beyond the applicable maximum pressure as

Howmet warrants that the Wheel is free from defects in material

specifi by Howmet;

and workmanship for 60 months from the date of manufacture

(e)

Except as permitted by the Service Manual for Alcoa^®Wheels

as shown on the Wheel, provided that Howmet does not warrant

(“Service Manual”), changing the original condition of the Wheel

against and does not provide remedies for immaterial cosmetic

by alteration or by subjecting it to any processing or changes,

defects such as minor discoloration, buffi marks, or nicks.

such as welding, straightening, painting, coating, installing a

Howmet agrees, without charge, to repair or replace a Wheel

new tire valve, or heat treating;

that fails in normal use (see the qualifi

below) because of

(f)

Accidents or abnormal or severe operating conditions including

defects in material and workmanship. Howmet warrants the Alcoa

and without limitation tyre fi

brake fi

severe brake

Dura-Flange^®rim fl

treatment against wear which creates a

system drags or seizures or running with a fl tyre;

sharp edge that would require maintenance for 24 months from

(g)

Failure to follow maintenance, instructions or warnings set

the date of manufacture as shown on the Wheel. Howmet warrants

forth in the Service Manual, Technical Bulletins or other

the Alcoa Dura-Bright^®surface treatments against:

literature for Wheels. Recommended maintenance includes,

(i) fi corrosion (worm or hair like lines, underneath surface

without limitation, using proper torque, periodic cleaning,

protective treatment and emanating from damage to the surface

polishing, replacing the valve, inspecting rim fl

wear and

treatment); and

following rim fl

maintenance procedures, and periodically

(ii) blistering or peeling due to loss of adhesion of the surface

inspecting tyres and system components connected to the

treatment.

Wheel for damage and loose lug nuts;

The foregoing Alcoa Dura-Bright^®surface treatmentis warranted

(h)

Nicks, scratches and other surface blemishes resulting from

for 60 months from the date of manufacture as shown on the

neglect, road salt, harsh conditions, improper maintenance,

Wheel. If the Alcoa Dura-Flange^®rim fl

treatment or Alcoa

cleaning, road debris, curbing, accident or operation;

Dura-Bright^®surface treatment failin normal use or service (see

(i)

Rim fl

wear (unless the rim fl

has been treated with

the qualifi

section below) to meet the foregoing warranties

Dura-Flange^®);

on a Wheel, Howmet agrees, without charge, to replace the

(j)

Using a spacer or adaptor of any kind;

Wheel with a like or similar Wheel. Wheel replacement does not

(k)

Damaging the surface during tyre mounting and installation

include replacement of items manufactured by third parties, such

of the wheel [or] of the wheel on the vehicle due to the use of

as tire pressure monitoring systems and valve fi

Repair or

improper tools or balancing with wheel weights;

replacement, as provided for in this limited warranty, are subject to

(l)

Damage due to cleaning with strong chemicals (acids or

adherence to Howmet’s return material authorization process.

alkaline) or abrasives, such as abrasive brushes, steel wool, or

scouring pads; or

Qualifi

(m) further use of a Wheel after discovery of a defect.

Howmet is not liable for, does not warrant, and will not repair or

replace or make adjustment with respect to any Wheel or surface

or rim fl

treatment on such Wheel that has been subjected to

misuse, abuse or improper modifi

including the following:

^1.The “ALCOA” name and geometric symbol are registered trademarks of Alcoa USA Corporation and are licensed to Howmet Aerospace Inc. and

its subsidiaries.

THERE IS NO WARRANTY THAT THE WHEEL SHALL BE

This limited warranty should be used in conjunction with the

MERCHANTABLE OR OF SATISFACTORY QUALITY OR FIT FOR

Service Manual and the Dura-Bright^®Wheels Cleaning Guide.

ANY PARTICULAR PURPOSE, NOR IS THERE ANY OTHER EXPRESS

The Service Manual contains important safety information and

WARRANTY,EXCEPTSUCHASISEXPRESSLYSETFORTHHEREIN.

warnings. Failure to read and understand that information may

ANY TERMS OR WARRANTIES IMPLIED BY

result in serious injury or death.

APPLICABLE LAW ARE, TO THE FULLEST EXTENT PERMITTED BY

LAW, EXCLUDED IN RELATION TO THE SALE OF WHEELS. SAVE

Latest version of the limited warranty can be

FOR ANY LIABILITY WHICH CANNOT BE EXCLUDED

found here

OR LIMITED BY APPLICABLE LAW, HOWMET SHALL NOT BE

LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, INDIRECT OR

SPECIAL DAMAGES FOR ANY BREACH OF WARRANTY. HOWMET’S

LIABILITY AND THE EXCLUSIVE REMEDY AVAILABLE TO ANY

The Service Manual and cleaning guide are

PARTY RIGHTFULLY SEEKING WARRANTY COVERAGE IS LIMITED

available at www.alcoafl

or by contacting

TO REPAIR OR REPLACEMENT OF THE WHEEL AS STATED IN THIS

Howmet Wheel Systems Europe at the address

LIMITED WARRANTY.

below:

THIS LIMITEDWARRANTYDOESNOT APPLYTO ANDHOWMET

MAKES NO WARRANTY WHATSOEVER WITH RESPECT TO GOODS

Howmet-Köfém Ltd.

MANUFACTURED BY THIRD PARTY SUPPLIERS, SUCH AS TIRE

Fleet Service Center

PRESSURE MONITORING SYSTEMS AND VALVE FILTERS. ANY

1-15 Verseci út

WARRANTIES WITH RESPECT TO SUCH GOODS ARE LIMITED

H-8000 Székesfehérvár

TO THOSE WHICH ARE OFFERED BY SUCH SUPPLIERS AND ARE

Hungary

TRANSFERABLE.

Warning

Wheels that are not properly installed or maintained may not be safe.

Failure to follow proper wheel installation or maintenance practices may result in injury or death.

Follow the proper wheel installation and maintenance practices as contained in this Service Manual for Alcoa^®Wheels.

For the most recent update of the Service Manual and other useful

ETRTO (European Tyre and Rim Technical Organisation) Info

documents, contact your Howmet Wheel Systems location or go to

available at www.etrto.org

the web page

EUWA (Association of European Wheel Manufacturers) Info

available at www.euwa.org

ISO (International Organization for Standardization) Info available at

www.iso.org

JATMA (Japan Automobile Tyre Manufacturers Association) Info

Publications available for download from Howmet:

available at www.jatma.or.jp

• Service Manual for Alcoa^®Wheels

• Specifi

Sheet of Alcoa^®Wheels

SAE International (Society of Automotive Engineers) Info available at

• Cleaning of Alcoa^®Wheels

www.sae.org

• General Brochure for Alcoa^®Wheels

• … and many more

TIA (Tire Industry Association)

Info available at www.tireindustry.org

Information available through industry:

TMC (Technology and Maintenance Council) Info available at http://

tmc.trucking.org

DIN (German Institute for Standardization)

Info available at www.din.de/en

TRA (Tire and Rim Association) Info available at www.us-tra.org

3. Safety

Tubeless wheels and tyres require equal care. Even though tubeless

assemblies have fewer parts than multi-piece wheels, they still

Warning

require respect and proper handling.

Pay particular attention during crucial steps:

An infl

wheel and tyre assembly contains enough air

• Removal of tyre and wheel assemblies from vehicles

pressure to cause an explosive separation.

• Demounting tyre from wheel

• Wheel inspections

Unsafe handling or failure to follow approved mounting and

• Mounting of tyre to wheel

demounting procedures can lead to serious injury or death.

• Infl

of tyre

• Handling and storing of infl

assembly

Study, understand and follow the procedures contained in

• Mounting of the assembly to the vehicle

this manual.

Safety andserviceinformationis readily available.Wheel, tyre, and

Safety is serious and everyone's business. Do not attempt to service

service equipment manufacturers off service manuals and

any wheel assembly without proper training.

other training materials. Stay up to date on proper procedures and

keep current instructional materials readily available in the shop.

Proper equipment is important. Be sure to have the recommended

Study safety and service information and practice it on the job.

tools and equipment on hand and use them according to

manufacturers’ instructions.

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, statis-

tically one in every 10 serious accidents is a fatality.

That’s 100 times more often than in most other

industries.

1 in 1000

1 in 10

TYPICAL INDUSTRY

THE SERVICE INDUSTRY

Graphic 3-1

Introduction

As theleading manufacturer of aluminium wheels, we advanced

Find the most nearby to you here:

the transportation industry with the fi forged aluminium

wheel in 1948 and have been reinventing it ever since. Find more

Alcoa^®Wheels is a brand and product of the

information on our website: www.alcoawheelseurope.com

Howmet Wheel Systems business unit, which is

part of Howmet Aerospace Inc. (formerly known as Alcoa Inc.).

Alcoa^®Wheels is the best solution for your business. We off

a wide range of forged aluminium wheel dimensions. Our

high-quality Alcoa^® Wheels can be selectedin the truck, bus and

trailer manufacturer's option books as well as they are available

through our wide network of authorized Alcoa^®Wheels distributors.

4. Wheel selection

4.a. Specifi

Sheet for Alcoa^®Wheels

Wheel specifi

listed in the Specifi

Sheet are subject

Note: Dura-Bright^®wheels produced after November 2002

to change without prior notice. For information consult the latest

have the part number for Alcoa^®Wheels ending with “DB”. The

‘Specifi

Sheet’ for Alcoa^®Wheels, contact

Dura-Bright^®surface treatment is available on most wheel sizes.

Howmet Wheel Systems or an authorized

distributor of Alcoa^®Wheels. To view the

Note: Dura-Flange^®wheels have the part number for Alcoa^®Wheel

document online or download go to:

ending with “DF”. The Dura-Flange^®rim fl

treatment is also

available on Dura-Bright^®surface treated Alcoa^®Wheels.

The Specifi

Sheet for Alcoa^®Wheels

Note: the part number for Alcoa^®Wheels ending with “DD”

contains the current part number availability and complete

indicates a Dura-Bright^®and Dura-Flange^®surface treated wheel.

specifi

such as wheel dimension, off

(inset), half dual

spacing (outset) and load rating. It is recommended to keep old

Specifi

Sheets for later reference.

4.b. Disc brake equipped axles

Most Alcoa^®Wheels come with a protected or outboard valve

Europe:

design that reduces the risk that during rotation foreign parts like

All current produced 22.5” and 19.5” Alcoa^®Wheels have a protected

stones entered in the inner wheel area can be taken up by the

or outboard valve design that can be mounted on axles with disc

valve. Objects striking the static brake caliper of a disc brake system

brakes. Some 17.5” Alcoa^®Wheels do not have a protected valve

can lead to damages on the valve or brake caliper. Objects getting

design (inboard valve) and can be fi

on axles with drum

stuck between the static brake caliper and rotating wheel can also

brakes only. See Specifi

Sheet for Alcoa^®Wheels.

lead to damage and premature failure of the wheel.

Asia, Latin America and Oceania:

Consult the regional Howmet location for details with regards

to use of inboard valve design wheels with disc brake operated

vehicles or disc brake operated axles.

Graphic 4-1 Outboard valve

Graphic 4-2 Inboard valve

4.c. General characteristics

Wheel material:

forged aluminium alloys

Approvals by:

LBF, TÜV, KBA, JWL-T and all European MD and HD commercial vehicle manufacturers, INMETRO

Certifi

from:

ISO 14001: 2015 (Environmental Management System)

IATF 16949: 2016 (Quality Management System)

Tyre sizes:

All ETRTO approved sizes

Maximum infl

pressure:

900 kPa, 130 psi (cold), unless stated otherwise

Nuts:

2-piece nut or 2-piece sleeved nut following DIN 74361-3 standards

Mounting:

Hub centred following DIN 74361-3 standards

Valve torque:

12 to 15 Nm (9 to 11 Ft-Lb)

Wheel nut torque:

Recommended by vehicle - or axle manufacturer

Availability wheels:

Through all vehicle manufacturers or authorized distributors of Alcoa^®Wheels

4.d. Identifi

of Alcoa^®Wheels

Since 1977, all Alcoa^®Wheels are identifi with a roll stamp that

Alcoa^®Wheels may have markings in the roll stamp to designate

shows the wheel load rating, maximum infl

pressure, date of

certifi

in other regions as follows:

manufacture, part number, wheel description and United States

• Wheels approved by INMETRO, the Instituto Nacional de

DepartmentofTransportation (DOT)markingdesignation.

Metrologia, are marked with the symbol [symbol INMETRO].

• Wheels approved by the Japanese Ministry of Transportation,

Prior to June 1996, all heavy-duty vehicle Alcoa^®Wheels had the

are marked with the symbol [symbol Japanese Ministry of

Alcoa^®identifi

symbol [symbol Alcoa^®identifi

on the

Transportation].

outside of the disc near the hand hole in line with the valve location.

This marking was phased out on heavy duty vehicle wheels

All Dura-Bright^®surface treated wheels have the letters “DB” after

manufactured after June 1996.

the part number e.g., 89U513DB.

Identifi

of Alcoa^®Wheels is usually located 180 degrees from

All Dura-Flange^®wheels have the letters “DF” after the part number

the valve stem on the open side of the wheel.

e.g., 88U520DF.

IMPORTANT

Wheels treated with both Dura-Bright^®and Dura-Flange^®have the

Wheel identifi

must be legible. Wheels should be taken out of

letters "DD" after the part number e.g., 88U513DD.

service and scrapped if this identifi

is not legible or does not

meet requirements.

Symbol Alcoa^®identifi

Symbol INMETRO

Symbol Japanese Ministry of

Transportation

Graphic 4-3

Graphic 4-4

Graphic 4-5

Wheels made between 1996 and 2009

• ALCOA^®FORGED

• MAX LOAD 3550 Kg (wheel load rating)

• MAX KPa 952 (maximum infl

pressure)

• T-DOT (FMVSS 120 designation)

• JWL-T (symbol Japanese impact test)

• MADE IN HUNGARY (can also be: JAPAN / MEXICO / U.S.A.)

•

021703 (date 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)

Picture 4-6

Wheels made between 2009 and 2012

• ALCOA^®FORGED

• MAX LOAD 4500 kg (9920 LB) (wheel load rating)

• MAX PRESS. 900 kPa (130 PSI) (maximum infl

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 off (inset) or half dual spacing

(outset))

• T-DOT (FMVSS 120 designation)

• JWL-T (symbol Japanese impact test)

Picture 4-7

Wheels made between 2012 and 2017

•

22.5 X 9.00 - 176 (wheel size and off (inset) or half dual

•

spacing (outset))

• MAX LOAD 4125 kg (9090 LB) (wheel load rating)

• MAX PRESS. 900 kPa (130 PSI) (maximum infl

pressure)

• ALCOA^®FORGED

• MADE IN HUNGARY (made in…) (can also be: CHINA / JAPAN /

MEXICO / U.S.A.)

Picture 4-8

• REG 000809/2012 (Inmetro registration number/year)

(preceded by Inmetro logo)

• T-DOT (FMVSS 120 designation)

• JWL-T (symbol Japanese impact test)

•

011416 (date of manufacture month/day/ year, in this case

January 14, 2016)

• PART NO 892510 (part number)

Wheels made as from 2017

•

22.5 X 9.00 - 176 (wheel size and off (inset) or half dual

spacing (outset))

• MAX LOAD 4125 kg (9090 LB) (wheel load rating)

• MAX PRESS. 900 kPa (130 PSI) (maximum infl

pressure)

• FORGED

• MADE IN HUNGARY (made in…) (can also be: CHINA / JAPAN /

MEXICO / U.S.A.)

• REG 000809/2012 (Inmetro registration number / year

Picture 4-9

preceded by Inmetro logo)

• T-DOT (FMVSS 120 designation)

• JWL-T (symbol Japanese impact test)

•

120516 (date of manufacture month/day/ year, in this case

December 5, 2016)

• PART NO 892513DB (part number)

4.e. Table: matching tyre to rim according to ETRTO standard

Before mounting a tyre to a wheel check if tyre and wheel size

Contact Howmet Wheel Systems or an authorized distributor of

match.

Alcoa^® Wheels as:

• Some wheel dimensions listed in this table may not be available

Contact the manufacturer of the tyre as:

in certain continents

• There may be additional rim to tyre matches not shown here

• Specifi tyre manufacturers may have other or supplementary

Note:

recommendations

• Do not load wheel beyond its maximum load capacity

• Do not infl

assembly beyond the maximum infl

pressure

as indicated in the roll stamp. See 4.d.

Rim width to tyre matching chart for commercial vehicle tyre sizes according to ETRTO Standards Manual 2021

Tyre size/ section code

Approved rim contours (dimensions in inches)

Normal Section Sizes

8 and 8.5

5.25

6.00

6.75

9 and 9.5

6.00

6.75

7.50

8.25

9.00

9.75

‘70’, ‘75’, ’80’ and ‘90’ Series

205

5.25

6.00

6.75

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

6.75

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

365

9.75

11.75

10.50*

375

9.75

11.75

445

13.00

14.00

605

18.00

*standardized by TRA for 365/70

Chart 4-10

Rim width to tyre matching chart for Free Rolling Tyres (FRT*) sizes according to ETRTO Standards Manual 2021

Tyre size/ section code

Approved rim contours (dimensions in inches)

Normal Section Sizes FRT

9.5

17.5

6.00

6.75

17.5

6.75

7.50

22.5

7.50

8.25

22.5

8.25

9.00

’75’ Series FRT

215/75

17.5

6.00

6.75

235/75

17.5

6.75

7.50

’70’ Series FRT

245/70

6.75

7.50

255/70

22.5

6.75

7.50

8.25

265/70

17.5

6.75

7.50

8.25

265/70

19.5

7.50

8.25

275/70

22.5

7.50

8.25

285/70

19.5

8.25

9.00

‘65’ Series FRT

205/65

17.5

6.00

6.75

385/65

19.5

11.75

12.25

425/65

22.5

12.25

13.00

14.00

445/65

22.5

13.00

14.00

‘60’ Series FRT

255/60

19.5

7.50

8.25

275/60

19.5

8.25

9.00

’55’ Series FRT

265/55

19.5

8.25

385/55

11.75

12.25

425/55

19.5

13.00

14.00

‘50’ Series FRT

435/50

14.00

15.00

‘45’ Series FRT

445/45

19.5

14.00

15.00

455/45

22.5

14.00

15.00

‘40’ Series FRT

365/40

19.5

11.75

455/40

22.5

15.00

16.00

FRT* or Free Rolling Tyres: commercial vehicle tyres restricted to the equipment of

non-driven axles, excluding motor vehicle front steering axles

Source: European Tyre and Rim Technical Organisation -Standards Manual- 2021

Chart 4-12

4.f.

Wheel measurement

4.f.i. How to measure minimum dual spacing (for dual mounted wheels)

Minimum dual spacing measurement is determined by tyre

there will be enough minimum dual spacing. Wheel half dual

manufacturers and may be obtained from the tyre manufacturers’

spacing (outset) and off

(inset) is given for each wheel on the

handbooks. To determine if an assembly with dualled Alcoa^®

Specifi

Sheet for Alcoa^®Wheels.

Wheels have adequate minimum dual spacing for the selected

tyres, double the wheel half dual spacing or outset measurement of

Both off (inset) and half dual spacing (outset) of wheels are

the Alcoa^®Wheels used.

measured from the mounting surface of the wheel to the centreline

of the rim. Maintaining correct tyre infl

and load ratings are

If the doubled half dual spacing or outset measurement is equal

essential to maintain enough minimum dual spacing.

to or greater than the tyre manufacturers’ recommendations,

1. Dual spacing

2. Tyre clearance

3. Vehicle clearance

4. Tyre section width

5. Hub bore

6. Bolt circle

7. Wheel outset, or half dual spacing

8. Wheel inset, or off

9. Back space

10. Tyre / rim centreline

Graphic 4-13

Alcoa^®Wheels that can be mounted in dual position show the Half

DUAL MOUNTING

Dual Spacing (HDS) behind the wheel dimension (e.g., 22.5 x 9.00

- 176) in the roll stamp. This means the HDS is 176 measured in

DO NOT mount wheels with a diff

Half Dual Spacing (HDS),

millimetres.

unless vehicle or trailer axle manufacturer approved:

• Never mount wheels with a smaller Half Dual Spacing as there is

HMA: abbreviation of Halber Mittenabstand, commonly used on

a risk of tyres “kissing” in loaded condition. This will generate heat

German made wheels, stands for Half Dual Spacing (HDS).

and may cause tyres to blow out.

• Mounting wheels with a smaller Half Dual Spacing reduce the

track width. The stability and/or suspension components of the

vehicle may be compromised especially when loaded or curving.

4.f.ii. How to measure off

(for singlemountedwheels)

The off (or inset) measurement is determined by the vehicle or

Alcoa^®Wheels that can be mounted in a single position only, show

(trailer) axle manufacturer and may be obtained from the vehicle or

the off

(or inset) after the wheel dimension

axle manufacturers’ handbooks. To determine if the wheel matches

(e.g., 22.5 x 11.75 - 120) in the roll stamp. This means the off

the recommended off (or inset) of a vehicle or trailer axle, consult

120 measured in millimetres.

the Specifi Sheet for Alcoa^®Wheels.

ET: abbreviation of Einpresstiefe, commonly used on German made

wheels, stands for off

(or inset).

a Rim (tyre) centreline

a) Rim (tyre) centreline

b) Mounting fl

wheel disc

c) Off

or inset:

Off (mm)

distance rim centreline to mounting fl

measured in Millimetres

Mounting fl

Graphic 4-14

SINGLE MOUNTING

Off

/inset higher / lower

DO NOT mount wheels with a diff

off

(or inset), unless

• Alteration of the tyre / rim centreline will distribute loads

vehicle or trailer axle manufacturer approved: e.g., do not fi 22.5 x

diff

on the bearings. It may shorten the service life or

11.75 with off (or inset) 120 at axle where off

135 is

cause failure of bearings. It may generate heat to one or the

standard, or do not fi 22.5 x 11.75 with off

135 where off

120

other bearing, causing or igniting a fi

is standard.

• Geometry of the alignment of axles can be infl

causing

diff

manoeuvrability of the vehicle.

Off

/ inset higher

• Wheel or tyre may contact parts of brakes, steering, suspension

Off

/ inset lower

or chassis. This may cause a tyre blow out, damage to

• The wheel tyre assembly may exceed the allowed maximum

components with the risk of accidents causing injuries or death.

vehicle width voiding road and traffi regulations.

• The stability and/or suspension components of the vehicle may

be compromised especially when loaded or curving.

Note:

Off

(Inset) + wheel disc thickness = Half Dual Spacing (Outset). For reference consult Specifi

Sheet for Alcoa^®Wheels or wheel data

specifi

sheets of other steel or alloy wheels if used.

4.g. Mixed application of Alcoa^®Wheels

Changes to design and specifi

may result in a mix of Alcoa^®

The combined load rate of the wheels must meet or exceed the

Wheels on one vehicle or one axle.

load rating of the axle. Consult the vehicle - or axle specifi

When mixing Alcoa^®Wheels on one axle, wheel dimension, bolt

Trucks, buses, and trailers may have a variety of wheel load ratings

hole diameter and off for single mounting or half dual spacing

on one vehicle. It is mandatory to respect the vehicle or axle OEM’s

for dual mounting must match.

homologation as well as local and national road vehicle legislation.

4.h. Mixed application of Alcoa^®Wheels and steel wheels

Alcoa^®Wheels can be operated in dual mounting with a steel wheel

IMPORTANT

mounted at the inner position. In the event a steel inner wheel is

Consult and respect the vehicle or axle OEM’s homologation as well

used, extreme care must be taken to properly mount both wheels

as local and national road vehicle legislation for the application of

to the hub.

mixed assemblies e.g. steel and aluminium wheels on one axle or

one vehicle.

The selection of correct hardware i.e., nuts, sleeved nuts and studs

are crucial to obtain a safe fi

as well as enough pilot tab

length on the hub to properly centre the outer aluminium wheel.

Both wheels, steel and Alcoa^®Wheels, must match wheel size and

half dual spacing (outset), wheel load index, as well as being fi

with identical tyres and tread of the same depth.

A mixed dual fi

is subject to all recommendations and

guidelines that apply for safe and proper fi

of a steel dual

and aluminium dual fi

referring to manuals of steel wheel

^®Wheels.

manufacturer and the Service Manual for Alcoa

Graphic 4-15

Warning

When mounting painted steel wheels with Alcoa^®Wheels, in dual application, be cautious of excessive paint build-up on the steel

wheel.

Excessive paint (> 90 μm or 3.5 mil) can reduce the clamping force and allow the wheels to become loose, which can lead to serious

injury or death.

Follow the proper wheel installation and maintenance practices as described in this Section.

For more information about mounting and hardware for Alcoa^®Wheels see Sections 10, 11 and 12

When mounting a steel wheel at the inside position and an aluminium wheel with sleeved nuts on the outer position it is important to

a) Determine the amount of threading engaged as set forth in Section 11.b.

b) Check if no ‘bottom out’ condition occurs when using long sleeved nuts as described in Section 11.b.ii.

✓

❌

Graphic 4-16

Graphic 4-17

Warning

The use of a wrong selection of wheels and hardware may result in improper fi

of wheels.

Improper mounting of wheels may lead to separation of wheels or loss of assemblies from the vehicle.

Separating wheels or loss of assemblies from the vehicle can lead to injuries or death.

For more information about mounting and hardware for Alcoa^®Wheels see Sections 10, 11 and 12

HUB ENGAGEMENT

1. Stud standout and thread engagement (hardware)

For use with 2-piece fl

nuts and replacing (with longer) studs

For use with 2-piece sleeved nuts and maintaining the original studs

the minimal stud standout must be:

the minimal number of thread engagement between stud and nut

1x disc thickness steel wheel + 1x disc thickness Alcoa^®Wheel +

must be:

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

• 14 full turns for M22 x 1.5

(Metric, Volvo from 2005)

UNF).

• 13 full turns for M20 x 1.5

(Metric)

• 12 full turns for M18 x 1.5

(Metric)

Example: the disc thickness of 1x steel wheel and 1x Alcoa^®Wheel

• 10 full turns for 7/8”-11 BSF

(Scania)

added with a regular 2-piece fl nut M22 x 1.5 must result in a

• 12 full turns for 7/8”-14 UNF

(Volvoupto2004)

minimal stud standout of 14 + 22 + 27 + 3 = 66 mm.

2. Piloting

Hubs designed for steel hub piloted wheels may not have enough

pilot length to locate dualled Alcoa^®Wheels or with a wheel from

Alcoa^®Wheels at the outer position and a steel wheel at the inner

position.

Pay close attention to the pilot tab length, particularly when

converting from dualled steel wheels to dualled aluminium wheels.

Measure the hub pilot tab to make sure the hub has a minimum

pilot tab length that allows no less than 5 mm for the outer wheel

to be centred, excluding the bevelled edges.

For example:

The horizontal part of the pilot tab should be at least 27 mm in

case theinner aluminium wheel’s disc thicknessis 22 mm. The

horizontal part of the pilot must be at least 19 mm for a mixed dual

in case theinner steel wheel’s disc thicknessis 14 mm.

Picture 4-18

3. Torque

When dualling steel wheels with Alcoa^®Wheels, follow the vehicle

manufacturers’ recommendations regarding the proper torque and

use of thread lubricants to mount the wheel.

Caution

Steel wheels and forged aluminium wheels have diff

IMPORTANT

mechanical properties.

On occasion Alcoa^®Wheels are dualled with steel wheels: it

Due to the diff

of mechanical properties, it may

is recommended that Discmates for Alcoa^®Wheels or nylon

decrease the lifetime of one or the other.

protection gaskets are used to help prevent corrosion. See picture

4-19.

It is therefore recommended not to use mixed fi

in vocational, heavy load hauling fl

and/or off

In the event a steel wheel is used at the inner position, extreme

applications.

care must be taken to properly seat it to the hub or drum before

mounting the aluminium wheel at the outer position.

Selection of the correct hardware is required as providing adequate

thread length, to secure the outer aluminium dual wheel, is critical

to a safe assembly.

Howmet Wheel Systems recommends the use of sleeved nuts for

this purpose.

Picture 4-19

4.i.

Owner / in-service identifi

Some fl

wish to identify wheels as to OWNERSHIP and IN-SERVICE dates. Howmet Wheel Systems advises fl

and owners to stamp

wheels with the date they are put 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 centres and a minimum of 2,5 cm

or 1 inch from the periphery of any hand hole.

3. Location of stamped identifi

on inside of wheel should be as close to the factory identifi

stamping as possible.

Note: Use of an impression stamp on Dura-Bright^®surface treated wheels can aff

the appearance and performance of the Dura-Bright^®

surface treatment at the stamp and in the stamp area.

5. Putting wheels in service

Warning

• Do not exceed the maximum wheel load indicated on the

• Some wheels are not designed for use on axles with disc

wheel.

brake systems.

• Exceedingthemaximumwheelloadmaycause the

• Attempting to mount or use wheels that are not designed

wheel / tyre to explode causing serious injury or death.

for axles with disc brake systems may cause wheel or

• Customer must compare vehicle and tyre load rating to

vehicle components to fail causing injuries or death.

maximum wheel load rating.

• For reference see part number on the wheel and

Specifi

Sheet for Alcoa^®Wheels to ensure the wheel

can be used on disc brake operated axles / vehicles.

Before mounting the tyre, always perform a wheel fi

check to

ensure proper clearance from any obstructions. See ‘Wheel fi

check’ Section 5.d.

Warning

• Do not over-infl

the tyre / wheel assembly.

• Exceeding the maximum wheel load may cause the wheel / tyre to explode causing serious injury or death.

• Refer to tyre and wheel manufacturers’ recommendations for correct tyre pressure.

The maximum wheel load rating and infl

pressure is in the wheel's roll stamp. See Section 4.d.

Under no circumstances exceed cold infl

pressure listed by the tyre - and wheel manufacturer that is indicated on the tyre and wheel.

5.a. Putting wheels in service / hidden damage

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 cracks, fretting, enlargement, and

elongation which can occur if the nuts are not kept tight. See

Section 12.a. Dirt streaks radiating from bolt and / or vent holes

may indicate loose nuts. See picture 5-1.

Picture 5-1

5.b. Putting wheels in service / wheel alteration

Howmet Wheel Systems does not approve any form of alteration

Wheel identifi

must be legible. Wheels should be taken out

to wheels except minor cosmetic buffi for appearance purposes.

of service if such identifi

is not legible or does not meet

Sanding and/or grinding is permitted to maintain the rim fl

requirements.

area of the wheel. See Section 13.g.

Do not alter wheels by welding, brazing or other heat application,

Warning

e.g., powder coating, in an attempt to repair or straighten a wheel.

Welding, brazing or otherwise heating any area of Alcoa^®

Use of adapter plates or bead-locks are not approved on Alcoa^®

Wheels will weaken the wheels.

Wheels.

Weakened or damaged wheels can lead to an explosive

Do not paint, powder coat or otherwise coat wheels in any way that

separation of tyres and wheels or wheel failure on the

may interfere with the mounting surfaces.

vehicle. Explosive separations of tyres and wheels or wheel

failure on the vehicle could cause serious injuries or death.

Any wheel that shows signs of alteration should be removed from

service and scrapped.

Never attempt to weld, braze, or heat any surface of Alcoa^®

Wheels.

5.c. Putting wheels in service / mounting area and support

surface diameters

The support surface or backup of the hub should be fl to the diameter recommended (per ISO 4107, SAE

J694 and DIN 74361-3) below to properly accommodate the wheel disc area.

Backup

Graphic 5-2

Applicable to hub pilot mounting type Alcoa^®Wheels:

Howmet

ISO 4107 Backup

SAE J694 Backup

DIN 74361-3

Bolt circle Ø mm

Nr of bolts

Thread size

recommended

Ø mm

Backup Ø mm

backup Ø mm

205

M18 x 1.5

250 - 251

245 - 250

250

245 - 251

245

M18 x 1.5

290 - 291

290

285 - 291

275

M20 x 1.5

320 - 321

315 - 320

320

315 - 321

275

M22 x 1.5

334 - 343

320

334 - 343

225

M22 x 1.5

270

273 - 279

335

M22 x 1.5

385 - 386

380 - 385

385

380 - 386

Chart 5-3

Warning

• Due to the limited contact area of star shape hubs, proper maintenance and cleaning of hub, wheel and mounting hardware is

important.

• As per recommendation from the Association of European Wheel Manufacturers, EUWA, wheels used on star shape hubs must be

checked for cracks on the inner and outer attachment face each 50.000 km.

• In case cracks are detected wheels must be removed from service immediately and permanently.

5.d. Putting wheels in service / before tyre mounting / WHEEL FITMENT CHECK

• Do not exceed maximum wheel load. Customer must compare

attempt to soften them for straightening or to repair other

OEM vehicle axle load ratings to maximum wheel load ratings.

damage. The special alloy used in these wheels is heat-treated,

• Refer to tyre manufacturers’ recommendations for proper tyre

and uncontrolled heating will weaken the wheel.

pressure.

• Do not weld the wheels for any reason.

• Before mounting the tyre, perform a wheel fi check to

• When tyres are removed, the entire wheel must be cleaned and

ensure proper clearance from any obstructions. See ‘Wheel

inspected. With a brush, remove any contamination from the

check’.

wheel’s bead seats (portions of the wheel that support the tyre).

• Do not use a wheel that has been subjected to high pressure tyre

• Check the wheel’s fl

for wear with Alcoa^®Wheels' Rim

and rim separation, run fl excessive heat, or other physical

Flange Wear Gauge. REMOVE SHARP EDGES ON THE RIM FLANGE

damage. A wheel subjected to any of these conditions may no

as explained in Section 13.g.iii.

longer have a correct dimension and contour to retain the tyre

• It is recommended that valves are replaced at every tyre change.

bead while under pressure.

See Section 5.e.iv.

• A cracked or damaged wheel may cause the wheel to fail or

• It is recommended to lubricate wheel fl

wheel bead seats

come off the vehicle while the vehicle is moving.

and tyre beads each time the tyre is mounted or demounted.

• Do not straighten the wheels. Do not heat the wheels in an

Wheel fi

check

1. Remove current wheel(s) from axle end(s) to perform fi

checkasnecessary.

2. Clean the mounting surface of the hub and mounting surface of the wheel to be installed (see Section 10.1. steps 1, 2 and 3).

3. Place the wheel for the fi

check over studs and hold the wheel on the hub and check for a fl

mount. The mounting surface of

the wheel (and balancing weights) must fi fl to the hub mounting surface. The backside of the wheel (and balancing weights) must

not rest against any obstructions, such as the brake calliper, steering and suspension components, rivets, etc.

4. Install three nuts and hand tighten. Rotate the wheel (and turn the steering column fully in both directions if checking the steer

position) to ensure clearance from any obstructions.

5. Repeat steps for each axle end as applicable.

5.e. Valves for Alcoa^®Wheels

New Alcoa^®Wheels come with valves fi

All valves and valve

If the P/N of a wheel and matching valve is not found contact

nuts are nickel plated and come with a metal dust cap that includes

Howmet Wheel Systems or an authorized distributor of Alcoa^®

a seal for air tightness. Metal valve caps are recommended.

Wheels:

Valves used by Howmet Wheel ^Systems for Alcoa^®Wheels are

standardized by ETRTO: the use of valves that do not meet

these specifi

or non-genuine valves may jeopardize the

roadworthiness of the vehicle or safety.

Consult the Specifi

Sheet for Alcoa^®Wheels for the correct

and matching valve when ordering and replacing valves.

Original equipment valves and - replacement valves may be

obtained from an authorized distributor of Alcoa^®Wheels

Note: Metal valve stem caps are required per DOT (Department of

Transportation) instead of plastic.

5.e.i. Valves with black / orange T-shape grommet with 1-piece nut

40MS-00N, 54MS-00N, 60MS-00N (not pictured), 70MS-07N2,

It also reduces the chance of damaging the valve hole when

83MS-00N original equipment valves (Picture 5-4)

applying too much torque to the valve nut.

70MS-27N, 70MS-45N (not pictured), 70MS-60N (not pictured)

Thesevalvesdonotnecessarily needlubricationorgreasingwhen

replacement valves (Picture 5-5)

checking or replacing.

Thesevalves come with a 1-piecenutwith enlarged contact surface

Lubrication or greasing helps to prevent corrosion and eases the

that evenly distributes the forces in the valve hole area.

insertion of the valve when mounting. See VALVEgrease.

Picture 5-4

Picture 5-5

VALVE grease

When mounting or replacing valves use VALVEgrease for

Alcoa^®Wheels or a non-water and non-metal-based lubricant.

DO NOT use tyre mounting paste when mounting or replacing

metal valves.

VALVEgrease for Alcoa^®Wheels is available from authorized

distributors of Alcoa^®Wheels.

Picture 5-6

Check the Specifi

Sheet for Alcoa^®Wheels for the correct and matching valve. If the P/N is not found contact

Howmet Wheel Systems or an authorized distributor of Alcoa^®Wheels.

See the Specifi

Sheet for Alcoa^®Wheels:

Original equipment valves and - replacement valves may be obtained from an authorized distributor of Alcoa^®Wheels.

Caution

Valves with a T-shape grommet may get squeezed or folded upon installing.

As a result, the T-shape grommet may get cut or torn causing air loss.

Carefully insert the valve to avoid the T-shape grommet from being squeezed or folded. Lubrication or greasing helps to ease the

insertion of the valve when mounting.

5.e.ii. Valve nuts and torque

Valves for Alcoa^®Wheels have 14, 16 mm or 5/8” hex nuts. The recommended torque is 12 to 15 Nm (9 to 11 Ft-Lb).

5.e.iii. Valves, general recommendations

DO’s

DON’Ts

1. It is recommended that valves be replaced at every tyre change

1. Do not fi valves for steel wheels. Valves for steel wheels may

with an original / genuine valve for Alcoa^®Wheels which are

have diff

diameters, diff

bends (angles) and/or

available from authorised Alcoa^®Wheel distributors.

insuffi

thread length.

2. Before mounting the new valve, check if the valve corresponds

2. Do not use brass valves without plating. Aluminium and brass

with the wheel. Use the Specifi

Sheet for Alcoa^®Wheels

cause accelerated galvanic corrosion. This corrosion may result

for reference.

in leakage.

3. To avoid loss of air by improper fi

Alcoa^®Wheels should

3. Do not bend the standard valve to another shape.

be fi

with chrome- or nickel-plated valves that meet the

4. Do not use rubber O-rings or grommets.

standards and that are specially designed for Alcoa^®Wheels.

5. Do not use tyre mounting paste when installing or replacing

4. When replacing O-rings or grommets, use silicone, Viton^®or

valves.

EPDM O-rings or grommets.

6. Do not infl

the tyre with air coming from an air system, using

5. When replacing valve stems, it is recommended that the O-ring

lubrication for pneumatic power tools.

or grommet be lubricated with VALVEgrease for Alcoa^®Wheels

7. Do not use liquid tyre balancers or sealants. These products

or with a non-water non-metal-based lubricant.

may cause extremely rapid corrosion of the valve hole area,

6. Use only dry air for tyre infl

Be sure that the in-line air

bead seats and drop centre. Cracks may be initiated with air

dryer is maintained properly. The use of moisture traps in the

loss as a result.

air compressor feed line is recommended.

8. Balancing with powder or granulates is not recommended.

7. Valve dust caps with an air seal are recommended.

These products may cause malfunctioning of the valve core

with air loss as a result.

9. Do not use metal or brass valve extensions without a solid

support. Unsupported metal extensions accelerate fatigue to

the valve base or valve hole area due to centrifugal forces. As a

result, cracks may occur in the valve base and/or the valve hole

areats, causing air loss.

10. Do not use extension tubes without a proper clamping

installation attached to the outer wheel. Loose extension tubes

may cause damage to the wheel and tube with air loss as a

result.

5.e.iv. Replacing valves

The best occasion to check the valve is when tyres are replaced. It

is recommended to fi a new valve every time when a new tyre is

mounted.

Clean the valve seat and valve hole thoroughly after removal of the

valve. Remove all dirt, grease, and oxidation. Make sure all contact

areas are dry. Check for sharp edges or burrs. See picture 5-7.

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, a soft wire brush or

Picture 5-7

Bristle discs for Alcoa^®Wheels will help to clean the valve hole area

without harming the surface.

Apply a layer of VALVEgrease for Alcoa^®Wheels or non-water

non-metal-based lubricant in the valve hole and the outer and inner

side wheel surface, up to 2,5 centimetres or 1 inch in diameter

around the valve hole. See picture 5-8.

Before installing the valve, apply a thin coat of VALVEgrease for

Alcoa^®Wheels or non-water non-metal-based lubricant at the base

of the valve and the O-ring or T-shape grommet is located. See

picture 5-9.

Do not use any other lubricants that are water-based or lubricants

that contain metals.

Picture 5-8

Upon installing hold the valve in its position and check the

alignment to be able to mount a valve extension for dual mounting

applications. This applies to valves with a bend or angle.

Note:

Upon installing valves with T-shape grommet, insert the valve

carefully to avoid the T-shape grommet from being squeezed

or folded. As a result, the T-shape grommet may get cut or torn

causing air loss.

Install the valve with care and do not over torque: the

recommended torque is 12 to 15 Nm (9 to 11 Ft-Lb).

IMPORTANT

Refer to the vehicle OEM for installing or replacement of valves

with tyre pressure monitoring system (TPMS) modules. For more

Picture 5-9

information about valves with TPMS modules, consult Section 5.e.v.

5.e.v. TPMS valves and modules

Vehicle OEM may off a Tyre Pressure Monitoring System (TPMS)

Application Guidelines for Alcoa^®Wheels, with TPMS for individual

on vehicles, replacing the Alcoa^®Wheels valve. A TPMS is an

vehicle OEM, are available from Howmet Wheel Systems.

electronic system designed to monitor the air pressure inside the

tyres of vehicles.

Valves used for inboard versions i.e., the TPMS module is in the

Caution

air chamber, use special valves designed by / for the vehicle

manufacturer. These TPMS valves are available through the

vehicle manufacturer organization and authorized Alcoa®

When de- or mounting tyres avoid contact between tyre

Wheels distributors.

beads and inboard TPMS module to prevent from damaging

tyre and/or inboard TPMS module.

Outboard versions may be fi

or connected using the Alcoa^®

Wheels valve as a base. Care needs to be taken for correct fi

A damaged TPMS module may cause malfunctioning of the

i.e., matching threading, correct torque, enough stabilizing or

system or cause a tyre blow-out with serious injury or death

support to avoid additional stresses on the valve or valve bore.

as a result.

Unless the vehicle / axle OEM recommends otherwise: apply a layer

Consult the vehicle OEM network for proper installation,

of VALVEgrease for Alcoa^®Wheels or non-water non-metal-based

parts and tools required.

lubricant in the valve hole and the outer and inner side wheel

surface, up to 2,5 centimetres or 1 inch in diameter around the

valve hole.

5.f.

Valve extensions

Authorized distributors of Alcoa^®Wheels off diff

valve

extensions. A quality extension of 150 mm (6inches) will enable

tyre pressure checks and adjustment of the infl

of the inner

tyre of a dual fi

A valve stem stabilizer must be used if metal valve extensions are

used.

The mass of metal valve extensions and rotation may cause forces

that can lead to cracks in the valve hole area of the wheel or the

valve stem.

Picture 5-10

POM plastic valve stem extensions (Picture 5-10) are recommended

and can be obtained from an authorized distributor of Alcoa^®

Wheels.

When using extension tubes, attach the tube with a proper

clamping bracket (Picture 5-11) attached to a vent hole of the outer

wheel.

ATTENTION: Use of stabilizers or clamping brackets on Dura-Bright^®

surface treated wheels can aff

the appearance and performance

of the Dura-Bright^®surface treatment at the area of contact with

Picture 5-11

the stabilizer or clamping bracket.

Valves availability

Only use original valves for Alcoa^®Wheels. These valves are specially made to fi Alcoa^®Wheels and are not available in the aftermarket /

replacement market. Howmet Wheel Systems off

all listed valves for Alcoa^®Wheels through its distributor network. For more info, please

contact an authorized distributor of Alcoa^®Wheels or Howmet Wheel Systems.

6. Before mounting tubeless tyres

6.a. Safety and compliance

Tyres and wheels that are not properly fi

or maintained may

not be safe.

Warning

Always comply with the procedures in the tyre and wheel

manufacturers’ catalogues, instruction manuals or other industry

Tyre and wheel servicing can be dangerous.

and government instructional materials.

Failure to read and comply with all of these procedures and

Follow the proper tyre fi

and maintenance practices as

practices may result in serious injury or death.

contained in the tyre manufacturers’ manuals and Sections

6.b. to 7.c. of this manual.

Tyre and wheel servicing must only be performed by trained

personnel using proper procedures and tools.

Always wear adequate protective eyewear (or face shield),

protective foot and hand wear and hearing protection while

servicing tyres and wheels to avoid injury.

6.b. Tools and machines

Always:

• Use those tools recommended by the tyre or wheel

Warning

manufacturer

• Keep tools clean and inspect them frequently

If you do not know how to use tyre servicing tools: Stop!

Never:

Failure to follow proper procedures can result in serious

• Use a tyre tool for anything except for demounting and mounting

injury or death.

tyres

• Use an extension bar with tyre irons

Tyre servicing must only be performed by trained

• Use tools with a loose or cracked handle

personnel.

• Use bent, cracked, chipped, dented, or mushroomed tools

• Alter or apply heat to any service tool

Typical tyre service tools:

Not all tyre mounting / demounting machines work the same. Be

• Bead unseating tools

sure to read the operating or instruction manual for your machine

• Tubeless tyre iron set

before attempting to mount or demount tyres.

• Clip-on air chuck / in-line gauge with enough hose length

• Safety restraint / tyre cage

6.c. Inspection

1. Do not gouge or nick the wheel during inspection.

Note:

2. Do not use a wheel that has been exposed to excessive heat

• For inspection of tyres refer to the manufacturers’

from tyre fi

brake fi

severe brake system drags or

documentation.

seizures or other causes. See Section 13.d. Heat damage.

• For inspection of Alcoa^®Wheels refer to Sections 13 of this

3. Do not use a damaged tyre or damaged wheel. Inspect them

manual.

carefully before mounting. See Section 13 Wheels in service.

4. Do not use a severely corroded wheel. See Sections 13.i. and

13.j.

5. REMOVE SHARP EDGES ON THE RIM FLANGE. See Section 13.g.

Rim fl

wear.

Warning

Use of inner tubes in tubeless wheels will hide slow leaks.

Mounting damaged tyres or wheels can lead to an explosive

Slow leaks may indicate cracked or damaged wheels which

separation of tyres and wheels.

lead to wheel failures. See Section 13.h.iv.

Explosive separations of tyres from wheels can cause serious

Wheel failures can cause accidents which may result in

injury or death.

serious injury or death.

Inspect tyres and wheels for damage before mounting the

Never use an inner tube on tubeless Alcoa^®

Wheels.

tyres. If damage is found, immediately and permanently

Immediately and permanently remove cracked or damaged

remove damagedtyres or wheels from service.

wheels from service and scrap.

6.d. Matching of tyre, wheel, and axle load

1. Use only the appropriate tyre size, matching the rim

width, according to ETRTO and/or tyre manufacturers’

recommendations. Refer to the OEM vehicle documentation

Warning

and tyre manufacturers’ documentation. See Section 4.e. Tables:

matching tyre to rim.

Never assemble a tyre and wheel unless you have positively

2. Alcoa^®Wheels for commercial vehicle tubeless tyres have a 15°

identifi

and correctly matched the tyre and wheel

bead seat angle and accommodate tubeless tyres. Never use

diameter.

tube type tyres on Alcoa^®Wheels.

3. Do not exceed maximum wheel load. Customer must compare

If an attempt is made to seat the tyre bead by infl

OEM vehicle axle load ratings to maximum wheel load rating.

a mismatched wheel, the tyre bead will break, or tyre will

4. Before mounting the tyre, perform a wheel fi

check at the

separate from the rim with explosive force and may result in

vehicle to ensure proper clearance from any obstructions.

serious injury or death.

See ‘Wheel fi

check’ Section 5.d.

5. Refer to tyre manufacturers’ recommendations for proper tyre

Before assembling a tyre and a wheel be sure to identify if

pressures. The recommended tyre pressure may not exceed the

the tyre - and the wheel diameter match.

maximum infl

pressure of the wheel.

Mismatching tyre and wheel diameters are dangerous. A

mismatched tyre and wheel assembly may separate and can result

in serious injury or death. This warning applies to 15” and 15.5”, 16”

and 16.5”, 17” and 17.5”, 19” and 19.5”, 22” and 22.5”, 24” and 24.5”

tyre and wheel assemblies as well as other sized assemblies.

6.e. Valve

1. Check if the matching valve is mounted in the right way with proper torque. See Section 5.e. of this manual

(Valves for Alcoa^®Wheels).

2. When match-mounting tyres on Alcoa^®Wheels, locate the valve adjacent to the low point mark on the tyre.

3. For matching valves and additional information see Specifi

Sheet for Alcoa^®Wheels, column ‘Valves’

6.f.

Lubricant

1. When selecting a lubricant, it is preferable to use a

non-water-based lubricant for tyre mounting that also does not

contain metals and is pH neutral.

Warning

2. Alternatively use a non-fl

vegetable or soap-based

rubber lubricant, always pH neutral, on the tyre beads and rim

Never use starter fl

propane, ether, gasoline, or other

surfaces.

materials and/or accelerants to lubricate the

beads of a tyre or bead seats of the rim.

Lubricating bead seats and drop well:

• Preferably use a non-water-based lubricant for tyre mounting

This practice can cause the explosive separation of the tyre

that does not contain metals and is pH neutral.

/ the wheel during servicing or during road use, which may

• Water-based lubricants accelerate corrosion on the bead seats

result in serious injury or death.

and drop well surface.

• Corroded bead seats may not be airtight. Corrosion in the bead

Use appropriate and designated lubricants for lubrication of

seats may initiate cracks with air loss as a result.

the beads of a tyre and/or bead seats of the rim.

• Corrosion at the drop well may initiate cracks with air loss as a

result.

Lubricating valve and valve hole area:

• Use VALVEgrease for Alcoa^®Wheels or a non-water-based

lubricant that does not contain metals and is pH neutral.

• Water-based and / or metal-based lubricants may cause and

accelerate corrosion at the valve and valve hole area.

• Corrosion at the valve and valve hole area may result in loosing

air tightness of the valve O-ring or grommet.

• Corrosion may initiate a crack in the valve hole area with air loss

as a result.

6.g. Mounting tyres on symmetrical and non-symmetrical drop well wheels

Alcoa^®Wheels may contain a symmetrical drop well with a narrow

other wheel designs feature an increased under well diameter and

ledge on both sides of the rim. This feature allows mounting of the

also have a non-symmetrical sloping rim profi which provides

tyre from either side of the wheel.

additional brake clearance.

However, some Alcoa^®Wheels are non-symmetrical and contain

In order to minimize the possibility of tyre bead damage, mounting

a non-symmetrical drop well or narrow ledge on only one side of

and demounting of the tyre should be performed only from the

the wheel (see graphic 6-1). Reduced well wheels as well as some

narrow ledge side of the wheel.

Graphic 6-1

mount from this side

do not mount from this side

Tyres should be mounted/demounted only

across the disc side of the wheel.

6.h. Symmetrical drop well wheels with safety hump

Alcoa^®Wheels often contain a safety hump on one bead seat of

In case of a symmetrical drop well mounting and demounting of

the rim. This design feature is requested by European vehicle

the tyre may be performed from the side of the wheel without the

manufacturers. It prevents the tyre bead from slipping into the

safety hump by preference.

drop well when tyres are operated at low or defl

tyre pressure

when curving.

safety hump

Graphic 6-2

Graphic 6-3

7. Mounting tubeless tyres on

Alcoa^®Wheels

7.a. Mounting tyre to rim

IMPORTANT

• Not all tyre mounting / demounting machines work the same.

Be sure to read the operating or instruction manual for your

machine brand before attempting to mount or demount tyres.

Follow your machine brand operating and instruction manual.

• Use special fi

for aluminium wheels on the machine’s

chuck for clamping aluminium wheels. See for example picture

7-1 .

• Use a plastic or nylon mounting aid for mounting tyres on Alcoa^®

Wheels. See for example picture 7-2.

Picture 7-1

Before mounting:

• Inspect the tyre for damage. Refer to tyre manufacturers’

documentation and guidelines.

• Clean the beads of the tyre. Be sure the beads and inside of the

tyre are dry before it is mounted.

• Do not exceed the maximum wheel load. Compare vehicle/ axle

load rating to maximum wheel load rating.

• Perform a wheel fi

check on the vehicle/axle to ensure

proper clearance from any obstructions.

• See ‘Wheel fi

check’ Section 5.d.

Picture 7-2

1. Do not gouge or nick the wheel.

Note: Additional care should be used when mounting Dura-Bright^®surface treated wheels since minor nicks and scratches cannot be

polished out. See Section 14.b. for specifi cautions, care and maintenance procedures.

2. Inspect the wheel for damage. Do not use a damaged or severely corroded wheel. See Section 13. REMOVE SHARP EDGES ON THE RIM

FLANGE. See Section 13.g.

3. Identify the short side of the drop centre well. Single-piece tubeless rims and wheels must be mounted from the short side of the drop

centre well. I.e. tyre beads should be mounted over the rim fl

closest to the wheel well.

Note: Aluminium wheels typically have symmetrical drop centres so tyres can be mounted from either side. However, certain aluminium

wheels, have a non-symmetrical drop centre, or the short side of the drop centre well is located on the disc side. See Section 6.g.

4. Before mounting a new tyre, clean the bead seats thoroughly until a smooth and clean surface is reached. For reference see Section 10,

pictures 10-2, 10-3 and 10-4.

Note: Avoid using strong abrasive tools and/or excessive force that could cause dents in the surface. Uneven or damaged surfaces can

lead to leakage.

Note: Frequent changing of tyres in undesirable conditions, use of water-based lubricants or lubricants with a pH value other than

neutral for tyre fi

as well as neglecting to clean the surface of the bead seat, can lead to loss of air caused by corrosion, oxidization

of the aluminium and dirt build up.

Note: Certain types of rubber can “fuse” to the bead seat of the wheel. If this rubber and other residues are not removed before the

of a new tyre the uneven surface can lead to loss of air.

After cleaning the bead seats, insert a wire down the valve stem to ensure it is not blocked.

5. Position the wheel on the machine. Lubricate wheel bead seats and tyre beads using an approvedlubricant. Tyre beads should be

mounted starting over the rim fl

closest to the wheel well.

Note: When match-mounting tyres on Alcoa^®Wheels locate the valve stem adjacent to the low point mark on the tyre.

10. Position the “tool arm” to the front in level with the rim fl

(without contacting it) making sure the “tool arm” engages the

bead completely. Position the valve location on top. Attach

the mounting aid a little above the “tool arm”, below the valve

location. Turn the wheel clockwise until the second bead is

properly mounted. Detach the mounting aid and disengage the

“tool arm”.

IMPORTANT

Do not cut or damage the bead of the tyre.

Picture 7-13

7.b. Manual operation mounting and demounting tubeless tyres

Please refer to instructions and guidelines of suppliers and/or

manufacturers of tools used for manual de- and mounting of

tubeless tyres.

See Alcoa^®Wheels’ YouTube channel (from left to right):

Mounting / demounting tyres, 22.5 x 9.00

Note:

Mounting / demounting tyres, 22.5 x 11.75 off

When hand mounting and demounting tyres, placing aluminium

Mounting / demounting tyres, 22.5 x 11.75 off

120

wheels on a clean wooden fl

or rubber mat is recommended.

Additional care should be used when mounting and demounting

Dura-Bright^®surface treated wheels since minor nicks and

scratches cannot be polished out. See Section 14.b.

7.c. Infl

and bead seating check

Warning

A pressurized tyre/wheel assembly can explode and separate

Never use a volatile or fl

material, such as ether or

violently.

gasoline, as an aid to seating the tyre beads on the wheel.

Such use can lead to an uncontrolled pressure build-up in

This violent separation can cause serious injury or death.

the tyre and may result in an explosion.

Always contain the tyre/wheel assemblyin an approved

Explosive separation of the tyre from the wheel can occur

infl

cage duringinfl

while seating beads in this manner, while adding pressure

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.

NEVERre-infl any tyre that has been operated in a run-fl

or underinfl

condition i.e., operated at 80% or less of the

Warning

recommended operating pressure. Demount, inspect, and match

all tyre and rim components before re-infl

in a safety cage.

An infl

tyre and wheel assembly contains enough air

If an emergency puncture repair infl

gaswasusedona

pressure to cause an explosive separation.

tubeless tyre, defl

and re-infl

the tyre several times to remove

potentially explosive propellant before servicing the tyre.

Unsafe handling or failure to follow approved mounting and

demounting procedures can lead to serious injury or death.

Study, understand and follow the procedures contained in

this manual to ensure your safety.

Note:

Picture 7-14 is an example of one type of a restraining device or tyre

cage. Manufacturers recommend that approved restraining devices

or tyre cages be free standing and located away from any vertical

fl or solid surface. The restraining device or tyre cage should not

be bolted to the fl

1. Before infl

any tyre rim/wheel assembly, be sure to read,

understand and comply with ALL WARNINGS.

2. Use only dry air for tyre infl

Be sure that the in-line

air dryer is maintained properly. The use of moisture traps

in the air compressor feed line is recommended.

After mounting the tyre on the wheel, if needed use a

compressed air tank with a quick release valve to seat the

beads. Do not exceed 20 psi / 140 kPa / 1.4 bar before placing

the assemblyin an approved restraining device or tyre cage.

Infl

the tyre, with the valve core removed, using a clip-on air

Picture 7-14

chuck with an in-line valve or pressure regulator and a suffi

length of hose. Infl

the assembly to 20 psi / 140 kPa / 1.4 bar.

6. Place tyre/wheel assembly inside an approved restraining

device or tyre cage after the tyre beads are seated. See picture

IMPORTANT

7.14.

Look for distortions, undulations, or other irregularities in

7. Continue to infl

the tyre to its recommended infl

the tyre sidewalls. Pay attention to any popping or snapping

pressure. Refer to tyre manufacturers’ recommendations for

sounds. If ANY of these conditions are present: STOP! DO

proper tyre pressures. Using a clip-on air chuck or a self-locking

NOTapproach tyre. Before removing the assembly from the

straight chuck with remote valve and pressure gauge, infl

approved restraining device or tyre cage, completely defl

the

the tyre/wheel assembly to proper pressure.

tyre remotely. Remove the clip-on air chuck. Mark the tyre as

damaged for a potential “blow out”. Mark the tyre immediately

unserviceable, non-repairable and scrap.

Continue to infl

until the beads are seated on the wheel.

Inspect both sides of the tyre to be sure that the beads are

evenly seated. Visually inspect tyre rim/wheel assembly

throughout the infl

process for improper seating. Do not

exceed 20 psi / 140 kPa / 1.4 bar before placing the assembly in

an approved restraining device or tyre cage.

NEVER infl

beyond 20 psi / 140 kPa / 1.4 bar to seat any

tyre beads. If the beads are not seated at 20 psi / 140 kPa / 1.4

bar: STOP! Completely defl the tyre, remove the assembly

from the restraining device or tyre cage, and demount the

tyre to determine the cause. Reposition the tyre on the rim,

re-lubricate, and re-infl

IMPORTANT

When infl

a tyre, stay out of the trajectory. See graphics 7-15,

7-16 and 7-17. DO NOT stand or lean any part of your body against,

or reach over, the approved restraining device or tyre cage during

infl

IMPORTANT

Look for distortions, undulations, or other irregularities in the tyre

sidewall. Pay attention to any popping or snapping sounds. If ANY

of these conditions are present: STOP! DO NOT approach tyre.

Before removing the assembly from the approved restraining

device or tyre cage (picture 7-14), completely defl

the tyre

remotely. Remove the clip-on air chuck. Mark tyre as damaged

for a potential “blow out”. Mark tyre immediately unserviceable,

non-repairable and scrap.

Graphic 7-15

Trajectory

Graphic 7-16

Graphic 7-17

8. Do not over-infl

Use the tyre or vehicle manufacturers’ recommended pressures, but under no circumstances exceed cold tyre

pressure as roll stamped on the wheel. If no popping or snapping sounds are present, remove the clip-on air chuck, install the valve core,

and adjust the infl

pressure to the recommended operating infl

pressure.

9. Before removing the tyre wheel assembly from the restraining device or tyre cage, always visually inspect for proper and concentric

seating of the beads and all parts.

10. Conduct a fi inspection. Heavy-Duty vehicle tyres have a “guide rib” or "mounting ring" moulded into the sidewalls next to the tyre

beads. See picture 7-18. When the tyre is infl

this moulded ring should be evenly spaced from the rim fl

all the way around the

wheel. See picture 7-19. Check the position of the mounting ring before removing the assembly from the approved restraint device or

tyre cage.

If the rib or ring and wheel are not concentric, defl

the assembly in the cage. After demounting the tyre re-lubricate, re-mount and

re-infl

the tyre in the approved restraint device or tyre cage. Repeat step 4 to 9.

8. Defl ting and demounting tubeless

tyres from Alcoa^®Wheels

8.a. Before defl

and demounting

If there is known or suspected damage to the tyre or wheel or if

the tyre has been operated at 80% or less of its recommended

operating pressure, let the assembly cool down to ambient

temperature fi

Completely defl any tyre by removing the

valve core before removing the tyre/wheel assembly from the axle.

8.b. Machines, tools, and lubricants

Warning

Demounting damaged tyres or wheels can lead to an

An aluminium wheel can be structurally weakened by

explosive separation of tyres and wheels.

excessive heat. See Section 13.d. Heat damage.

Explosive separations of tyres from wheels can cause serious

Tyre/wheel assemblies, using wheels that have been

injury or death.

exposed to excessive heat, may experience a sudden and

unpredictable tyre/wheel separation causing serious injury

or death.

Inspect tyres and wheels for damage before removing

from vehicle. If damage is found, the tyre must be

completely defl

before loosening nuts. Immediately and

Immediately and permanently remove any wheel from

permanently remove damaged tyres or wheels from service.

service that has been subjected to excessive heat such as a

tyre fi

wheel bearing failure or braking system drag / seize

or a high-pressure tyre/wheel separation.

8.b.i. Machines

IMPORTANT

• Not all tyre mounting / demounting machines work the same.

• If using a tyre mounting / demounting machine on aluminium

Be sure to read the operating or instruction manual for your

wheels, care should be taken to prevent gouging the wheel.

particular machine before attempting to mount or demount

• Contact of parts of the machine with the wheel while operating

tyres. Follow the particular operating and instruction manual.

can cause deformation of the metal or wheel.

• Use special fi

for aluminium wheels on the machine’s

• Impacts or forces can structurally damage the rim or wheel and

chuck for clamping aluminium wheels. See for example pictures

cause cracks with air loss as a result.

8-9 and 8-10.

8.b.ii. Tools

Use the proper tools to demount or mount tyres and wheels. Refer to “Typical Tyre Service Tools”. See Section 6.b.

• NEVER strike the tyre and/ or the wheel with a hammer to unseat the beads.

• DO NOT use slide impact bead unseating tools with the risk of damaging bead seats, safety hump or drop well.

• Keep tyre tools smooth. Use them with care.

8.b.iii. Lubricants

Useanon-fl

vegetable or soap-based lubricant on bead seats and other rim surfaces which is pH neutral. Lubricate the tyre beads

and the bead seats of the wheel to make tyre demounting easier after defl

and before demounting the tyre from the wheel.

8.c. Defl

and demounting

IMPORTANT

Always completely defl

the tyre/wheel assembly before

attempting to demount a tyre from the wheel. Remove the valve

core and insert a wire down the valve stem to ensure complete

defl

Never demount a tyre from a wheel unless it is

completely defl

Note:

Most Alcoa^®Wheels typically have symmetrical drop centres so

tyres can be demounted from either side. However, on certain

aluminium wheels, the short side of the drop centre well is located

on the disc side. See Section 6.g.

Picture 8-1

1. Identify the short side of the drop centre well. Single-piece

tubeless rims and wheels must be demounted from the

short side of the drop centre well. I.e. tyre beads should be

demounted over the rim fl

closest to the wheel well.

2. Remove valve core to defl

the tyre, prior to remove the

assembly from the vehicle. Insert a wire down the valve stem to

ensure complete defl

3. Position the assembly on the machine. Lift the assembly to

enable the bead breaker disc to contact the back bead of the

tyre without contacting the wheel rim fl

Picture 8-2

4. Rotate the wheel while moving the bead breaker disc towards

the drop well, without contacting the wheel. Apply an approved

lubricant on the tyre bead and bead seat of the wheel while

rotating the wheel.

5. Move the bead breaker disc to the front and repeat step 4.

Picture 8-3

Fixture for clamping aluminium wheels

Fixtures attachment to machine’s chucks

Picture 8-9

Picture 8-10

Plastic mounting aid used when mounting

Lever - with plastic protection- used when demounting

Picture 8-11

Picture 8-12

Caution

Do not use a hammer or a slide impact tool on wheels to

Demounting tyres with tyre changer

avoid damage of rim fl

bead seats, safety hump or

drop well of a wheel.

Do not contact the wheel, i.e. rim fl

bead seat, safety

hump or drop centre, with the bead breaker disc while

Impacts on rim fl

bead seats, safety hump or drop well

pushing the beads of the tyre towards the drop well.

of the wheel may cause cracks at a later stage with air loss as

a result.

Damaging, carving, denting, or deforming the metal with the

“bead breaker disc” may cause cracks at a later stage with air

Make sure to unseat tyre beads without damage to rim

loss as a result.

bead seats, safety hump or drop well.

Make sure to unseat tyre beads without contacting rim

bead seats, safety hump or drop well with the “bead

breaker disc” or other parts from the tyre changer.

9. Balancing Alcoa^®Wheels with adhesive

weights

Alcoa^®Wheels are fully machined and do not require balancing.

Powder, granulate, liquid balancers or liquid

However, the tyre-wheel combination may need to be balanced.

sealants

Internal balancing compounds (powder or liquid) are not

recommended. Use of coated balancing weights is recommended

• Balancing with powder, granulates or liquids are not

to avoid staining and corrosion of wheel surface.

recommended, nor sealing with liquid sealants.

Powder, granulate or liquid balancers as well as liquid sealants

Regulations from the European Commission (2000/53/EG) banned

may harm the inner liner of tubeless tyres. For information

use of lead for balancing of cars and vans up to 3.5T GVW as from

consult the tyre manufacturers’ recommendations.

2005. At the time of writing this service manual, balancing weights

• The use of liquid tyre balancers or sealants in Alcoa^®Wheels may

used for commercial vehicles over 3.5T GVW may still contain lead.

cause extremely rapid corrosion of the valve hole area, drop

centre and bead seat areas. Wheels with severe corrosion at the

NOTICE

valve hole, drop centre and bead seat areas are unsuitable for

service.

• Always follow the recommended procedures of the balancing

• The policy of Howmet Wheel Systems is not to endorse any

weight manufacturer. It may be necessary to reduce the tyre

specifi brand or entity of balancing powder or balancing

pressure when installing clip-on weights to allow clearance for

granulates. The use of powder or granulate balancers in Alcoa

the weight's clip between the tyre and rim fl

Wheels may cause clogged valves. A fi

valve core is

• Adhesive weights should be applied only to a clean surface

recommended when using balancing powder or granulates.

per the recommended procedures of the balancing weight

manufacturer. Balance weights should be installed in a location

NOTICE

where they will not contact the brake -, steering - or suspension

components during vehicle operation.

The use of balancing powders and granulates will not void the

• Proper pre-cleaning is an essential factor for adhesive balance

limited warranty (See Section 2), unless inspection of the wheel

weights. It is recommended to evaluate the surface cleaning

shows anomalies related to its use.

techniques and products with the manufacturer or supplier

of balancing weights. Relocating wheels from a cold place to a

Alcoa^®Wheels corroded by the use of liquid tyre balancers or

warmer place may cause condensation on wheel surfaces which

sealants will not be replaced under the Howmet Aerospace limited

can aff the adhesion negatively.

warranty. See Section 2.

Improperly installed weights could ‘come off during use and

damage the vehicle and/or surrounding objects or cause personal

injury.Excessiverim fl

wear (see Section 13.g.) could dictate

the use of‘stick-on’ or adhesive balancing weightsif thereis

inadequate rim fl

to properly hold a clip-on (knock on) style

weight.

Caution

The usage of clip-on style balancing weights will not

adequately engage at the hardened Dura-Flange^®surface.

Clip-on balancing weights are not recommended for

Dura-Flange^®Alcoa^®Wheels and may disengage from the

wheel causing serious injury or death.

Howmet Wheel Systems recommends adhesive style

balancing weights for Dura-Flange^®Alcoa^®Wheels.

10. Wheel installation

10.a. Wheel installation preparation

For free training on proper installation and maintenance or for the

most recent updates of online materials, contact Howmet Wheel

Warning

Systems via web page www.alcoawheelseurope.com.

Wheels that are not properly installed or maintained may not

be safe.

Failure to follow proper wheel installation or maintenance

practices may result in serious injury or death.

Follow the proper wheel installation and maintenance

practices as contained in this Service Manual for Alcoa^®

Wheels.

STEP 1

Clean the mating face of the hub / axle, remove dirt, oxidation, and

paint. Do not apply any rust inhibitor, surface coating, grease, oil, or

paint. Follow the recommendations of axle / vehicle manufacturers.

Picture 10-1

STEP 2

Clean the mating face of the wheel (disc), remove dirt, oxidation,

and paint. Do not apply any rust inhibitor, surface coating, grease,

oil or paint. If the mating face(s) of wheel(s) is (are) severely

corroded, remove wheel(s) from service.

Picture 10-2

STEP 3

Clean the inner side of the hub bore of the wheel. Remove dirt,

oxidation, and other foreign residues.

Picture 10-3

Picture 10-11: Torque wrench

STEP 6

1. Refer to the owner’s manual of the vehicle or axle for correct

torque value: Nm (kgf).

2. Hand tighten all nuts.

3. Impact wrenches, if used, should be carefully adjusted to apply

torques within or below the limits recommended. See section

12.b.

4. Tighten to the recommended torque with a calibrated torque

wrench (Picture 10-11) following the proper sequence. See

graphics 10-12, 10-13, 10-14 and Section 12.b.

Graphic 10-12

After each wheel mounting, torque should be checked with a

calibrated torque wrench (Picture 10-11).

IMPORTANT

After 8 - 80 kilometres or 5 - 50 miles of operation torque should be

recheckedunless vehicle/axlemanufacturer or your documented

practices determine otherwise.

Check torque frequently from then on.

NOTICE

If nuts require frequent tightening, studs break frequently, wheel

Graphic 10-13

nut washers break or bolt holes are pounding out, hardware and

mounting practicesshould be reviewed.

For free training on proper installation and maintenance or for the

most recent updates of online materials, contact Howmet Wheel

Systems via web page www.alcoawheelseurope.com

For additional information see Section 12.a.

Graphic 10-14

10.b. At wheel installation

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.

Warning

If two or more studs are broken, replace all the studs for that

Wheels that are not properly installed or maintained may not

wheel position. Check with the stud manufacturer for regular

be safe.

maintenance and stud replacement practices.

Failure to follow proper wheel installation or maintenance

All wheel fastener hardware should be grade 8 or metric conversion

practices may result in injury or death.

10.9. Follow the hardware manufacturers’ recommendations when

replacing studs. See Section 11.b.iii.

Follow the proper wheel installation and maintenance

practices as described in this Section.

IMPORTANT

• Perform a wheel fi

check to ensure proper clearance from any obstructions. See ‘Wheel fi

check’

Section 5.d.

• Do not exceed maximum wheel load. Customer must compare OEM vehicle axle load ratings to maximum

wheel load rating.

• Refer to tyre manufacturers’ recommendations for proper tyre pressure, before mounting the tyre.

1. Make sure all wheel nuts are properly torqued. Check them

4. Do not introduce any foreign objects such as spacers or top

often. See Section 12.a. If the wheel is loose, the holes will

hats (hub caps or covers) into the contact surface areas of the

pound out or deform. If some nuts are tight and others are

mounting system unless approved by Howmet Wheel Systems.

loose, the wheel may develop cracks or studs may break. This

Do not paint, powder coat, or otherwise coat Alcoa^®

condition may cause wheels to loosen and disengage from the

Wheels.

vehicle. Dirt streaks or rust radiating from bolt holes and / or

vent holes can indicate loose nuts. See Section 13.h.

5. Additional care should be used when mounting Dura-Bright^®

surface treated Alcoa^®Wheels, since minor nicks and scratches

2. Ensure the end of the wheel wrench is smooth or cover the

cannot be polished out. See Section 14.b. for specifi cautions,

wheel mounting surface with a protective shield prior to

care, and maintenance procedures.

tightening the nuts. The wheel wrench end will mar the wheel

around the nuts if it is not smooth.

6. Discmates for Alcoa^®Wheels or nylon protection gaskets are

designed to be placed between wheels and hub or brake drum

3. Keep all component contact surfaces smooth and clean. Dirt or

contact surfaces and as well as between the dual mounted

projections on mounting surfaces may lead to lose or loosing

wheels contact surfaces. See Section 4.h. Discmates for Alcoa^®

wheels. Remove all projections resulting from burrs, nicks, etc.

Wheels or nylon protection gaskets are recommended to be

Take care that loose dirt does not fall onto mounting surface

replaced when the tyre/wheel assemblies are removed and

during assembly.

reinstalled.

10.c. Hub centring

All European type Alcoa^®Wheels for medium and heavy-duty

Measure the hub pilot tab length to make sure the hub properly

commercial vehicles are hub centred wheels. European type

centres the wheels. The pilot tab length for suffi

centring

Alcoa^®Wheels have cylindrical bolt holes and are not suitable for

must be 5 mm or more for single mounting (Graphic 10-15) and 1x

bolt centring with conical or spherical nuts: never use any kind

disc thickness + 5 mm or more for dual mounting (Graphic 10-16).

of this type of hardware on wheels with cylindrical bolt holes.

In both cases dimensions are excluding bevelled edges. Longer

For reference consult the Specifi

Sheet for Alcoa^®Wheels

spigots make mounting easier.

available from the web or consult Howmet Wheel Systems.

Hubs designed for steel hub piloted wheels may not have enough

pilot tab length to locate dual aluminium wheels. Pay close

attention to pilot tab length, particularly when converting from steel

to aluminium duals.

Graphic 10-15

Graphic 10-16

NOTICE

Always apply HUBgrease for Alcoa^®Wheels or another grease

that does not contain metal or water, on the pilot tabs or spigots

(Picture 10-17) to reduce corrosion and make it easier to remove

wheels when replacing tyres or other components for service.

Picture 10-17

10.d. Disc thickness and thread engagement

The mounting fl

or disc of Alcoa^®Wheels for medium and

heavy-duty vehicles is thicker (19.1 to 28.6 mm) than the mounting

of steel wheels (9 to 16 mm) and therefore requires diff

Warning

mounting hardware.

Insuffi

engagement of threading between stud and nut

For correct mounting of Alcoa^®Wheels use:

may cause cracking or breaking of the stud.

• Longer (replacement) studs with standard nuts, as described in

Section 11.a., or

Cracking or breaking studs may result in separation of the

• Sleeved nuts (available from Howmet Wheel Systems) with

tyre/wheel assembly from the vehicle resulting in serious

standard length studs, as described in Section 11.b.

injury or death.

For reference see the latest Specifi

Sheet for Alcoa^®Wheels

Follow the proper wheel installation and maintenance

with details about wheel sizes, part numbers, dimensional

practices as described in this Section.

properties such as disc thickness, bolt hole diameters and more.

11. Mounting hardware

Depending on the mounting hardware or type of mounting an Alcoa^®Wheel may be off

with diff

bolt hole diameters:

Picture 11-1

Picture 11-2

Picture 11-3

From left to right various bolt hole diameters for M22 or 7/8” bolt / stud diameters:

• Picture 11-1

26 mm bolt hole for standard nuts and longer studs. See Section 11.a.

• Picture 11-2

32 mm bolt hole for sleeved nuts and standard studs. See Section 11.b.

• Picture 11-3 Bolt hole a.k.a. 'dual hole' for Volvo OEM hardware only. See Section 11.d.

Warning

Use of chrome-plated wheel nuts, which have chrome plating on the surfaces that contact the wheel, can cause reduced and

inconsistent wheel clamping.

This condition can cause wheels to loosen and disengage from the vehicle, causing serious injury or death.

Never use wheel nuts with chrome-plated contact surfaces. Use only recommended hardware on Alcoa^®Wheels. See Sections 4.c. and

11.b.iii.

IMPORTANT

1-piece fl

nuts are not approved for use on any Alcoa^®Wheels

application. See picture 11-4.

Stud standout is critical to understand for the proper application of

the various nuts used for these three diff bolt hole diameters.

The stud standout must be checked very carefully.

Picture 11-4

The stud standout is measured from the fl mounting surface

of the hub, or drum brake, which is in contact with the disc of the

wheel, to the outer end of the stud.

The stud standout on steer axle / single mounting (picture 11-5) and

stud standout on drive axle / dual mounting (picture 11-6) must be

checked both for suffi

length.

Picture 11-5

Picture 11-6

11.a. Mounting Alcoa^®Wheels with standard 2-piece fl

nuts and replacing wheel studs

Alcoa^®Wheels with this type of mounting system require longer studs than for steel wheels. The stud standout must be long enough to

cover the disc thickness of single or dual mounted aluminium wheels, the height of the wheel nut and an additional two threads of the stud

protruding from the top of the nut.

For single mounting the minimum stud standout required =

For dual mounting the minimum stud standout required = 2x disc

1x disc thickness of the Alcoa^®Wheel + height of standard nut +

thickness of the Alcoa^®Wheel + height of standard nut + 2 full

2 full threads, 3 mm** with M22, M20 or M18 x 1.5 studs.

threads, 3 mm** with M22, M20 or M18 x 1.5 studs. See Graphic

See graphic 11-7.

11-8.

Graphic 11-7

Graphic 11-8

1. Disc thickness of the Alcoa^®Wheel

** or 2 full threads in case of 7/8”-11 BSF studs (Scania) or

2. Height of standard nut

7/8”-14 UNF studs (Volvo >2004)

2 full threads

4. Total stud standout

11.a.i. How to measure stud standout (axles with drum brakes)

Stud standout is measured from the axle end mounting surface:

• I.e., from the hub for disc brake operated axles and inboard mounted drums of drum brake operated axles to the fi

complete thread at

the outside end of the stud. See graphic 11-9.

• I.e., from the drum for outboard mounted drums of drum brake operated axles to the fi

complete thread at the outside end of the

stud. See graphic 11-10.

Inboard mounted drum

Outboard mounted drum

1. Hub

2. Inboard drum

3. Outboard drum

4. Mounting surface

5. First full thread

6. Stud standout

7. Exposed shoulder

Graphic 11-9

Graphic 11-10

IMPORTANT

Check for bottom out” when using sleeved nuts at exposed shoulder. See graphic 11-9 (7).

• The (sleeved) nut must be able to clamp the wheel or wheels.

• See Section 11.b.ii. for reference and information about ‘bottom out’ condition.

Measure the diameter of the exposed shoulder (See graphic 11-9 (7)) and compare with bolt hole diameter of

wheel:

• The diameter of the exposed shoulder must measure less than the diameter of bolt hole.

Backup

• The wheel mating face must be fl and in full contact with the hub- or drum mating faces.

Check the shape and measure the diameter of the mounting face. See graphic 11-11.

• Wheels mounted on hub- or drum mating faces that are not circumferential need to be checked regularly.

See section 13.h.i.

• The hub- or drum mating face must comply with the recommended diameters.

See section 5.c. chart 5-3 or section 13.h.i. chart 13-44.

Graphic 11-11

11.a.ii. Confi

proper stud standout

For safe mounting the stud standout must meet the following conditions. If not met, then the wheel studs must be replaced with wheel

studs that will meet the requirement. For use with standard 2-piece fl

nuts and replacing studs the minimal stud standout must be:

Single mounting:

Dual mounting:

• 1x disc thickness of an Alcoa^®Wheel + height of nut + 3 mm for

• 2x disc thickness Alcoa^®Wheels + height of nut + 3 mm for use

use with M22, M20 or M18 x 1.5 threads (or 2 full threads in case

with M22, M20 or M18 x 1.5 threads (or 2 full threads in case of

of other type of threading such as BSF or UNF).

other type of threading such as BSF or UNF).

• Example 1x 22.5 x 14.00 Alcoa^®Wheel with 28.6 mm disc

• Example 2x 22.5 x 7.50 Alcoa^®Wheels with 22.2 mm disc

thickness and a regular 2-piece fl

nut M22 x 1.5 result in a

thickness and a regular 2-piece fl

nut M22 x 1.5 result in a

stud standout of 28.6 + 27 + 3 = 58.6 mm. See graphic 11-7.

stud standout of 2x 22.2 + 27 + 3 = 74.4 mm. See graphic 11-8.

Mixed mounting:

For use with standard 2-piece fl

nuts and replacing studs the

minimal stud standout must be:

• 1x disc thickness wheel of Alcoa^®Wheels + 1x disc thickness steel

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 20.5 mm disc thickness

and 1x 22.5 x 9.00 steel wheel with 13 mm disc thickness and a

regular 2-piece fl

nut M22 x 1.5 result in a stud standout of

1x 20.5 + 1x 13 + 27 + 3 = 63.5 mm

• See Section 4.h.

11.a.iii. Availability nuts

If hex nuts with greater overall height are used, more stud length is

required. See picture 11-12.

Standard nuts delivered and fi

by vehicle or axle OEM can be

used for mounting of Alcoa^®Wheels.

Howmet Wheel Systems in Europe do not off OEM nuts. Consult

Picture 11-12

the manufacturers of vehicles or axles for availability of nuts.

11.a.iv. Availability studs

Prior to retrofi Alcoa^® Wheels (with standard nuts and longer

studs) consult your truck, trailer, or axle OEM for the availability of

longer replacement studs with proper standout.

11.a.v. Extra-long studs

Some vehicle manufacturers off axles with “combined” or

extra-long stud lengths, suitable for both thinner disc steel wheels

and thicker disc aluminium wheels. In some cases, Alcoa^®Wheels

can be mounted without replacing studs or use of sleeved nuts.

To determine correct and safe fi

follow the procedures as

described in this Section.

Picture 11-13

11.b. Mounting Alcoa^®Wheels with standard length studs and sleeved nuts

Warning

Use of chrome-plated (sleeved) wheel nuts which have chrome plating on the surfaces that contact the wheel can cause reduced and

inconsistent wheel clamping.

This condition can cause wheels to loosen and disengage from the vehicle, causing serious injury or death.

Never use wheel nuts with chrome-plated contact surfaces. Use only recommended hardware on Alcoa^®Wheels.

See Sections 4.c. and 11.b.iii.

IMPORTANT

1-piece fl

nuts (Picture 11-4) are not approved for use on any

For reference consult the Specifi

Sheet for

Alcoa^®Wheels application.

Alcoa^®Wheels for mounting hole diameters.

If in doubt consult Howmet Wheel Systems.

The standard wheel stud length can accommodate Alcoa^®Wheels,

with more disc thickness compared to steel wheels, when a special

Note:

sleeved nut is used. The shank or sleeve of these nuts extends into

Wheels with 26 mm mounting hole diameter,

the larger diameter mounting holes and compensates the standard

either use longer studs with standard nuts (M22 x 1.5, 7/8”-11 BSF

stud length securing suffi

thread engagement.

or 7/8”-14 UNF) or use standard studs with sleeved nuts (M18 x 1.5).

Only use the Alcoa^®Wheels with an appropriate mounting hole

Check the specifi

of the studs on the vehicle.

diameter to allow the sleeve of the nut to easily pass through it.

To ensure correct mounting with sleeved nuts, there must be

Sleeved nuts are available for:

enough thread engagement with the stud:

Wheels with 32 mm mounting hole diameter for mounting with

The recommended length of engagement between the threads of

sleeved nut:

the stud and the sleeved nut is equivalent to 95% or more of the

• M22 x 1.5 (Metric, Volvo 2005 >)

diameter of the stud.

• 7/8”-11 BSF (Scania)

•

7/8”-14 UNF (Volvo > 2004)

The minimum recommended number of threads engaged

between the stud and sleeved nut is:

Wheels with 30 mm mounting hole diameter for mounting with

sleeved nut:

• 14 full turns for M22 x 1.5 (Metric, Volvo 2005 >)

• M20 x 1.5 (Metric)

• 13 full turns for M20 x 1.5 (Metric)

• 12 full turns for M18 x 1.5 (Metric)

Wheels with 26 mm mounting hole diameter for mounting with

• 10 full turns for 7/8”-11 BSF (Scania)

sleeved nut:

• 12 full turns for 7/8”-14 UNF (Volvo > 2004)

• M18 x 1.5 (Metric)

Picture 11-14

Picture 11-15

11.b.i. How to check suffi

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 centre hub piloted type wheels with sleeved nuts.

The sleeves of the nut do NOT centre the wheel(s); this mounting system still requires a hub piloting or hub centring axle. This applies to

both single and dual mounted wheels. The pilot tab length for suffi

centring must be 5 mm or more for single mounting or 1x disc

thickness (of the inner wheel) + 5 mm or more (for the outer wheel) for dual mounting, excluding bevelled edges of the pilot tabs.

Graphic 11-16

Graphic 11-17

Single mounted wheels require sleeved nuts with a short sleeve

Dual mounted wheels require sleeved nuts with a long sleeve

Short- and long-sleeved nuts are available from Howmet Wheel Systems in thread sizes for most European medium- and heavy-duty

commercial vehicles. The torque to obtain the correct clamping force is recommended by vehicle, trailer, or axle manufacturers.

11.b.ii. Wheel studs with unthreaded part / 'bottom out' condition

Studs that have an unthreaded part or exposed shoulder can cause

This space (x) must be at least 2 mm less than the disc thickness(es) of

insuffi

or no clamping of the wheel(s) at all. Sleeved nuts may

the wheel(s) to be accommodated. Determine this space when the nut is

‘bottom out’ on the stud’s unthreaded part or exposed shoulder

‘bottomed out’ at the stud without a wheel mounted.

even before the wheels are clamped correctly.

Before mounting Alcoa^®Wheels on hubs with studs with

Mixed mounting:

unthreaded part or exposed shoulder, the space between the

washer and the hubs mounting face must be determined.

When mounting a steel wheel at the inside position and an Alcoa^®

Wheel with sleeved nuts on the outer position it is important to:

a) Determine the amount of threading engaged as set forth in

Section 11.b.

b) Check if no ‘bottom out’ condition occurs when using long

sleeve nuts as described in Section 4.g.

Graphic 11-18

All wheel fastener hardware should be grade 8 or metric conversion

10.9. Follow the hardware manufacturers’ recommendations when

Warning

replacing studs.

The use of a wrong selection of wheels and hardware may

result in improper fi

of wheels.

Improper mounting of wheels may lead to separation of

wheels or loss of assemblies from the vehicle causing serious

injuries or death.

Follow the proper wheel installation and maintenance

practices as described in this Section.

Picture 11-19

11.b.iii. Wheel studs inspection

In service, stud dimensions and condition may change over time

due to environmental conditions, multiple re-installations, improper

torquing. and other factors.

Consult your vehicle, hub or stud manufacturer for regular

maintenance recommendations and stud replacement practices.

Picture 11-20

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.

11.c. 2-piece hex head sleeved nuts for Alcoa^®Wheels

NOTICE

Warning

• 1-piece nuts are not approved for use on any Alcoa® Wheels

application for medium - and heavy-duty vehicles.

• Only 2-piece nuts or 2-piece sleeved nuts with an integral freely

Use of chrome-plated nuts which have chrome plating on the

turning washer, designed for hub centring mounting systems,

surfaces which contact the wheel, can cause reduced and

must be used for fastening European type Alcoa^®Wheels for

inconsistent wheel clamping.

medium- and heavy-duty vehicles.

• Regular 2-piece nuts that come with truck, bus or trailer axles

This condition can cause wheels to loosen and disengage

with steel wheels can also be used with Alcoa^®Wheels with

from the vehicle, causing serious injury or death.

corresponding bolt hole diameters given the thread engagement

is suffi

See Section 11.a.

Never use nuts with chrome-plated contact surfaces. Use

• The following 2-piece hex head sleeved nut types are available

only recommended hardware on Alcoa^®Wheels.

from Howmet Wheel Systems:

• M22 x 1.5 (Metric, Volvo 2005 >)

Design and specifi

of nuts, washers and studs used for

• M20 x 1.5

Alcoa^®Wheels must comply with DIN standard 74361-3. Alcoa^®

• M18 x 1.5

Wheels in Europe are commonly used with 2-piece hex head nuts

• 7/8”-11 BSF (Scania)

that have following threading:

•

7/8”-14 UNF (Volvo > 2004)

• Some vehicles come equipped with right-hand and left-hand

• M22 x 1.5

threads. These vehicles have on the right-side right-hand threads

• M20 x 1.5

and on the left-side left-hand threads. If an “R” or “L” is stamped

• M18 x 1.5

on the studs and nuts, it indicates right and left-hand threads

• 7/8” - 11 BSF

respectively.

•

7/8” - 14 UNF

Alcoa^®Wheels 2-piece sleeved nuts:

Sleeved nut P/N^*1

Replaces^*1

Thread size

For

Sleeve

Application

GAX687632G

GAX578032

M22 x 1.5

Metric & Volvo 2005 >

Short

Single

N/A

GAX57803201^*2

M22 x 1.5

Metric, LH thread

Short

Single

GAX687732G

GAX578132

M22 x 1.5

Metric & Volvo 2005 >

Long

Dual

N/A

GAX57813201^*2

M22 x 1.5

Metric, LH thread

Long

Dual

GAX614230G

GAX614230

M20 x 1.5

Metric

Short

Single

GAX614330G

GAX614330

M20 x 1.5

Metric

Long

Dual

GAX542026G

GAX542026

M18 x 1.5

Metric

Short

Single

GAX542126G

GAX542126^*3

M18 x 1.5

Metric

Long

Dual

GAX688032G

GAX578432

7/8”-11 BSF

Scania

Short

Single

GAX688132G

GAX578532

7/8”-11 BSF

Scania

Long

Dual

GAX687832G

GAX578232^*3

7/8”-14 UNF

Volvo > 2004

Short

Single

GAX687932G

GAX578332

7/8”-14 UNF

Volvo > 2004

Long

Dual

Table 11-21

*1 At the moment of editing this manual the current portfolio and

NOTICE

stock were subject to change. Consult Howmet Wheel Systems

or authorized distributors of Alcoa^®Wheels for updates and

Though sleeved nuts are designed to compensate standard stud

specifi

length suffi

a minimal stud standout i.e. thread engagement

is required. See Section 11.b.

*2 Available, as long as stocks last. The extension 01 on sleeved

nut part numbers indicate left-hand thread versions.

In case of mixed application, dualling steel wheels and Alcoa^®

Wheels, short sleeve nuts can be used. See Sections 4.g., 11.b.ii. and

*3 Available, as long as stocks last.

12.c.

11.d. Mounting hardware for Alcoa^®Wheels specifi

made for Volvo

Stud thread specifi

• During the 4Q of 2004 and 1Q of 2005 Volvo trucks and busses

Warning

changed stud thread specifi

from 7/8”-14 UNF to M22 x 1.5.

• When retrofi

wheels of Volvo vehicles, check the correct stud

DO NOT MIX Alcoa^®Wheels specifi

made for Volvo and

thread specifi

Volvo OEM sleeved nuts with Alcoa^®Wheels and sleeved nuts

• Sleeved nuts for retrofi

wheels of Volvo vehicles are available

for Alcoa^®Wheels.

from Howmet Wheel Systems.

Mixing Alcoa^®Wheels specifi

madefor Volvo / Volvo OEM

Mounting holes and sleeved nuts:

nuts and Alcoa^®Wheels / sleeved nuts can result in incorrect

installation and separation of wheels from the vehicle during

1. Volvo vehicles may also be equipped with Alcoa^®Wheels

operation, causing serious injury or death.

ex-works that have a diff

mounting system and

consequently diff

hardware. See picture 11-22.

Follow the proper wheel installation and maintenance

^®Wheels specifi

made for Volvo have the Volvo logo/

2. Alcoa

practices as described in this Section.

name in the roll stamp of the wheel and have diff

Alcoa^®

Wheels part numbers.

For more information consult the Volvo organization or contact

3. Alcoa^®Wheels specifi

made for Volvo have diff

Howmet Wheel Systems.

mounting holes a.k.a. ‘dual hole’ i.e., each mounting hole comes

with two diff

diameters. See picture 11-23.

4. Alcoa^®Wheels specifi

made for Volvo are installed with

longer studs and Volvo OEM sleeved nuts which diff from the

sleeved nuts available from Howmet Wheel Systems.

5. Alcoa^®Wheels specifi

made for Volvo and Volvo hardware,

i.e., studs and nuts, are available from the Volvo organization

only.

Picture 11-23

Picture 11-22

Picture 11-22, from left to right:

• Volvo OEM sleeved nut for single and dual mounting: only

suitable for Volvo‘dual hole’ wheels

• Sleeved nut from HowmetWheel Systems for single mounting

• Sleeved nut from Howmet Wheel Systems for dual mounting

12. Wheel nuts

12.a. Tightening nuts

Studs with 2-piece fl

nuts M22 x1.5, M20 x 1.5, M18 x 1.5,

7/8" - 11 BSF or 7/8" - 14 UNF may be subject to diff

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.

IMPORTANT

Check all parts, including wheels, studs, and nuts. Check for paint,

Graphic 12-1 - Six Stud

dirt, corrosion, or damage. Check mounting faces of wheels, hubs,

and drums.

Friction caused by paint, dirt, corrosion, or damage on nuts and/

or studs can absorb a substantial part of the torque applied on

the nut and cause a reduced clamping force.

Remove paint, dirt, and rust; replace damaged parts. Follow correct

tightening sequences and torque levels.

See Section 10.a.

Lubrication of nuts and studs:

Warning

Lubricants should not be applied to the nut’s washer i.e.

Graphic 12-2 - Eight Stud

nut-to-wheel contact surface. Application of excessive

lubricant to the threads of the stud and/or nut can cause

excessive torque beyond the yield point of the stud.

Over-torque can stretch studs causing them to fail. Failed

studs can cause the wheel to disengage from the vehicle,

causing serious injury or death.

Follow the proper wheel installation and maintenance

practices as described in this Section.

IMPORTANT

Lubricants must be completely removed from the nut’s washer i.e.

nut-to-wheel contact surfaceif applied accidentally.

Do not allow oil to contact mounting surfaces of the wheel, hub,

drum, or brakes. Do not use aerosol cans for lubrication of stud

Graphic 12-3 - Ten Stud

threads. See Section 10.a. See graphics 10-9 and 10-10.

Position one of the hub’s pilot tabs at the twelve o’clock position.

After positioning wheels on the pilot tabs, hand tighten all 2-piece

nuts, then tighten to the recommended torque, following

the proper sequence shown for your wheel type. See graphics 12-1,

12-2 and 12-3.

Picture 12-4

Torque wrench

After 8 - 80 kilometres or 5 - 50 miles of operation, torque should be

Under and over torque

recheckedunless vehicle/axlemanufacturer or your documented

practices determine otherwise. Check torque frequently from

then on.

Warning

Nuts must be kept tight, and studs and nuts should be checked

frequently.

Under torqued nuts allow wheels to run loose, pounding out

(deforming) the bolt holes, fatiguing studs or losing nuts,

Impact wrenches, if used, should be carefully adjusted to apply

as well as cause cracks in the bolt hole area. Over torquing

torques within or below the limits recommended.

can stretch studs (See Picture 11-19) causing them to fail with

Tighten to the recommended torque with a calibrated torque

loss of clamping force.

wrench. See picture 12-4.

Torquing of nuts should be done in recommended sequences.

Both under and over torquing can lead to wheel

After each wheel mounting, nut torque should be checked with a

disengagement causing serious injury or death.

torque wrench. Nuts should be retorqued if necessary.

At tyre changes, nuts and studs should be inspected to be sure

Follow the proper wheel installation and maintenance

they are in good condition. If cracks, stripped or damaged threads

practices as described in this Section.

are found, remove these nuts from service. Check wheel studs

accordingly.

NOTICE

If nuts require frequent tightening, studs break frequently

(picture 12-5), wheel nut washers break (picture 12-6) or bolt

holes are pounding out, hardware and mounting practices

should be reviewed.

Picture 12-5

Picture 12-6

12.b. Keep wheel nuts tight

Nuts must be kept tight. 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 frequently, hardware and mounting

practices should be reviewed. Dirt streaks from nuts and / or vent

holes may indicate looseness. See picture 12-7.

For proper installation of 2-piece fl

nuts, two drops of motor oil

should be applied between the nut and integrated washer and two

drops to the fi two threads at the tip of each stud. See Section

10.a.

IMPORTANT

For proper nut torque, always refer to vehicle or axle

Picture 12-7

manufacturers’ recommendations, prior to using chart 12-8.

Hubpilotedwheels using 2-piece fl

nuts

(nuts with integrated washer):

For

Thread Size

Torque Level Nm

Metric

M18 x 1.5

340 - 400

Metric

M20 x 1.5

380 - 450

Metric *¹

M22 x 1.5

610 - 675

Scania

7/8" - 11 BSF

540 - 660

Volvo *²

7/8" - 14 UNF

640 - 700

Chart 12-8

^*1Including Volvo from 2005

^*2Volvo up to 2004

For more details see Section 11.d. "Mounting hardware for Alcoa^®

Wheels specifi

made for Volvo".

NOTICE

1. Tightening wheel nuts to their specifi torque is extremely

important. Under tightening can result in loose wheels, can

damage wheels, studs, and hubs, and may result in wheel loss.

Over tightening can damage studs, nuts and wheels and may

result in loose wheels also.

2. All torque wrenches, air impact wrenches and any other tools

should be calibrated periodically to ensure the proper torque is

applied.

3. Refer to vehicle or axle OEM for torque range for any hardware

that is noted above.

12.c. Dualling with steel wheels

When dualling steel wheels with Alcoa^®Wheels, follow the steel

wheel manufacturers’ recommendations regarding the proper

torque and use of thread lubricants to mount the wheel. See

Warning

Section 4.g.

Using long sleeve nuts for mixed duals may cause a ‘bottom

IMPORTANT

out’ condition, see Section 11.b.ii.

On occasion Alcoa^®Wheels are dualled with a steel inner wheel.

A ‘bottom out’ condition may lead to loss of wheels causing

When this application occurs, it is recommended that Discmates

serious injury or death.

for Alcoa^®Wheels or nylon protection gasket is used, to prevent

galvanic corrosion.

Follow the proper wheel installation and maintenance

practices as described in Section 4.g.

In the event a steel inner wheel is used, extreme care must be

taken to properly seat it to the hub or drum before mounting the

outer aluminium wheel.

Selection of the correct hardware is required as providing

adequate thread length to secure the outer aluminium dual wheel

Warning

is critical to a safe assembly.

When mounting painted steel inner wheels with outer

Howmet Wheel Systems recommends the use of sleeved nuts for

aluminium wheels, be cautious of excessive paint build-up on

Alcoa^®Wheels for this purpose:

the inner steel wheel.

• Short sleeve nuts can be used

• When using sleeved nuts, the minimal thread engagement

Excessive paint (> 90 μm / 3.5 mil) can reduce the clamping

required is indicated in Section 11.b.

force and allow the wheels to become loose. Wheels

separating from the vehicle can lead to serious injury or

death.

Follow the proper wheel installation and maintenance

practices as described in Section 10, 11 and 12.

12.d. Incorrect assemblies

The following are examples of incorrect wheel assemblies.

Graphic 12-9

Graphic 12-10

1. Hub piloted aluminium wheel

1. Stud located, ball seat aluminium wheel

2. Ball seat or spherical nut

2-piece fl

nut

3. Insuffi

contact area

3. Little (if any) contact area

• Do not use ball seat / spherical or conical seat nuts with hub

piloted wheels.

• Do not use standard 2-piece fl

nuts with stud located ball

Warning

seat / spherical or conical seat wheels.

• Do not use sleeved nuts using too small or too large bolt holes.

Using the wrong wheel nuts can cause loss of clamping force,

• Do not use standard 2-piece fl

nuts on wheels designed for

broken studs or cracked wheels.

use with sleeved nuts.

• Do not use Volvo OEM sleeved nuts on any other type of wheel.

Loss of clamping force, broken studs or cracked wheels can

• Do not use standard 2-piece fl

nuts on Alcoa^®Wheels

lead to wheels separating from the vehicle causing serious

specifi

made for Volvo. See Section 11.d.

injury or death.

Use only hardware designed specifi

for each wheel type.

See Section 11 for proper hardware assemblies.

13. Wheels in service

13.a. Inspect thoroughly and frequently

Safe operation requires thorough examination of wheels and

attaching hardware, at frequent intervals, both on and off the

Warning

vehicle.

Failure to inspect wheels and hardware thoroughly and

Wheels that are in service need to be inspected at regular intervals

frequently may cause wheels to fail unexpectedly.

to assure proper and safe performance.

Unobserved wear, corrosion or cracks may result in a wheel

It is not always possible to predict the useful life of a wheel. Wheels

- or hardware failure or wheel loss causing serious injury or

will eventually wear out. But generally, older wheels and wheels

death.

operating in extreme conditions should be examined more

frequently for obvious signs that they should be removed from

Inspect wheels and hardware periodically for a safe

service.

operation of the vehicle.

Examine all exposed areas frequently. Clean wheels, inspect valves

and look for cracks, corrosion, wear, 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, the surfaces of the rim, the

mounting fl

and mounting holes.

13.b. Hidden damage

Do not exceed maximum wheel load. Customer must compare

Check mounting holes for cracks, fretting, enlargement, and

OEM vehicle axle load ratings to maximum wheel load rating and

elongation which can occur if the nuts are not kept at proper

infl

pressure which is roll stamped onto the wheel. See Section

torque. Dirt streaks radiating from bolt holes and / or vent holes

4.d.

may indicate loose nuts. See Section 12.b.

Do not over-infl

Use the tyre - and wheel manufacturers’

recommended pressure, but under no circumstances exceed cold

infl

pressure listed by the tyre - and wheel manufacturer

which is on the tyre and wheel. Before mounting the tyre, perform

a wheel fi

check to ensure proper clearance from any

obstructions. See ‘Wheel fi

check’ Section 5.d.

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.

Picture 13-1

Warning

Damaged tyres or wheels can lead to an explosive separation of tyres and wheels. An explosive separation can result in serious injury

or death.

Inspect tyres and wheels for damage before removing from vehicle.

If damage is found, tyres must be completely defl

before loosening wheel nuts. Remove damaged tyres or wheels from service.

13.c. Wheel alteration

Howmet Wheel Systems does not approve any form of alteration

to wheels except minor cosmetic buffi for appearance purposes.

Sanding and/or grinding is permitted to maintain the rim fl

Warning

the wheel. See Section 13.g.

Welding, brazing or otherwise heating any area of an Alcoa^®

NOTICE

Wheel will weaken the wheel. Weakened or damaged wheels

can lead to an explosive separation of tyres and wheels or

Buffi

polishing, sanding, grinding or other kind of abrasive

wheel failure on the vehicle.

handling of Dura-Bright^®surface treated wheels will remove the

Dura-Bright^®surface treatment. For more information see Section

Explosive separations of tyres and wheels or wheel failure on

14.b.

the vehicle can cause serious injuries or death.

Wheels must not be altered by welding, brazing or other heat

Never attempt to weld, braze, or heat any surface of Alcoa^®

application, e.g. powder coating in an attempt to repair or

Wheels.

straighten a wheel.

Use of adapter plates or bead-locks are not approved on Alcoa^®

See Section 13.d. Heat Damage.

Wheels.

Wheels should not be painted, powder coated or otherwise coated

in any way that may interfere with the mounting surfaces.

Any wheel that shows signs of modifi

alteration or

adaptation should be removed from service and scrapped.

Thewheelidentifi

must be legible. Wheels should be taken

out of service if such identifi

is not legible or does not meet

regulatory requirements. See Section 4.d. Identifi

of Alcoa^®

Wheels.

13.d. Heat damage

Warning

Excessive heat from fi brake malfunction, wheel bearing failure, tyre failure or other sources of heat may weaken the metal and

cause the tyre/wheel assembly to separate explosively.

An exploding tyre/wheel assembly can cause serious injury or death.

Immediately and permanently remove from service any wheel that has been exposed to excessive heat.

Wheels must be inspected if they have been exposed to excessive

A wheel may discolour from excessive heat. It can show a dull

heat before being returned to service. A wheel that has been

greyish colour and will not polish to a bright fi

as a typical wheel

exposed to excessive heat may appear charred or burned.

would.

A wheel that has been exposed to excessive heat may appear to be

Starting in January 2009 the new Alcoa^®Wheels logo sticker on the

in good condition if it has been cleaned.

wheel may not show heat damage. Inspect all axle end components

for signs of exposure to excessive heat.

Do not use any wheel that has been overheated regardless of

appearance. Even if a wheel does not appear to be obviously

Check the brake lining of drum brakes or brake pads of disc brakes,

burned, inspect labels, tyre beads, brake components and the

Discmates for Alcoa^®Wheels or nylon protection gaskets and tyre

Discmate for Alcoa^®Wheels or nylon protection gasket for evidence

beads for heat damage. If one of these components show signs of

of charring, melting, blistering, or burning.

overheating, the entire assembly, including the wheel, should be

replaced, and removed from service permanently.

Any wheel run with a fl tyre longer than the time necessary to

immediately pull off the road, should be checked for excessive heat

damage.

Alcoa^®Wheels manufactured from January 2009 and onwards have a 2.5 cmor 1 inch round clear heatindicator sticker located at the wheel

next to the roll stamp along with a same sticker located on the tyre side drop well close to the valve hole as shown in pictures 13-2 to

13-5.

Heat Indicator

Picture 13-2 Heat Indicator at wheel fl

Picture 13-3 Heat indicator at wheel drop well

Picture 13-4 Heat indicator version 2 at wheel fl

Picture 13-5 Heat indicator version 2 at wheel drop well, close to serial

number and valve hole

Wheels without heat indicator (prior to 2009):

A blistered, blackened or cracked looking logo decal on Alcoa^®

Picture 13-6 Charred logo decal

Wheels may indicate that the wheel has been exposed to excessive

Picture 13-7 Discolouration of rim with charred rubber

heat. Discolouration of the wheel and/or a charred Discmate for

Picture 13-8 Charred Discmate for Alcoa^®Wheels or other nylon

Alcoa^®Wheels or other nylon protection gasket also may indicate

protection gasket

that the wheel has been exposed to excessive heat. See pictures

below.

Picture 13-6

Picture 13-7

Picture 13-8

Wheels with heat indicator (from 2009):

If either of these heat indicators show

Picture 13-9 Charred, discoloured heat indicator next to roll stamp

signs of blistering, charred, discoloured, or

Picture 13-10 Charred, discoloured heat indicator next to roll stamp (close up)

a cracked look, this may indicate that the

Picture 13-11 Charred, discoloured heat indicator in drop well inside the wheel

wheel has been exposed to excessive heat.

NOTE

Wheels with ANY discoloration of the heat indicator should have dimensional checks performed before returning the wheel to

service. See Section 13.e.

Picture 13-9

Picture 13-10

Picture 13-11

IMPORTANT

If any of the conditions as described and pictured on this page are

observed, remove the wheel from service immediately and perform

dimensional checks per Section 13.e.

This includes any heat damage to the tyre, discolouration to the

wheel and/or brake parts, as well as any burnt or charred labels.

Do not attempt to mount and infl a tyre on a wheel that

shows conditions as described and pictured in this Section, until

dimensional checks are performed per Section 13.e.

13.e. Dimension checks

Warning

Wheels that have run fl been subjected to high pressure tyre and rim separation, excessive heat damage or have other physical

damage, may no longer have the correct dimensions and contours to retain the tyre beads while 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 a tyre. Immediately and permanently remove from service

any wheel that has been exposed to high pressure, tyre and rim separation or excessive heat.

IMPORTANT

Follow dimension check procedures described in this Section during each wheel inspection.

13.e.i. Dimension checks

Best inspection method: with a wheel rim ball tape

Picture 13-12

Picture 13-12 shows an example of a wheel rim ball tape.

Measure the circumference of the bead seat on the open side with

a ball tape. See picture 13-13.

Picture 13-13

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 centre fl

wide base wheels, or wheels with

off

(or insets) less than 76 mm or 3 inches, both bead seats

should be checked.

All wheels should be inspected prior to mounting.

If a ball tape or carpenter square is unavailable, roll the wheel,

without a tyre, a minimum of 3 metres or 10 feet over a smooth,

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. See pictures 13-20,

13-21 and 13-22. Remove the wheel from service until it can be

properly checked with a wheel rim ball tape.

If you do not fully understand any of these inspection methods as

described in this Section contact Howmet Wheel Systems.

13.f. Tyre wear or vibrations

If you experience irregular tyre wear or vibrations it may be helpful

to check radial run out. Remove the wheel from the vehicle, defl

and remove the tyre. See Section 8 for defl

and demounting

tubeless tyres and Section 7.c. forinfl

and bead seating check.

Remount the wheel on the vehicle without the tyre. Be sure to

follow proper mounting procedures to assure the wheel is well

centred on the hub. Place a dial indicator as illustrated in picture

13-23 to trace the bead seats of the wheel. Rotate the wheel noting

the amount of variation shown on the dial indicator. Alcoa^®Wheels

should be tested for radial run out only at the bead seat surface. A

total reading of 0.75 mm or 0.03 inch or less is acceptable.

Irregular tyre wear can also be caused by improperly seated tyres.

Picture 13-23

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, defl

the tyre and break the bead seats. See Section 8

Defl

and demounting tubeless tyres.

Adequately lubricate the bead seats and properly reseat the tyre

beads. See Section 8.b.iii. Lubricants and Section 7.c. Infl

and

bead seating check.

Re-infl

the tyre wheel assembly in a safety restraint or tyre cage.

See Section 7.c. Infl

and bead seating check.

NOTICE

Run-out tolerance or total indicator reading may be 0.75 mm or

0.03 inch for a new wheel.

If the wheel has been in use it may already have been exposed to

impacts. Some deformation may occur.

13.g. Rim fl

wear

Rim fl

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 fl

is caused by

abrasion from the tyre. Rim fl

wear happens most often in

applications with heavy or shifting loads.

If excessive rim fl

wear is observed, consider using

Dura-Flange^®Alcoa^®Wheels. These wheels have been specially

treated to signifi

reduce rim fl

wear.

Picture 13-24

For information consult QR code

Remove wheels from service when rim fl

wear is excessive.

Excessive wear can be determined using a Howmet Wheel Systems

approved wear gauge and procedures detailed under Section

13.g.ii.

If rim fl

wear creates sharp edges and/or cuts the tyre, see ‘Rim

maintenance / edge removal procedures’ detailed under

Section 13.g.iii.

13.g.i. Alcoa^® Wheels rim fl

wear gauge instructions

These gauges are to be used for Alcoa^®Wheels and rim fl

wear only. They are not a bead seat angle or diameter tool. For steel wheels

and other aluminium wheels other regulations may apply.

Alcoa^® Wheels rim fl

wear gauges are

Wear gauge

available from authorized distributors

of Alcoa^®Wheels.

Rim fl

Daylight in this area indicates

No daylight in this area

acceptable fl

indicates excessive wear

Graphic 13-25

Graphic 13-26

Rim acceptable

Rim NOT acceptable

13.g.ii. Determining rim fl

wear

STEP1

Removethe tyre/wheel assembly from the vehicle and remove

the tyre from the wheel according to Section 8, Defl

and

demountingtubelesstyresfromAlcoa^® Wheels.

STEP2

After the tyre is removed from the wheel, verify if the circumference

of the bead seat on the open side is acceptable. See Section 13.e.

Dimension checks.

Picture 13-27 SERVICEABLE

Check the rim fl

with the Rim Flange Wear Gauge for Alcoa^®

Wheels to determine if the wheel must be removed from service for

excessive rim fl

wear. See pictures 13-27 and 13-28.

See Alcoa^®Wheels rim fl

wear gauge instructions, Section

13.g.i. and preceeding graphics to make this determination.

Rim Flange Wear Gauges are available from authorized distributors

of Alcoa^®Wheels

Picture 13-28 NOT SERVICEABLE

STEP3

If the rim fl

wear gauge shows the wheel is serviceable, examine the wheel fl

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.

Picture 13-29

Picture 13-30

A rubber sharpness gauge or a suitable piece of rubber attached to

Run the sharpnessindicator gauge along the wheel at the area

a block of wood.

of the wear to determine if this wear is sharp enough to cut or

damage the rubber on the sharpness indicator.

By running the sharpness indicator gauge along the wheel in the

area of the wear, determine if this wear is sharp enough to cut or

damage the rubber on the sharpness indicator. If the rubber is cut,

Caution

then follow the edge removal instructions as describedin Section

13.g.iii.

Do not run unprotected hands or fi

across worn rim

areas of used wheels.

NOTICE

Examine the tyre for cuts in the bead areas and side walls. If

Worn rim fl

areas are sharp and can cut hands or

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

Always wear gloves when handling used wheels or when

normal tyre procedures recommended by the tyre manufacturer.

checking for edge sharpness of rim fl

NOTICE

Check the wheel at every tyre change or minimum ONCE PER YEAR

for rim fl

wear and any sharp edges. Following this practice, it

will signifi

reduce the possibility of a rim fl

cutting into

the tyre.

If a rim fl

cuts, or appears close to being sharp enough to

cut, the rubber on the sharpness indicator gauge, the edge can be

removed as per the edge removal procedures in following pages.

If the rubber is not cut, then the wheel can be returned to service

without further work for rim fl

wear.

13.g.iii. Rim fl

maintenance/edge removalprocedures

There are many tools available to remove a sharp edge on the wheel caused by rim fl

wear. Here are some examples of commonly

used tools:

Picture 13-31 Air or electric power sander

Picture 13-32 Air or electric power grinder

A very quick and eff

method of removing the sharp edge.

Another quick and eff

method of removing the sharp edge

Operators should use all care to keep a uniform rim fl

when

caused by rim fl

wear. Be careful as grinding pads may “gum

using these tools.

up” from the aluminium that is removed. Avoid gouging the wheel.

Picture 13-33 Angle die grinder

Picture 13-34 Angle die grinder, tips

Using with a sanding wheel, cutting stone, or grinding tool, this is a

After removing the tyre from the wheel, leave the wheel on the

version of an electric grinder. This tool is very quick and eff

tyre changer. Let the wheel rotate slowly and use the die grinder

well. Remove metal as uniformly as possible and do not gouge the

to remove the sharp edge from the wheel rim fl

Remove the

wheel.

metal as uniformly as possible, without swinging, or adding force to,

the angle die grinder. Do not gouge the wheel.

Caution

Removing sharp edges with hand or power tools produces metal fi

and sparks. Power tools may have parts that are sharp. Some

power tools produce excessive noise and may heat up during use.

Metal fi

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 parts can produce cuts and hot surfaces can cause burns.

Always wear appropriate safety gear such as protective eye wear, gloves, protective clothing, and hearing protection when using hand

or power tools.

Picture 13-35 Sharp edge before removal

Picture 13-36 Sharp edge removed

STEP4

Pictures 13-35 and 13-36 show the result of removing the edge.

With whatever tool is selected, work the tool around the wheel’s

Warning

circumference, removing only enough material to eliminate the

sharp edge. This should only be a small amount of metal.

Welding or brazing the rim fl

or any area of an Alcoa^®

Wheel will weaken the wheel. Weakened or damaged wheels

Perform this work on both fl

if there is evidence of sharpness.

can lead to an explosive separation of tyres and wheels or

Make sure the edge removal is as uniform as possible. Avoid

wheel failure on the vehicle.

gouging the wheel.

Explosive separations of tyres and wheels or wheel failure on

the vehicle can cause serious injury or death.

STEP5

After the sharp edge is removed, run the sharpness indicator gauge

Never attempt to weld or braze any surface of an Alcoa^®

(Section 13.g.ii. STEP 3) along the area of edge removal to check for

Wheel.

any remaining sharpness.

If the rubber is still cut, perform the previous steps again to remove

the sharp edge. Always remove the minimum amount of material

necessary to eliminate the sharp edge.

Warning

Returning wheels to service with inadequate fl

height as

STEP6

determined by the Rim Flange Wear Gauge for Alcoa^®Wheels

Check the rim fl

height with the Rim Flange Wear Gauge for

can lead to an explosive separation of tyres and wheels.

Alcoa^®Wheels to make sure there is adequate height remaining to

safely support the tyre. Section 13.g.ii. STEP 2 shows how the gauge

Explosive separations of tyres and wheels can cause serious

is to be used. Move the gauge all around the wheel’s circumference

injury or death.

and make sure that no area of the fl

is below what the gauge

indicates as acceptable. If the entire wheel fl

is within the limits

Wheels with a fl height that falls below the Rim Flange

of the rim fl

wear gauge, the wheel may be returned to service.

Wear Gauge have inadequate rim fl height to support

the tyre on the rim. Immediately and permanently remove

any wheel from service that has inadequate rim fl

STEP7

height.

Always inspect the wheel for any other conditions that would

warrant removal from service. See all paragraphs of this Section.

IMPORTANT

Always follow safe mounting procedures as recommended in this

Warning

manual and use an approved safety restraint or tyre cage when

infl

a tyre/wheel assembly.

Excessive heat from fi brake malfunction, wheel bearing

failure, tyre failure or other sources of heat may weaken

Rim fl

wear could dictate the use of “stick-on” or adhesive

the metal and cause the tyre/wheel assemblies to separate

balancing weights if there is inadequate rim fl

to properly hold

explosively.

a clip-on style balancing weight.

Exploding tyre/wheel assembly can cause serious injury or

death.

NOTICE

Use Alcoa^®Wheels Rim Flange Wear Gauge for Alcoa^®Wheels only.

Immediately and permanently remove from service any

wheel that has been exposed to excessive heat.

13.h. Cracked or damaged wheel checks

Visually inspect wheels for cracks or damage. Remove wheels

from service with known or suspected damage. See the following

Sections for reference.

Warning

Cracked or damaged wheels may fail or come off the vehicle.

Wheels that fail or come off the vehicle while it is moving can

cause serious injury or death.

Immediately and permanently remove cracked or damaged

wheels from service.

13.h.i. Mounting area

Cracks in the mounting - or disc area are usually caused by

Pictures of examples below show cracks starting in the disc area.

improper installation (see Sections 10 and 11), excessive loading or

Probable causes are:

insuffi

mounting fl

support (see Section 13.h.i.) by the hub

• Incorrect attachment parts or mounting hardware, see Section

or brake drum. Remove the wheel from service immediately and

11 (Picture 13-38)

permanently.

• Insuffi

torque, see Sections 10 and 12 (Picture 13-39)

• Undersized diameter of wheel support surface (Picture 13-40)

The indication may be caused by, one or a combination of following

• Presence of paint, dirt, and corrosion at mating faces of wheel

conditions:

and hub, when installing (Picture 13-41)

• Overloading, uneven distribution of load on axles and / or

• Support surface not fl (Picture 13-42)

• Improper fi

lack of lubrication hardware and/or

• Insuffi

maintenance (cleaning mating faces), and/or

• Application / use of non-spec / non-genuine hardware

Picture 13-38

Picture 13-39

13.i. Corrosion

Certain environments canlead to corrosion, such aslivestock

Mild corrosion should be removed thoroughly by wire brush and

haulage or food related transport subject to frequent disinfectant

the tyre mounted with a non-water non-metal-based tyre lubricant.

cleaning. Some of the more common corrosives are salt,

magnesium chloride and calcium chloride compounds used for

Remove any severely corroded wheel from service.

snow removal and highly acid or alkaline materials.

Discolouring of the wheel part covered by the tyre is an indicator of

If the air used to infl

tubeless tyres, or the tyre, or the wheel

entrapped moisture. See pictures 13-64 and 13-65.

itself, is not dry, the areas of the wheel, drop centre, valve hole area

and bead seats, covered by the tyre can corrode severely.

Corrosion at the drop centre, valve hole area and bead seats

(Section 13.h.iv.) and hub bore is often caused by entrapped

moisture.

Picture 13-64

Picture 13-65

13.i.i. Corrosion at hub bore and wheel disc or mounting face

Picture 13-66

Picture 13-67

After removal of corrosion:

• The hub bore diameter may not exceed 0.5 mm or 0.02 inch

more than the dimension of the hub bore diameter as listed in

the Specifi

Sheet for Alcoa^®Wheels.

Remove wheels from service with severe hub bore corrosion.

Specifi

Sheet for Alcoa^®Wheels:

• The wheel disc i.e., when measuring the thickness, between the

mating areas with either hub or dualled wheel, may not be less

than 0.5 mm or 0.02 inch than the disc thickness as listed in the

Alcoa^®Wheels Specifi

Sheet.

13.j. Regular inspection and removal of corrosion

In addition to the recommendations provided in Section 14 Care

NOTE

and Maintenance of this manual, maintenance of aluminium

The inside facing surface of non-reversible Dura-Bright^®wheels

wheels is required to ensure a safe and reliable service life.

have no surface treatment.

Frequent cleaning of aluminium wheels and removing corrosion

IMPORTANT

will not only contribute to the looks of the vehicle but -more

Oxidation will occur with corrosion build up as a result.

important- will add to a safe and reliable operation of the vehicle

If wheels are not cleaned regularly, excessive corrosion build

during the wheels’ servicelife.

up may contribute to cause wheels to fail either by initiating or

accelerating hair line cracks.

Brushed, Mirror Polished and LvL ONE^®Alcoa^®Wheels are

uncoated. The bare aluminium or non-surface treated and highly

Any excessive corrosion build-up must be removed at vehicle

corrosion resistant alloy that is used for Alcoa^®Wheels reduces

inspection intervals, before placing wheels in service again or upon

oxidation to a minimum. Corrosion build up may occur on all

tyre change or repair.

surfaces if wheels are not cleaned regularly.

CLEANING MATING FACES (wheel disc and hub or drum):

Dura-Bright^®Alcoa^®Wheels have a surface treatment that protects

the wheels’ surface against oxidation. The treatment may get

After cleaning the mating faces, the disc (bolt hole) area of the

damaged or erode during service life.

wheel and the mounting area of the hub, must be dry, clean,

smooth, and fl before mounting.

Consult section 10.a. Wheel installation preparation

Picture 13-77

Picture 13-78

Picture 13-79

The abrasive tools used in these pictures are available from

authorized distributors of Alcoa^®Wheels, reference: Bristle Discs for

Alcoa^® Wheels.

For documentation contact Howmet Wheel

Systems or go to the web page

Picture 13-80

CLEANINGNON-MATINGFACES:

For more information about care and maintenance of untreated

surfaces (Brushed, Mirror Polished and LvL ONE^®) and

Dura-Bright^®surface treated Alcoa^®Wheels refer to the following

pages, Section 14, of this manual.

14. Care and Maintenance

Regular cleaning

Clean the wheels regularly with steam or high-pressure water.

Do not use harsh acidic or harsh alkaline cleaners. Do not use

hydrofl

acid. Do not use abrasive products or tools to clean or

polish Alcoa^®Wheels.

14.a. Maintenance against corrosion for Brushed, Mirror Polished and LvL ONE^®

wheels (non-Dura-Bright^®surface treated wheels)

These wheels can be identifi by the blue Alcoa^®logo on the sticker:

The following information is for Alcoa^®Wheels without the

Dura-Bright^®surface treatment.

See Section 14.b. for specifi instructions on the care and cleaning

of Dura-Bright^®surface treated Alcoa^®Wheels.

For Alcoa^®Wheels with Brushed, Mirror Polished or LvL ONE^®

1. Clean frequently with steam or high-pressure water. The use of

a mild detergent will speed the cleaning process. Use no harsh

acidic or harsh alkaline cleaners. Do not use hydrofl

acid.

Picture 14-1

Picture 14-2

2. When tyres are removed the entire wheel must be cleaned and

inspected. See Sections 5, 6 and 13.

With Bristle Discs for Alcoa^® Wheels or a wire brush, remove

dirt and contamination from the tyre side of the rim. Do not

use Bristle Discs for Alcoa^®Wheels or a wire brush to remove

dirt and corrosion from the appearance surface

of the wheel. Bristle Discs for Alcoa^®Wheels are

available from authorized distributors of Alcoa^®

Wheels.

Picture 14-3

Picture 14-4

3. To maintain the original appearance of your Alcoa^®Wheels, the

UseALcleanandALpolishfromHowmetWheelSystems

following procedures are recommended:

a) After installing new wheels and prior to operating your

Alcoa^®Wheels with Brushed, Mirror Polished and LvL ONE^®fi

vehicle, use the ALbrush for Alcoa^®Wheels or a soft fi

are uncoated. The highly corrosion resistant alloy that is used for

brush to wash the visible wheel surfaces with a mild

Alcoa^®Wheels reduces oxidation to a minimum. Maintaining the

detergent and warm water solution.

original lustre of the wheels is easy with ALclean and ALpolish.

b) Flush thoroughly with clean water.

Regular and frequent maintenance will keep your wheels bright

c) Wipe dry to avoid water stains.

and shiny for years.

d) Clean your Alcoa^®Wheels every week to maintain their

appearance.

For reference see the 'How to Clean' page on our

website:

14.b. Maintenance and cleaning Dura-Bright^®XBR^®and Dura-Bright^®EVO surface

treated wheels

These wheels can be identifi by the Alcoa^®logo on the sticker,

Dura-Bright^®surface treated wheels’ part number have extension

which is black for Dura-Bright^®XBR^®or black and green for

DB or DD. See Section 4.d.

Dura-Bright^®EVO.

Ultra ONE^®DURA-BRIGHT^®EV

Picture 14-5

Picture 14-6

Picture 14-7

Dura-Bright^®wheels are easy to clean and stay bright and shiny

material. If soils and dirt remain, use Dura-Bright^®Wheel Wash

when properly maintained.

or warm water and a mild detergent using high pressure power

washer.

Dura-Bright^®wheels are maintained best with Dura-Bright^®Wheel

Wash, a standard car wash soap or a near pH neutral detergent.

Always dilute the detergent according to the manufacturers’

recommendations; never use the detergents straight without

If soils and dirt attached to the surface do not come off with cold

diluting with water.

water, try warm water and wipe with a soft towel or chamois

Dura-Bright^®Wheel Wash for Alcoa^®Wheels is available from

authorized distributors of Alcoa^® Wheels.

For reference see the 'How to Clean' page of our website:

IMPORTANT

Dura-Bright^®Alcoa^®Wheels should NOT be polished with polishing compounds or ALpolish.

Picture 14-8

IMPORTANT

Do not use strong acidic or strong alkaline products on Dura-Bright^®surface treated

wheels.

Hydrofl

acid (HF) should never be used on Dura-Bright^®surface treated

wheels.

The pH value of the cleaner can be found in the MSDS (Material Safety Data Sheet).

If the cleaner is undiluted, consult your cleaning products supplier to determine pH

levels and dilution.

Pictured an example of how to test pH value with pH indicator strips (See picture

14-9).

NOTE

Dura-Bright^®Wheel Wash for Alcoa^®Wheels can be used without diluting.

Picture 14-9

IMPORTANT

The Dura-Bright^®surface treatment for Alcoa^®Wheels is developed to enable eff

cleaning wheels, with mild and environmentally

friendly cleaning products, maintaining the looks and shine the easy way.

Professional cleaning products for commercial vehicles, stationary and mobile vehicle wash service providers may contain and use strong

acidic and alkaline components that may harm the Dura-Bright^®surface treatment for Alcoa^®Wheels.

Before cleaning Dura-Bright^®surface treated wheels it is recommended to check and evaluate following with the supplier or service

provider:

1. Type of chemical components in product(s) used as per material safety data sheet (MSDS).

2. Dilution of the product(s) with clean water, or pH value.

3. Temperature, of both wheel surface and mating components.

4. Time of exposure recommended for the product(s) to be used safely and eff

to clean the surface.

NOTE

Cleaners that are safe to use on windows and painted panels and bodywork can be used on Dura-Bright^®surface treated Alcoa^®Wheels

Consult the recommendations in this Section. In case of doubt contact Howmet Wheel Systems.

14.b.i. Maintenance and cleaning Dura-Bright^®XBR^®and Dura-Bright^®EVO surface

treated Alcoa^®Wheels in 5 steps

STEP1

Before cleaning, allow wheels to cool down to a temperature below

35°C or 95°F.

Picture 14-15

STEP2

Flush the wheels thoroughly to remove any loose and visible dirt

and debris. Flushing the wheels with water helps to help preventing

scratching and abrasion. Use a water hose or power washer to

remove soil, sand, etc.

Picture 14-16

STEP3

Use undiluted Dura-Bright^®Wheel Wash for Dura-Bright^®Alcoa^®

Wheels, a standard car wash or a (near pH neutral) detergent. Add

car wash or a mild detergent (e.g., common dish soap liquid) to the

water at the specifi dilution ratio before applying to the wheels.

• Do not use harsh acidic or harsh alkaline cleaners.

• Do not use hydrofl

acid (HF).

Picture 14-17

STEP4

Clean the wheels. Apply Dura-Bright^®Wheel Wash for Dura-Bright^®

Alcoa^®Wheels, soap, or detergent generously on wheel surface

with the ALbrush for Alcoa^®Wheels or a soft fi

brush. Do not use

abrasive tools and scouring pads (e.g., 3M Scotch-Brite^®).

Picture 14-18

STEP5

Flush the wheels thoroughly with clean water and remove all

remaining soap and dirt. Dry the wheels using a soft cloth free of

debris.

Picture 14-19

14.b.ii. Additional care and tips for Dura-Bright^®XBR^®and Dura-

Bright^®EVO surface treated Alcoa^®Wheels

Once in service, Dura-Bright^®surface treated Alcoa^®Wheels can

NOTICE

become nicked or scratched by road debris and/or mechanical

For maintenance of Dura-Bright^®surface treated Alcoa^®Wheels

damage. If this occurs, continue to follow the normal washing and

that were and are subject to damage, handling marks, erosion and

cleaning instructions provided in Section 14.b.i.

discolouring of the Dura-Bright^®surface treatment, refer to 2. and

3. of this section, or contact:

The mounting area on Dura-Bright^®surface treated Alcoa^®Wheels

can become scratched, marred, or discoloured when mounted

against another wheel, hub, or drum. Wheel mounting surface

Howmet Wheel Systems Fleet Service Center:

guards, such as Discmates for Alcoa^®Wheels or other nylon

protection gaskets, can be used.

1. Regular conditions do not require special routines

Dura-Bright^®wheels can be kept clean with Dura-Bright^®Wheel

Wash for Alcoa^®Wheels, soap an water, or with mild acid washes

How to clean:

that also can be used safely on the vehicles’ painted surfaces.

Products for cleaning:

2. Conditions that may require an additional maintenance practice

Handlingmarks, traces of use

Dura-Bright^®surface treated Alcoa^®Wheels with handling marks or

traces of use (e.g., scratches, nicks, dents, or gouges) build up disc

brake dust on those parts of the surfaces where the Dura-Bright^®

surface treatment is missing. These surfaces will look as if they have

not been treated with Dura-Bright^®.

Picture 14-20

Picture 14-21

Erosion

Dura-Bright^®surface treated Alcoa^®Wheels mounted on vehicles

used on gravel roads or on asphalt roads where sand, stones

or other material erode the Dura-Bright^®surface treatment, will

gradually show a declining layer of treatment.

Due to the missing full coverage of Dura-Bright^®surface treatment,

the surfaces will show oxidation or a gradual build-up of disc brake

dust at the rim fl

area.

Picture 14-22

Picture 14-23

Discolouring

Dura-Bright^®surface treated Alcoa^®Wheels on axles with disc

brakes may show a gradual discolouring over time. Mostly seen on

front axles, wheels will develop a brownish, copper, or golden haze

next or off to the vent holes depending on the rotation

direction. This discoloration is a tarnish, and the result of the

substances released from the disc brake pads when braking.

The above-mentioned conditions may appear sooner after a winter

period or at longer intervals between cleanings. More frequent

cleaning with Dura-Bright^®Wheel Wash for Alcoa^®Wheels, soap,

and water or a mild acid cleaner is recommended.

Picture 14-24

Notice

These conditions i.e., handling marks, traces of use, erosion and/or discolouring, are not warrantable.

Filiform corrosion (worm or hair like lines, underneath surface protective treatment and emanating from damage to the surface

treatment) and blistering or peeling due to loss of adhesion of the surface treatment is warrantable for a period of 60 months from

date of manufacturing.

See ‘Limited Warranty’ Section 2 for reference.

3. Additional maintenance practice

• Wheels or parts of wheels that show conditions as described

above may require additional maintenance.

• The use of ALclean with the ALbrush is recommended to remove

disc brake dust, corrosion, or discolouring, as with regular

untreated surfaces.

• The Dura-Bright^®surface treatment will not be aff

using

ALclean if it is used on limited occasions and time.

ATTENTION

Read the safety instructions on the label of

the ALclean 1 litre bottle or 5 or 25 litres can.

Material Safety Data Sheets are available via

'Safety Data (MSDS)' link at the bottom of the

Cleaning webpage:

Picture 14-25

Picture 14-26

ALclean 1 litre bottle

ALbrush2 soft fi

brush

ALclean and ALbrush2 are available from authorized distributors of

Alcoa^® Wheels.

How to proceed:

1. Allow the wheels to cool down before cleaning. The

recommended temperature of the wheels should be below

35°C or 95°F.

2. Remove all nut covers if present.

3. Thoroughly remove dust, sand, with water from a hose or a

high-pressure washer. Do not dry the wheel.

4. Use a limited quantity, 100 ml or 3.45 fl oz of undiluted ALclean

with the ALbrush, or brush with soft fi

and gently brush

the wheel 2 to 3 times with short breaks for 2 to 3 minutes in

total.

5. Flush the wheel thoroughly with cold or lukewarm water.

6. Repeat step 4 and 5 until disc brake dust, corrosion and/or

discolouring are removed.

7. After the wheel has dried, refi the nut covers.

For regular cleaning of Dura-Bright^®wheels, continue to use

Dura-Bright^®Wheel Wash for Alcoa^®Wheels or soap and water

frequently as described in Section 14.b.i.

Perform the additional maintenance using the ALclean as described

in steps 1 to 7 on limited occasions only.

15. Out-of-Service Wheels

Identifi

of Out-of-ServiceWheels and Proper Disposal

and Recycling

Alcoa^®Wheels are made of aluminium. Aluminium is almost 100%

recyclable.

Out-of-Service Wheels

Wheels should be removed from service when inspection reveals

out of service conditions that render a wheel no longer serviceable.

Conditions such as cracking, corrosion, wallowed bolt holes and

worn rim fl

are examples of conditions that may cause a

wheel to be removed from service. See Section 13 (Wheels in

service) of this manual or Technology and Maintenance Council

(TMC) Users Guide to Wheels and Rims RP222 for examples of

wheels that should be removed from service.

Proper Disposal and Recycling

Picture 15-1

Comply with local, state, and national environmental regulations

with respect to out-of-service wheels. Howmet strongly encourages

you to recycle wheels that are no longer serviceable. Before off

Alcoa^®Wheels to an appropriate recycling company:

• Make the wheel permanently unserviceable beyond repair by

drilling out the date stamp in the wheel or using a torch to cut a

slot into the rim fl

on the open side of the wheel

• Remove, deface, or make illegible the serial number, date code,

and part number

• Remove valves, tire pressure monitor sensors (TPMS), balancing

weights, and other components. Follow local, state, and national

environmental regulations for disposing of these components

According to the European Commission all Alcoa^®Wheels (part

numbers and fi

are classifi as non-hazardous waste and

can be disposed of and recycled.

Thank you for contributing to worldwide sustainability eff

returning Alcoa^®Wheels to the recycling chain, which reduces

landfi waste and leads to further opportunities for using the

aluminium.

16. Glossary of common terms and

conversion factors

16.a. Glossary of common terms

15° the angle of the tyre's beads and wheel's bead seats as used for

ET - stands for Einpresstiefe. Commonly found on steel wheels.

tubeless tyres and wheels for medium- and heavy-duty vehicles.

German for Off (or Inset). See INSET.

1 PIECE FLANGE NUT - A 1-piece washer and nut combination. Not

fl oz - fl

ounces, liquid volume measurement

recommended for use on any Alcoa^®Wheels application.

FMVSS - Federal Motor Vehicle Safety Standards (U.S.A.)

2 PIECE FLANGE NUT - A 2-piece washer and nut combination used

to secure hub piloted wheels.

FOOT-POUNDS / NEWTON METRES - The measure of the amount

of torque applied to a nut or other part. May be measured with a

AIR CHAMBER - The space enclosed by a tyre and rim of the wheel.

torque wrench.

BEAD SEAT - The tyre seating surface (2x) of the rim (See graphic

ft-lbs. - abbreviation for Foot-pounds, torque measurement.

16-1).

HDS or 1/2 DUAL SPACING - Measurement for use of wheels in dual

BOLT CIRCLE - The circle defi

by connecting the centres of the

application. Half the distance between the two centrelines

bolt holes (mounting holes) of a wheel, dimension of diameter

of a dualled tyre/wheel assembly. The dimension is the same as the

stated in millimetres or inches (See graphic 16-1).

OUTSET dimension (See graphic 16-1).

BOLT HOLES or mounting holes - Holes in the disc of the wheel

HMA - abbreviation of ‘Halber Mittenabstand’. German for Half Dual

through which the bolts (studs) pass.

Spacing see “HDS” (See graphic 16-1).

CENTREBORE - See“HUB BORE” (See graphic16-1).

HUB BORE - The centre hole of a disc wheel, dimension of diameter

stated in millimetres or inches (See graphic 16-1).

CLOSED SIDE - The disc face, top side or beauty face of a wheel that

can be mounted in a dual application. See also OPEN SIDE.

HUB PILOTED MOUNTING - A wheel mounting system which uses

the hub to centre the wheel (in single application) or both wheels (in

DC - Abbreviation for drop centre. See “DROP CENTRE” (See graphic

dual application) and 2-piece fl

nuts to secure wheel(s).

16-1).

in. - Abbreviation for inches (distance measurement). 1 inch equals

DISC AREA - The vertical part of the wheel which supports the rim

25.4 mm.

and is connected / faced to the hub, or the other wheel’s disc in

case of a dual mounting (See graphic 16-1).

INNER CAP NUT - Nut used to mount the inner wheel in a dualled

stud located wheel system. Not applicable for hub piloted wheels.

DISCMATE - A nylon protection gasket that goes between the hub

or brake drum and wheel and/or between two wheels to help

INSET or OFFSET - The distance from the wheel mounting surface

reducing corrosion.

to the rim centreline when the centreline is placed inboard of the

mounting surface. Measurement used for single wheel application.

DISC WHEEL - A 1-piece (forged) or 2-piece (welded) assembly of a

Dimension stated in millimetres or inches (See graphic 16-1).

disc and a rim.

kg - Abbreviation for kilogram, equal to 1000 grams, weight

DOT - abbreviation for Department of Transportation, federal

measurement.

cabinet department of the U.S. government concerned with

transportation.

kPa - Abbreviation for Kilopascal, 100 kPa equals 1 bar, pressure

measurement.

DROP CENTRE - The well or centre portion of the wheel rim that

enables the fi

of a tubeless tyre (See graphic 16-1).

lb. - symbol for pound, weight measurement.

DUAL WHEEL - Any wheel that can be mated disc side to disc side

LONG SLEEVE NUT - A (retrofi nut with a long extension sleeve

with a similar wheel resulting in an inner and outer dual wheel

used to secure dualled wheels (see also SHORT SLEEVE NUT).

assembly. See also SINGLEWHEEL.

MAXIMUM INFLATION - The highest amount of air pressure

RIM - That portion of the wheel which supports the tyre.

allowed, measured at ambient (cold) temperatures, approx. 20°C

SAFETY HUMP - Small and integral raised part of the wheel situated

(Celsius) or 68°F (Fahrenheit).

on lower end of one bead seat near the drop well. Prevents the tyre

bead from slipping into the drop well when tyres are operated at

millilitre - ml, 1000 millilitres equals 1 litre, liquid volume

low or defl

tyre pressure (See graphic 16-1).

measurement.

SHORT SLEEVE NUT - A retrofi nut with a short extension sleeve

mm - Abbreviation for millimetres. 1000 mm equals 1 meter.

used to secure a single wheel. See also LONG SLEEVE NUT.

MOUNTING FACE - Disc area, mounting area, support surface

SINGLE WHEEL - A single mounted wheel, or any wheel that cannot

diameter, that portion of the wheel face which contacts the hub or

be mated disc side to disc side with another wheel. See also DUAL

brake drum, or the adjacent wheel in case of a dual mounting (See

WHEEL

graphic 16-1).

STUDS - Threaded bolts extending from the hub surface to which

NEWTON METERS / FOOT-POUNDS - The measure of the amount

the wheels are secured by the nuts (See graphic 16-1).

of torque applied to a nut or other part. May be measured with a

torque wrench.

STUD LOCATED, BALL SEAT MOUNTING - A wheel mounting system

which uses the studs and spherical ball seat nuts to centre and

Nm - Abbreviation for Newton meters, torque measurement.

secure the wheel. Not applicable for hub centred wheels.

OFFSET - also referred to as INSET, see both INSET and OUTSET

TORQUE - The amount of force used to tighten nuts. Usually stated

(See graphic 16-1).

in Newton-meters or Foot-pounds and measured with a torque

wrench. Torque measurement.

OPEN SIDE - The side of the wheel opposite the disc face. The deep

side of a wheel that can be mounted in a dual application. See also

TPMS - abbreviation for Tyre Pressure Monitoring System, an

CLOSED SIDE.

electronic system designed to monitor the air pressure inside the

tyres of vehicles.

OUTER CAP NUT - A nut used to secure the outer stud located

wheel in a dualled wheel pair and threaded onto the inner nut. Not

TYRE BEADS - The parts of the tyre that sit on the bead seats of the

applicable for hub piloted wheels.

wheel's rim.

OUTSET - The distance from the mounting surface of the wheel to

the rim centreline when the rim centreline is mounted outboard

of the hub face. This dimension is the same as the HALF DUAL

SPACING dimension. See “HDS” and “HMA”. Dimension stated in

millimetres or inches (See graphic 16-1).

PCD - Pitch Circle Diameter, is the measurement of the diameter of

the imaginary circle drawn through the centre of all the bolt holes

of the wheel. See BOLT CIRCLE.

PILOT TAB or PAD / SPIGOT - The raised surfaces/parts on a hub

used to centre a hub piloted wheel.

POUND - symbol lb., weight measurement.

PSI - Abbreviation for pounds per square inch, pressure

measurement.

REVERSIBLE - Term applied to a disc wheel which can be reversed

on the hub without changing the position of the rim - and tyre

centreline.

RIM CENTRELINE - A line to the radial axis of the wheel running

through the midpoint between the rim fl

RIM FLANGE - That portion of the rim which extends above the

bead seat which helps to retain the tyre bead.

16.b. Common terms

Dual spacing

1. Rim fl

2. Tyre bead

3. Safety hump

4. Disc area

5. Stud

Bolt circle

2-Piece fl

nut

Hub bore

7. Hub bore groove

8. Mounting face

9. Air chamber

10. Drop centre

11. Bead seat

Wheel outset

Wheel inset

(HDS, HMA)

(OffS, H ET)

Rim centreline

Graphic 16-1

16.c. Conversion factors

Inches to Millimetres

Fluid ounces (US) to millilitres

Pounds to Kilograms

Inches x 25.4 = Millimetres

Fl oz (US) x 2.957.353 = millilitres

Pounds x 0.4536 = kg

Millimetres to Inches

Bar to kPa

Kilograms to Pounds

Millimetres x 0.03937 = Inches

Bar x 100 = kPa

kg x 22.046 = Pounds

Millilitres to fl

ounces (UK)

kPa to Bar

Foot-pounds to Newton Meters

ml x 0.035195065 = fl oz (UK)

kPa x 0.01 = Bar

Ft-lbs. x 135.582 = Nm

Fluid ounces (UK) to millilitres

psi to kPa

Newton Meters to Foot-pounds

Fl oz (UK) x 2.841.307 = millilitres

psi x 68.948 = kPa

Nm x 0.737562 = Ft-lbs.

Millilitres to fl

ounces (US)

kPa to psi

ml x 0.03381402 = fl oz (US)

kPa x 0.145 = psi