Step By Step Instruction & Information Guide
Axle Pro Equipment Instruction Guide Axle Pro Equipment Safety Procedure The first step in using the Axle Pro Equipment is SAFETY FIRST SAFETY ALWAYS. Please take a moment to make sure these safety precautions are in place. These components are heavy! For your protection wear safety shoes, safety glasses and use proper lifting techniques. Safety Glasses Safety Shoes 1. Bring the load as close as possible before lifting 2. Lift with legs - not back 3. Keep head up, back straight & bend at the hips 4.
Axle Pro Equipment Instruction Guide TABLE OF CONTENTS Part list / Photo Glossary-- Pages 6-7 Step 1: Remove, Inspect Components & Attach Mandrels-Page 8 Step 2: Pre-Drill Cutter & Reamer Setup-Step 3: Axle Alignment Assembly-- Page 9 Pages 10-11 Step 4: Leveling Bar & Drill Speed Setup-- Page 12 Step 5: Alignment Bushing & Drill Placement-- Page 13 Step 6: Engage Magnet & Assemble Coolant System-- Page 14 Step 7: Drilling Procedure-- Page 15 Step 8: Second Pass Reaming Process-- Page 16 Step
Axle Pro Equipment Instruction Guide Part list / Photo Glossary 1. Upper plate 2. Lower plate 3. 6 ½” threaded mounting rod with welded nut 4. Mandrel 5.
Axle Pro Equipment Instruction Guide Part list / Photo Glossary Cont... 6. Upper plate with four 6 ½” threaded mounting rods and one 6 ½” leveling threaded rod with extra nut 7. TiN coated cutter 8. Reamer with arbor unassembled 9.
Axle Pro Equipment Instruction Guide Step 1: Remove & Inspect Components - Attach Mandrels a. Remove all components including kingpins, steering knuckle and associated parts using standard shop procedures and practices. (See Photo 1A) Photo 1A b. Clean and inspect axle eye. Using a measuring tool (telescoping gauge and micrometer or STEMCO Kaiser “go no go gauge”) measure your axle eye size. Determine correct axle eye size and required cutter.
Axle Pro Equipment Instruction Guide Step 2: Pre-Drill Cutter and Reamer Setup a. Attach extension fitting and cutter to drill using allen wrenches. Critical step must attach the 2 inch extension. (Photo 2A) Photo 2A b. First time use, reamer must be mounted to arbor. Place reamer over arbor, interlocking reamer taper against arbor taper and aligning notches. (Photo 2B) Photo 2B Firmly strike small end of arbor against surface to assure proper taper interlock.
Axle Pro Equipment Instruction Guide Step 3: Axle Alignment Assembly a. Install four threaded rods with welded nuts against upper plate. (upper plate has no cut out) Do Not Tighten. b. Install adjusting threaded rod with welded nut against upper plate plus one additional nut. Do Not Tighten (See Photo 3A) Photo 3A c. Place upper plate over upper centering mandrel with threaded rods pointing down. (See Photo 3B) Photo 3B d. Pull bottom plate up carefully aligning threaded rods through appropriate holes.
Axle Pro Equipment Instruction Guide Step 3: Axle Alignment Assembly Cont… f. Tighten welded nuts into bottom side of upper plate; tighten four nuts against lower plate. Nuts against lower plate should be tightened with torque wrench 36 ft/lbs. Do not tighten nut on rear adjusting rod. (See Photo 3D) Photo 3D g. Ensure plates are mounted squarely onto axle. Visually check for gap between plates and axle. (See Photo 3E) Photo 3E h. Ensure mounting plates are securely attached.
Axle Pro Equipment Instruction Guide Step 4: Leveling Bar & Drill Speed Setup a. Place narrow edge of leveling bar against upper plate (See Photo 4A) Photo 4A b. Using leveling bar to test upper plate for flatness. Look for light under the bar or the bar rocking end to end. Adjust if needed with either the nut below lower plate or the nut above lower plate on the adjusting rod. (See Photo 4B) It is crucial to drilling accuracy that plate be properly adjusted. Photo 4B c.
Axle Pro Equipment Instruction Guide Step 5: Alignment Bushing & Drill Placement a. Place alignment bushing in upper plate hole. (See photo 5A) Photo 5A b. Plug magnetic base drill into proper outlet. Using proper lifting techniques place magnetic based drill onto upper plate. Do Not Engage Magnet. Caution must be taken as the unit is not secure at this time. (Photo 5B) Photo 5B c. Align cutter into alignment bushing.
Axle Pro Equipment Instruction Guide Step 6: Engage Magnet & Assemble Coolant System a. Engage drill magnet. (Photo 6A) Photo 6A b. Remove alignment bushing prior to cutting axle. (Photo 6B) Photo 6B c. Assemble the coolant system: Put pump into the bucket. Add 3 pints of coolant and 3 gallons of water and mix thoroughly. (Photo 6C) System comes with 3 pints of concentrated coolant. Dilute 3 pints of concentrate with 3 gallons of water. Photo 6C d. Thread coolant hose through notch in bucket.
Axle Pro Equipment Instruction Guide Step 7: Drilling Procedure a. Turn coolant on and ensure steady flow into axle throughout drilling process. (Photo 7A) Photo 7A b. Start drill motor, carefully lower cutter into upper plate and slowly begin cutting process. Slow/steady cutting motion is important. (Photo 7B) Photo 7B c. After one third of the axle is cut raise the cutter out of the axle and shut off drill motor. Use air nozzle or brush to remove shavings on cutter & axle. (Photo 7C) d.
Axle Pro Equipment Instruction Guide Step 8: Second Pass Reaming Process a. DO NOT DISENGAGE MAGNET! b. Remove cutter from drill motor. (Photo 8A) Photo 8A c. Install mounted reamer into drill motor using Allen wrenches. (Photo 8B) Photo 8B d. Turn coolant on to ensure steady flow into axle throughout reaming process. (Photo 8C) e. Begin reaming process being careful to start slowly Continue reaming with slow constant feed & do not stop and clean reamer.
Axle Pro Equipment Instruction Guide Step 9: Sleeve Installation a. Begin sleeve installation by placing lead into top of axle bore visually aligning lock pin cutouts. (Photo 9A) Photo 9A b. Using a STEMCO Kaiser bushing driver and brass hammer drive axle sleeve into position until flush. (Photo 9B) Photo 9B c. The axle eye is enhanced; proceed with the installation of your STEMCO Kaiser king pin kit. If you have any questions, please contact Photo 9C STEMCO Kaiser Tech Line: 888-854-6474 Ext# 7.
Part Listing For your protection, use Standard Shop Safety Procedures during this process Page 18 of 24 01 577 0092 SEPT 2011
Page 19 of 24 01 577 0092 For your protection, Use Standard Shop Safety Procedures during this process Axle Pro Equipment Cross-Reference Matrix AUGUST 2011
Page 20 of 24 01 577 0092 For your protection, Use Standard Shop Safety Procedures during this process Axle Pro Equipment Cross-Reference Matrix AUGUST 2011
Axle Pro Equipment Instruction Guide Example part breakdown PART NUMBER SUBORDINATE PART NUMBER 85.122.05 80.105.01 80.110.01 80.115.01 80.120.01 80.125.01 80.130.01 80.135.01 80.140.01 80.145.01 80.160.01 80.165.01 80.211.01 80.405.01 80.406.01 80.410.01 80.415.01 80.420.01 80.425.01 80.430.01 80.435.01 80.440.01 80.445.01 80.450.01 80.455.01 83.122.05 82.122.05 86.122.05 80.209.01 ST70-7T PART NUMBER SUBORDINATE PART NUMBER 84.931.12 83.931.12 82.931.12 86.931.12 80.209.
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01 577 0092 Axle Pro Step by Step Installation AUGUST 2011
