PTP PRO TRUCKING PRODUCTS AS3000 Replacement Clevis Kit User Manual

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of the PTP PRO TRUCKING PRODUCTS AS3000 Replacement Clevis Kit. This kit is designed as a direct replacement component for Gunite Automatic Slack Adjusters. Please read this manual thoroughly before attempting any installation or maintenance procedures to ensure safety and optimal performance.

2. Product Overview

The AS3000 Replacement Clevis Kit is a critical component for maintaining the functionality of your vehicle's braking system, specifically designed for use with Gunite Automatic Slack Adjusters. It ensures a secure connection between the pushrod and the slack adjuster.

2.1 Kit Contents

• 1x Standard Threaded Straight Clevis
• 1x Clevis Pin (1/2" diameter)
• 1x Cotter Pin
• 2x Washers

2.2 Key Specifications

• Model: AS3000PTP
• Application: Gunite Automatic Slack Adjusters
• Push Rod Thread: 5/8"-18
• Clevis Pin Diameter: 1/2"
• Material: Metal
• Finish: Unfinished (typically a protective coating like zinc plating, appearing yellowish/gold)

Figure 2.1: Complete AS3000 Replacement Clevis Kit showing the clevis, clevis pin, cotter pin, and washers.

3. Safety Information

Always prioritize safety when working on vehicle braking systems. Improper installation or maintenance can lead to serious injury or equipment damage.

• Ensure the vehicle is properly supported and secured before beginning any work.
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Consult a qualified mechanic if you are unsure about any part of the installation process.
• Use only the correct tools for the job.
• Never operate a vehicle with improperly installed or damaged brake components.

4. Installation Instructions

This section outlines the general procedure for replacing a clevis on a Gunite Automatic Slack Adjuster. Refer to your vehicle's specific service manual for detailed instructions and torque specifications.

4.1 Required Tools

• Wrenches (appropriate sizes for pushrod and clevis pin nuts/bolts)
• Pliers (for cotter pin removal/installation)
• Torque Wrench
• Wire brush (for cleaning threads)
• Thread lubricant/anti-seize compound (optional, but recommended)

4.2 Removal of Existing Clevis

1. Park the vehicle on a level surface, engage the parking brake, and chock the wheels.
2. Locate the automatic slack adjuster and the clevis connecting it to the brake chamber pushrod.
3. Remove the cotter pin and then the clevis pin that secures the clevis to the slack adjuster arm.
4. Unthread the clevis from the brake chamber pushrod. Note the orientation of the clevis for correct reinstallation.
5. Inspect the pushrod threads for damage. Clean any rust or debris with a wire brush.

Figure 4.1: The clevis with the clevis pin and cotter pin installed, illustrating the connection point.

4.3 Installation of New Clevis

1. Apply a small amount of thread lubricant or anti-seize compound to the pushrod threads.
2. Thread the new AS3000 clevis onto the brake chamber pushrod. Ensure it is threaded on sufficiently to engage all threads and align correctly with the slack adjuster arm. The clevis is a straight type, meaning its arms are parallel to the pushrod.
3. Align the holes in the clevis with the holes in the slack adjuster arm.
4. Insert the new clevis pin through the aligned holes. Ensure the washers are placed correctly on either side of the clevis pin if applicable.
5. Secure the clevis pin with the new cotter pin, bending the ends to prevent accidental removal.
6. Verify that the clevis and slack adjuster arm move freely without binding.
7. Perform a functional check of the brake system after installation, ensuring proper slack adjuster operation and brake application.

Figure 4.2: Detailed view of the 5/8"-18 internal thread of the clevis, designed to connect to the brake chamber pushrod.

5. Operation and Function Check

The clevis itself does not have an "operation" in the traditional sense, but its correct installation is crucial for the proper functioning of the automatic slack adjuster and the entire braking system.

• After installation, ensure the clevis allows for full, unrestricted movement of the slack adjuster arm.
• With the parking brake released (and wheels chocked), apply the service brakes several times to allow the automatic slack adjuster to set the correct brake stroke.
• Visually inspect the clevis and pin connection for any signs of binding, looseness, or misalignment during brake application and release.

6. Maintenance

Regular inspection of the clevis kit components is essential for safe vehicle operation.

• During routine vehicle inspections, check the clevis, clevis pin, and cotter pin for wear, corrosion, or damage.
• Ensure the cotter pin is securely in place and not bent or broken.
• Check for excessive play or looseness at the clevis pin connection. Any significant play may indicate wear and require replacement.
• Keep the area around the clevis clean from excessive dirt and debris.

7. Troubleshooting

If you encounter issues after installing the AS3000 Clevis Kit, consider the following:

• Clevis does not thread onto pushrod: Verify the pushrod thread size is 5/8"-18. Ensure threads are clean and free of damage. Do not force the clevis.
• Clevis does not align with slack adjuster arm: Check if the clevis is fully threaded onto the pushrod. Ensure the pushrod itself is not bent or damaged. The AS3000 is a straight clevis; ensure this is the correct type for your application.
• Excessive play at clevis pin: Ensure the correct 1/2" diameter clevis pin is used. If the pin or clevis holes are worn, replacement is necessary.
• Brakes not adjusting properly: While the clevis kit is a component, improper brake adjustment can stem from other issues with the slack adjuster or brake chamber. Ensure the clevis is installed correctly and then troubleshoot the slack adjuster or other brake components as per your vehicle's service manual.

8. Specifications

9. Warranty and Support

For warranty information, technical support, or inquiries regarding the PTP PRO TRUCKING PRODUCTS AS3000 Replacement Clevis Kit, please contact your original point of purchase or the manufacturer directly. Keep your purchase receipt as proof of purchase.