STEMCO Kaiser Qwik Kit® Training

STEMCO
29 Dec 201507:15

TLDRThis script outlines the comprehensive process of inspecting, removing, and replacing kingpins in a vehicle's wheel assembly. It emphasizes the importance of using proper personal protection equipment and following industry standards for kingpin replacement, such as a 10 thousandths of an inch movement threshold. The detailed steps include inspecting axle bores, cleaning, measuring, and identifying correct axle sizes, installing new bushings and kingpins with precise fit, and ensuring proper grease application for smooth operation. The guidance provided is crucial for maintaining vehicle safety and performance.

Takeaways

  • 🔍 Regularly inspect the axle for kingpin wear using a magnetic base dial indicator to ensure proper wheel alignment and performance.
  • 📏 The industry standard for kingpin replacement is based on a measurement of 10 thousandths of an inch movement, beyond which replacement is necessary.
  • 💡 Always use proper personal protection equipment when working with kingpins due to the potential dangers involved in their removal and replacement.
  • 🔧 Preparing the truck for kingpin replacement involves removing the wheel, brake, hub cap, and hub assembly, and then removing end plates and lock pin nuts.
  • 📌 When removing kingpins, note their sizes, placements, and directions, and avoid using heat on the axle to assist in removal.
  • 🛠️ Clean and inspect the axle thoroughly, removing burrs and ensuring smooth surfaces on axle bores and spindle faces for a quality repair.
  • 📏 Use a micrometer to measure the axle eye size and consult the Stem Co Keizer catalog to identify the correct axle size for the application.
  • 🔨 Install new kingpins by first checking for a slip fit in each individual bore and then sliding the kingpin through both bores simultaneously, addressing any binding or loose fits.
  • 💺 Pre-pack both bearings with grease to ensure maximum bearing life, compensating for wear with an additional 5/7 inch shim.
  • 🔩 Reassemble the wheel end by placing the kingpin through the upper spindle bore and aligning it with the lock flats, then installing the bearing and adjusting shims as needed for a proper fit.

Q & A

  • What is the first step in determining if a kingpin needs replacing?

    -The first step is to check the axle for the kingpin. This is done using a magnetic base dial indicator by placing the dial indicator on the side of the upper spindle and moving the wheel to obtain a reading.

  • What is the industry standard for kingpin movement that indicates the need for replacement?

    -The industry standard is 10 thousandths of an inch movement, which would indicate that kingpin replacement is needed.

  • What safety measures should be taken when removing and replacing kingpins?

    -It is crucial to use proper personal protection equipment to prepare the truck for kingpin replacement, as this can be dangerous work.

  • How do you prepare the truck for kingpin replacement?

    -To prepare the truck, you should remove the wheel, brake, hub cap, and hub assembly, then remove the end plates and lock pin nuts. After that, tap out the lock pins, noting their sizes, placements, and directions.

  • What is the recommended tool for cleaning the axle after removing the old kingpin?

    -A break hone is the recommended tool for cleaning the axle thoroughly, which will allow for a quality repair job.

  • How do you identify the proper axle size for the application?

    -It is critical to know the axle eye size, and the Stem Co. Keizer catalog can be used for identifying the proper axle size.

  • What is the correct method for installing a lip seal using the Stem Co. Keyser bushing driver?

    -Identify the side of the seal with the lip and place the seal on the driver with the lip pointing away from the tool. Insert the bushing driver into the spindle bore and use a brass or deadblow hammer to drive the seal down until it is just short of flush, ensuring the lip is toward the axle for grease flow.

  • How do you ensure a proper bushing fit during kingpin installation?

    -Each bushing should be inserted with a slight angle and a clockwise twist. Use the Stem Co. Keyser t-handle wrench to grip the bushing and continue the twisting until it is as far as possible into the bore. The bushing driver is then used to finish the installation, driving the bushing just pass flush.

  • What should you do if there is binding when sliding the kingpin through the bushings?

    -If binding occurs, remove the bushing and check for burs. If it is a loose fit, the spindle may be oversized. If the pin passes freely through each bushing separately but not both at the same time, then the spindle is spread. If issues persist, call technical service for assistance.

  • How do you pre-pack the bearings with grease for maximum bearing life?

    -Selections should be equal to the amount removed, plus one additional five thousand seven inch shim to compensate for wear. Place the kingpin through the upper spindle bore, align the 'top' of the pin with the lock flats, and slightly crimp shims by hand before placing them on the pin from under the bore.

  • What is the final step in assembling the wheel end after installing the kingpin and bearings?

    -Install the end plates for bolted and threaded styles, applying proper torque and playing the O-ring gasket combinations. For non-xored end plates, install grease fittings and then the plates. Grease the top unit until grease is visible between the axle and spindle, turn the spindle side to side, then grease again until grease is visible again. Repeat this process for the bottom unit.

Outlines

00:00

🔧 Kingpin Replacement and Preparation

This paragraph discusses the process of determining when a kingpin needs replacement by checking for movement with a magnetic base dial indicator. It emphasizes the industry standard for kingpin replacement and outlines the necessary safety precautions. The steps for preparing the truck for kingpin replacement are detailed, including the removal of wheels, hub caps, and hub assembly. The paragraph also explains the removal of end plates and lock pins, and the importance of noting the size, placement, and direction of these components. It further describes the cleaning and inspection of the axle and the use of specific tools for quality repair, including a break hone and a micrometer. The paragraph concludes with the identification of proper axle size and the preparation for bushing installation.

05:02

🛠️ Installing Bushings and Kingpins

The second paragraph focuses on the installation of bushings and kingpins. It begins with the preparation of the lip seal and bushing installation using the stem Co Keyser bushing driver. The paragraph details the process of inserting the bushing into the spindle bore and ensuring a proper fit. It then discusses the bench testing of the new kingpin and bushing fit, addressing potential issues such as binding or loose fits. The installation of bearings, both with and without built-in seals, is described, including the correct orientation and fitting. The paragraph also covers the adjustment of shims and the installation of the kingpin with precise alignment and torque. Finally, it explains the assembly of the wheel end, the installation of grease fittings, and the greasing process to ensure proper lubrication and protection against dirt and moisture.

Mindmap

Keywords

💡Kingpin

A kingpin is a critical component in the wheel hub assembly of a vehicle, which articulates the steering knuckle or axle stub with the wheel spindle. In the context of the video, it is important to determine when a kingpin needs to be replaced, as excessive play or wear can lead to handling issues and premature failure of other components. The video outlines a method for checking the kingpin's condition using a magnetic base dial indicator and provides steps for its replacement if necessary.

💡Axle

An axle is a central shaft for a rotating wheel or gear, typically used in the context of a vehicle to transfer power from the engine to the wheels. In the video, the axle is the central component around which the kingpin operates, and its condition is crucial for the proper functioning of the wheel assembly. The axle's integrity is checked during the kingpin replacement process to ensure smooth and clean surfaces, free from burrs and other imperfections.

💡Magnetic Base Dial Indicator

A magnetic base dial indicator is a precision measuring tool used to detect runout, parallelism, and other forms of misalignment in machinery. In the video, this tool is used to measure the alignment and movement of the kingpin in relation to the axle, which helps determine if the kingpin needs to be replaced. The dial indicator's needle is placed on the side of the upper spindle to obtain a reading, with an industry standard of 10 thousandths of an inch movement indicating a potential need for kingpin replacement.

💡Lock Pins

Lock pins are fasteners used to secure components in place, such as the kingpin within the wheel hub assembly. They are typically locked in place by tapping them out with a punch and hammer. In the video, the removal and replacement of lock pins are essential steps in the process of kingpin replacement, as they hold the kingpin and other components in their correct positions.

💡Bushings

Bushings are cylindrical components that reduce friction and absorb shock between moving parts. In the context of the video, they are installed around the kingpin to facilitate smooth operation and are replaced as part of the kingpin replacement process. The video emphasizes the importance of using the correct bushings, as well as the proper installation technique to ensure the longevity and performance of the wheel assembly.

💡Prepacked Bearings

Prepacked bearings refer to bearings that have already been filled with grease before installation. These bearings are designed to ensure maximum bearing life by providing optimal lubrication from the moment of installation. In the video, prepacking the bearings with grease is highlighted as a crucial step to ensure the longevity and smooth operation of the wheel assembly after kingpin replacement.

💡Shims

Shims are thin pieces of material, often used to adjust the clearance or to distribute loads between machine elements. In the context of the video, shims are used to fine-tune the fit of the kingpin and bushings within the axle, compensating for wear and ensuring proper alignment. The script mentions the importance of noting the size and quantity of shims removed during the tear down process, as they will need to be replaced to maintain the correct fit and function of the wheel assembly.

💡Telescope

A telescope, in the context of the video, refers to a measuring tool used to check the dimensions of the axle and other components. It is used to accurately measure the size of the axle eye and to ensure that the correct replacement parts are used during the kingpin replacement process. The use of a telescope ensures that the repair job is of high quality and that the components are compatible with each other.

💡Stem Co Keyser Equipment

Stem Co Keyser Equipment refers to a range of specialized tools designed for the maintenance and repair of vehicle wheel assemblies. In the video, this equipment is recommended for enhancing the repair process, such as the bushing driver for installing new bushings and the axle Pro equipment for correcting out of round and oversized axle eyes. The use of these tools is emphasized to ensure a complete and high-quality repair.

💡Kingpin Kits

Kingpin kits are comprehensive sets of parts designed to facilitate the replacement of kingpins in a vehicle's wheel assembly. These kits typically include new kingpins, bushings, shims, seals, and other necessary components, as well as the tools required for installation. In the video, the use of a Stem Co Keyser kingpin kit is highlighted to ensure that the repair job is done correctly and efficiently for the majority of applications.

💡Grease Fittings

Grease fittings are components used to inject grease into the bearing assemblies of a vehicle. They play a crucial role in the lubrication process, ensuring smooth operation and extending the life of the bearings. In the video, the installation of grease fittings and the process of greasing the wheel assembly are detailed to maintain proper lubrication after the kingpin replacement.

Highlights

Utilizing a magnetic base dial indicator to check axle for kingpin measurement

Industry standard for kingpin replacement is 10 thousandths of an inch movement

The importance of using proper personal protection equipment during kingpin replacement

Preparation steps for the truck before kingpin replacement, including removing wheel, hub cap, and hub assembly

Tapping out the old kingpin without heating the axle, and noting the size and direction of lock pins

Cleaning and inspecting the axle for quality repair, including removing all burrs and using a break hone

Identifying the proper axle size using the Stem Co Keizer catalog

Checking the spindle bores and axle faces for smooth, clean surfaces

Using a telescope and micrometer to accurately measure for wear and out-of-round conditions

Stem Co's recommendation of axle Pro equipment for enhanced out-of-round and oversized axle eye repairs

Removing and inspecting old bushings with the Stem Co Keyser bushing driver

Critical inspection and cleaning of all surfaces before reassembly

Installing the lip seal and bushings with precise methods to ensure a proper fit

Conducting bench tests to verify the fit of the new kingpin and bushings

Pre-packing the bearings with grease for maximum bearing life and proper shim placement

Aligning the kingpin with the lock flats and installing the bearing with precise tapping techniques

Ensuring proper installation of lock pins and end plates with correct torque and greasing procedures

Greasing the top and bottom units thoroughly to keep the components functioning optimally

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