Gunite Automatic Slack Adjuster Installation and Service Manual
Contents
1. Welded Clevis ASA Installation Procedure NOTE These installation instructions are for air chambers with a welded on clevis Welded on clevises have a 1 3 pin center distance Applu anti seize compound to the camshaft and install the automatic slack adjuster using the original mounting hardware Properly shim the automalic slack adjuster by placing one of the existing washers onto the camshaft Next install the automatic slack Insert the cotter pins into the large and small pin holes and secure adjuster onto the camshaft and place the second washer on the end the cotter pins of the camshaft on the outside of the automatic slack adjuster Re attach the retaining clip Using a 7 16 wrench or a socket rotate the hex extension clockwise until the holes in the Gunite automatic slack adjuster are properlu aligned with the corresponding holes in the welded clevis Hold the link down while rotating the hex extension clockwise Failure to do Fullu applu the brakes and allow the chamber push rod to travel so can cause the link to disengage from the drive Do not use an air its maximum stroke Clearance must exist between the Gunite impact wrench on the 7 16 hex It can damage the clutch automatic slack adjuster and all adjacent chassis components Release the brakes NOTE When installing the Gunite 2000 slack adjuster with a welded on clevis air chamber it is not necessary to use an installation gauge The proper mounting angle h2. SOLUTIONS AWES LIMITED WARRANTY TO FILE AWARRANTY CLAIM CALL 1 800 869 2275 ext 1 Accuride Wheel End Solutions AWES warrants to the original purchaser that its products are free from defects in material and workmanship The limited warranty time frame reference table below is based on the date of product manufacture and shall be void if the product is altered modified misapplied misused neglected repaired or not maintained in accordance with the instructions printed in the product specific Accuride Wheel End Solutions Safety amp Service Manuals Product Type Accuride Aluminum Wheels Accuride Steel Wheels Gunite Slack Adjusters Disc Brake Rotors Spoke Wheels GENERAL PRODUCT OVERVIEW 5 years 500 000 miles 5 years 60 months Industry Standard Aluminum wheels Duplex Aluminum Wheels ACCU SHIELD Wheels ACCU ARMORTM Wheels Extra Service Wheels ESW Styled Steel Wheels Tubeless Wheels and Demountable Rims Over The Road Line Operated Trucks and Trailers TRU SET Trailer 1 Time or miles whichever occurs first 2 Refer to appropriate Accuride Wheel End Solutions guide for additional limited warranty condition details Accuride Rim Wheel Safety amp Service Manual Gunite Heavy Duty Brake Drums Gunite Automatic Slack Adjuster Service Manual Gunite Disc Brake Rotors Maintenance Manual and Gunite Disc Wheel Hubs High Performance Hubs and Spoke Wheels Maintenan
3. completed warranty claim form can also be faxed to 1 815 964 0775 THE ABOVE WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY AWES AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED STATUTORY OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ALL OF WHICH ARE EXPRESSLY DISCLAIMED BY AWES IN NO EVENT SHALL THIS WARRANTY BE DEEMED TO COVER INCIDENTAL SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND 17 jn GUNITE NOTES EE E 7 TA m 4 U gt IDE 1 WHEEL END SOLUTIONS Your only single source for industry leading wheel end solutions STEEL amp ALUMINUM WHEELS DRUMS HUBS ROTORS SLACK ADJUSTERS 800 677 3786 815 964 3301 accuridewheelendsolutions com Gunite 302 Peoples Avenue Rockford IL 61104 7092 WE3 001 0914 Replaces GUN2 0005 Rev 4 0912 62014 Accuride Corporation
4. Gunite Automatic Slack Adjuster Installation and Service Manual i ka i U f B pae hu a TM l gt WHEEL END SOLUTIONS Your only single source for industry leading wheel end solutions STEEL amp ALUMINUM WHEELS DRUMS HUBS ROTORS SLACK ADJUSTERS LLLA LI i EE LLL LINE adha tH Assembled in the USA WHEEL END SOLUTIONS TABLE OF CONTENTS INTRODUCTION AUD a a i d ST IO 4 TSC IOI Si TR D ASA Installation Prepara tiOn a sir iri nee ee een nie 5 ASA Installation Procedures by Ch OVI So rin ai ia ear rr f 6 Eollar Sae EEA NE A ee ee ee 6 TA IG U fu 8 bal el o el A 10 Brake tiskatta ittie e a FK a id rt e Ea 11 Power KOA SOCOM 11 Recommended Maintenance RR RR 12 B SNIMO spec MUT 13 E SUI RO A c RR mms 13 Brake Lining and or Drum REGlACEM CR acsisisccaseicacssunsassarvesascedsesnsaseeuasapeesanacsocasecuabsnosatees saseansaausaustunssbiesabacscsasecuabosoaiatvanesseaauuaaasauaeaasbiesads 14 TOUDE OO a 15 WARNING AS WITH ALL PRODUCTS CLOSE ATTENTION SHOULD BE GIVEN TO ALL INSTRUCTIONS INCORPORATED IN THIS MANUAL IN PARTICULAR THE NOTES AND WARNINGS WHICH ARE HIGHLIGHTED THIS MANUAL IS FOR GUNITE AUTOMATIC SLACK ADJUSTERS ONLY FAILURE TO STRICTLY FOLLOW THESE INSTRUCTIONS
5. L DAMAGES OF ANY KIND FURTHER UNDER NO CIRCUMSTANCE SHALL AWES BE LIABLE FOR DAMAGES BEYOND THE PRICE OF THE GOODS PURCHASED BY THE ORIGINAL PURCHASER WHETHER IN CONTRACT IN TORT OR UNDER ANY WARRANTY OR OTHER USE AWES reserves the right to request product return as a condition of reimbursement Return expense may be paid by AWES or may be reimbursed to the original purchaser if product is found to be warrantable No goods are to be returned to AWES without a Returned Goods Authorization RGA If AWES determines that any of the returned goods are non warrantable AWES reserves the right to charge the Original purchaser for the recovery of all transportation costs and expenses incurred in examining processing and handling such goods Any controversy or claim that customer may wish to bring that is arising out of or related to this limited warranty or breach hereof must be commenced in writing within 30 days of notification of warrantable status Any product deemed non warrantable is the property of the original purchaser and can be returned to the original purchaser upon its request and at its sole cost and expense Should the non warrantable item s not be reclaimed AWES will disposition the product no sooner than 30 days after original purchaser notification has been made For all warranty related questions please contact your AWES warranty administrator at 1 800 869 2275 Option 1 or submit questions or claims to warrantyadmin accuridecorp com A
6. MAY RESULT IN THE UNIT PERFORMING IN AN UNSATISFACTORY MANNER AND RESULT IN INADEQUATE BRAKING ABILITY OR DRAGGING BRAKES THESE CONDITIONS COULD MAKE OPERATION OF THE VEHICLE EXTREMELY HAZARDOUS ATTENTION WHEN INSTALLING OR REPLACING A GUNITE AUTOMATIC SLACK ADJUSTER A NEW CLEVIS MUST BE INSTALLED REFER TO GUNITE PARTS CATALOG GUN1 0004 AND OR ITS ADDENDUM FOR CLEVIS SELECTION WARNING GUNITE AUTOMATIC SLACK ADJUSTERS SHOULD NOT BE MANUALLY ADJUSTED IN AN EFFORT TO CORRECT EXCESSIVE PUSH ROD STROKE EXCESSIVE PUSHROD STROKE INDICATES THAT A PROBLEM EXISTS WITH THE GUNITE AUTOMATIC SLACK ADJUSTER WITH THE INSTALLATION OF THE AUTOMATIC SLACK ADJUSTER OR WITH THE RELATED FOUNDATION BRAKE COMPONENTS WHICH MANUAL ADJUSTMENT WILL NOT FIX MANUAL ADJUSTMENT OF GUNITE AUTOMATIC SLACK ADJUSTERS IS A DANGEROUS PRACTICE THAT COULD HAVE SERIOUS CONSEQUENCES BECAUSE IT GIVES THE OPERATOR A FALSE SENSE OF SECURITY ABOUT THE EFFECTIVENESS OF BRAKES WHICH ARE LIKELY TO GO OUT OF ADJUSTMENT AGAIN SOON jie GUNITE Overview Gunite offers a complete line of unhanded automalic slack adjusters for installation on steer drive and trailer axles The space required for the Gunite automalic slack adjuster is similar to that which is required for manual slack adjusters Gunite automatic slack adjusters do not require any external brackets adapters or special mounting holes for installation Popular spline and arm length combinations allow them to b
7. acturer s Keep the existing mounting hardware Do not remove the clevis jam recommended procedures nut Check the operating condition of the foundation brakes including Refer to Figure 2 and determine if your Gunite automatic slack drums shoe and lining cams bushings rollers etc Replace or adjusters are equipped with the threaded clevis welded clevis or the repair as necessary collar lock clevis extended or standard length Refer to the correct installation procedure for the stule of clevis used on your Gunite automatic slack adjusters jie GUNITE Collar Lock Clevis ASA Installation Procedure Apply anti seize to the chamber push rod threads before installing the new clevis Also apply anti seize to the camshaft at this time When installing a Gunite automalic slack adjuster with a collar lock clevis place the 1 1 4 collar nut on the push rod against the 15 16 jam nut Next thread the 3 4 hex nut onto the push rod Install the slack onto the camshaft using the original mounting hardware Using the hex extension and a wrench adjust the Gunite automatic slack adjuster so that the collar nut aligns with the threaded area of the clevis Do not use an air impact wrench on the 7 16 hex It can damage the clutch TA 42d iut tl 4t s Before attaching the 1 1 4 collar nut to the clevis check to make sure the threaded push rod is fully engaged in the 3 4 hex nut If the push rod does not have full engage
8. as been designed into the product After completing this step refer to page 11 for Proper Brake Adjustment and Power Stroke Inspection Insert the large and small pins in the proper clevis holes 10 WHEEL END SOLUTIONS Follow this Procedure to Properlu Adjust the Brakes Using a 7 16 wrench or socket rotate the hex extension clockwise Using a 7 16 wrench or socket back off the Gunite automatic slack until the brake linings make contact with the braking surface of the adjuster bu rotating the hex extension counterclockwise 1 2 turn drum Do not use an air impact wrench on the 7 16 hex It can This will require 15 to 50 ft lbs of torque When backing off the damage the clutch slack a ratcheting sound will be heard WARNING Gunite automatic slack adjusters should not be manually adjusted in an effort to correct excessive pushrod stroke Excessive pushrod stroke indicates that a problem exists with the Gunite automatic slack adjuster with the installation of the automatic slack adjuster or with the related foundation brake components which manual adjustment will not fix Manual adjustment of Gunite automatic slack adjusters is a dangerous practice that could have serious consequences because it gives the operator a false sense of security about the effectiveness of brakes which are likely to go out of adjustment again soon Make an 90 psi brake application and allow the air chamber to travel its maximum stroke Measure
9. before cutting the push rod If the spring brakes are not fully caged the push rod can be cut too short Once the clevis is properly aligned with the Gunite automatic slack adjuster insert both the Large and small clevis pins and secure with the cotter pins supplied Tighten the jam nut against the clevis housing using 4O to 50 ft lbs of torque If you do not tighten the jam nut now it will allow the clevis to rotate freely and change the position of the clevis resulting in an improper installation NOTE Failure to tighten the jam nut will allow the air chamber push rod to rotate in the clevis and change the installed position of the slack preventing proper automatic slack adjuster function Fully apply the brakes and allow the chamber push rod to travel its maximum stroke Clearance must exist between the Gunite automatic slack adjuster and all adjacent chassis components Release the brakes After completing this step refer to page 11 for Proper Brake Adjustment and Power Stroke Inspection Apply anti seize compound to the camshaft and install the automatic slack adjuster using the original mounting hardware Use the hex extension to align the automatic slack adjuster with the clevis pin holes Hold the link down while rotating the hex extension clockwise Failure to do so can cause the link to disengage from the drive Do not use an air impact wrench on the 7 16 hex It can damage the clutch jie GUNITE
10. ce amp Installation Manual 1 year 12 months Duplex Steel Disc Wheels Duplex Demountable Rims Tube Type Wheels amp Demountable Rims Light Truck Wheels Steel Bolt Together Specialty Wheels 16 3 years 300 000 miles 3 years 350 000 miles School Bus City Delivery Vehicles TRU SET Front Steer TRU SET Rear 2 years 200 000 miles ACCU FLANGE Severe Service Garbage Refuse Trucks Fire Trucks Logging etc Limited Warranty Industry Standard Hubs Industry Standard Brake Drums Industry Standard Disc Brake Rotors Industry Standard Spoke Wheels WHEEL END SOLUTIONS ACCURIDE WHEEL END SOLUTIONS AWES LIMITED WARRANTV TO FILE A WARRANTY CLAIM CALL 1 800 869 2275 ext 1 ADDITIONAL PRODUCT SPECIFIC LIMITED WARRANTY CRITERIA Wheels The above warranty shall be void if the product is used with improper lire sizes inflation pressures or exceeded load ratings The above warranty shall be void if the product is not properly maintained in accordance with the Accuride Rim Wheel Safety amp Service Manual The above warranty also does not cover defects resulting from corrosion except as noted above other non Accuride components accident excessive speed or other abnormal or severe operating conditions ACCU ARMOR and ACCU SHIELD AWES does not cover the following conditions i Any damage in the areas of the mounting surfaces such as the area under the mount
11. chamber stroke tests clevis bushings and condition of the boot for cuts or tears may be necessary at earlier intervals See charts above for the Replace if necessary recommended stroke measurements WARNING A Gunite automatic slack adjuster should not have to be manually adjusted except for initial installation and at the time of brake reline Every Six Months or 50 000 Miles Grease the Slack Adjuster Gunite automatic slack adjusters are factory lubricated and extensively sealed to protect against dirt water salt and other corrosive elements Nevertheless periodic lubrication is recommended 1 A grease fitting is provided to allow lubrication during normal chassis servicing see Figure 4 With a conventional grease gun lubricate until grease appears on the camshaft NOTE Lubrication should be performed using an NLGI 1 or 2 grade grease Grease Fitting that has a working range of 40 F to 250 F A grease containing Molubdenum Disulfide should not be used as it will likely have a negative impact on the function of key friction components and reduce the operational efficiency of the automatic slack adjuster Figure 4 Lubrication Point 12 WHEEL END SOLUTIONS Recommended Maintenance Service Practices Points and Precautions 1 Replace the Gunite automatic slack adjuster if itis not functioning 4 Never operate the vehicle with small 1 4 pin missing from the properly as described under Function Test on pa
12. curs repeat the manual adjustment by repeating steps 1 through 3 under Brake Adjustment If the free stroke is greater than the recommended distance of 5 8 a function test of the Gunite automatic slack adjuster should be performed Figure 7 Free Stroke 4 To perform a function test place a 7 16 box wrench on the hex extension and rotate it 3 4 of a turn counterclockwise A ratcheting sound will be heard Mark the 7 16 hex extension with chalk and apply the brakes several times and watch for the hex to rotate clockwise The hex extension must rotate clockwise The adjustment is intentionally made in small increments so it Will take several cycles to bring the adjuster within the Maximum Legal Stroke Limit in the chart on page 12 If the power stroke is greater than the Maximum Legal Stroke Limit the free stroke is greater than 5 8 and the function test shows that the adjusting mechanism is working check the clevis pins clevis pin holes and arm bushing for wear Replacing clevises pins and bushings that show wear may bring the brake within the legal stroke limit 5 Check the clockwise and counterclockwise torque by attaching a torque wrench to the hex extension and turning in the clockwise and counterclockwise directions and record the measurement The clockwise torque specification is 10 ft lbs maximum The counterclockwise torque specification is 15 to 50 ft lbs If these torque specifications are violated the Gunite au
13. djusted remove the template and the two clevis pins When installing a Gunite automatic slack adjuster with a threaded clevis install the new clevis on the push rod in the same location as the clevis which was removed Do not tighten the jam nut at this time Inspect the clevis installation to make sure that the threaded push rod extends no more than 1 16 past the end of the opening of the clevis in the clevis housing If the push rod extends more than 1 16 past the clevis housing the clevis must be removed and the push rod cut to the proper length It is also important to make sure that the push rod is not too short for proper installation To do this check to make sure that the push rod is not more than 1 8 short of being flush with the clevis opening on a standard clevis 5 8 on an extended clevis If the threaded push rod is more than 1 8 from being flush with the clevis opening on a standard clevis 5 8 on an extended clevis it must be removed a new push rod must be installed and cut to the proper length Once the clevis has been installed on the threaded push rod install Follow instructions in this service manual for cutting a push rod to both the large and small clevis pins Now position the installation length template over both the large and small clevis pins Refer to page 5 for proper gauge WHEEL END SOLUTIONS NOTE On axles equipped with spring brake chambers be sure the chambers are fully caged
14. e used to replace most other slack adjusters However brands should not be mixed on the same axle Link Boot Grease Fitting Hex Extension THE BRAKES SHOULD BE IN GOOD OPERATING CONDITION AND STATE OF REPAIR WHEN GUNITE AUTOMATIC SLACK ADJUSTERS ARE INSTALLED NO SLACK ADJUSTER CAN COMPENSATE FOR PROBLEMS AND DEFICIENCIES IN THE FOUNDATION BRAKING SVSTEM Clevis 1 2 or 5 8 Pin 1 4 Pin Drilled amp Grooved Worm Wheel Figure 1 Gunite Automatic Slack Adjuster WHEEL END SOLUTIONS Clevis Descriptions 1 Pin Center Distance Clevises Use with Traditional 1 Pin Distance ASA Installation Gauge SDO4603 FF lM 1 Pin Center Distance 1 d JL a bs Enz y Collar Lock Clevis 3 4 Hex Nut Collar Lock Clevis 1 1 4 Hex Nut Standard Standard Collar Extended Extended Collar Threaded Clevis Lock Clevis Threaded Clevis Lock Clevis Standard length clevises can be used for Extended clevises should be used either truck or trailer applications for trailer applications only 1 3 Pin Center Distance Clevises Use with Gunite 2000 ASA Installation Gauge SD04604 1 3 Pin Center Distance Gunite 2000 Welded On Threaded Clevis Clevis Pushrod Figure 2 Clevis Types ASA Installation Preparation Block the vehicle s wheels If the axle is equipped with spring Remove the existing clevis and Gunite automatic slack adjuster brakes manually cage the brakes following the manuf
15. ge 15 clevis The Gunite automatic slack adjuster will not maintain 2 Replace the entire unit if damage is evident on the slack housing proper brake adjustment with either pin missing see below or assembly 5 Never attempt to disassemble a Gunite automatic slack adjuster Factory setting cannot be duplicated in the field Instead replace 3 The unit must be replaced if less than 15 ft lbs of torque exists the entire unit when turning the hex extension counterclockwise Refer to the test as described under Trouble Shooting on page 15 Bushing Replacement Insert clevis pin into a new bushing Support arm of Gunite Using a hammer drive the new bushing into the arm of the automatic slack adjuster and insert clevis pin with new bushing into automatic slack adjuster while driving out the old bushing Make old bushing sure the new bushing is flush with the sides of the arm Cutting Push Rods This Procedure is for Collar Lock and Threaded Clevis Applications Only 1 Install the brake chamber in the proper mounting holes of the 4 From the 90 degree mark measure back toward the air chamber chamber bracket for the Gunite automatic slack adjuster length the proper X distance from the following chart Mark the push required rod at the X dimension Cut the push rod at this mark see Figure 6 The clevis is now ready to install on the push rod Slack Adjuster 3 Using a square mark the universal push rod at the 90 degree Arm Lengt
16. h Gunite Standard Clevis Gunite 2000 Clevis position when the square edge is centered in the end of the 5 5 1 2 2 1 4 2 1 2 S Cam see Figure 5 Make sure the push rod is centered in the e 6 1 2 2 1 2 2 3 4 chamber and not cocked before marking the push rod 2 If the axle is equipped with spring brake chamber manually cage the spring brakes following the manufacturer s recommended procedures The chamber must be in the fully released position Cut Here S Cam Spline o a Cam Spline Figure 5 Marking the Push Rod Figure 6 Cutting the Push Rod 13 jie GUNITE Special attention must be given to following proper maintenance procedures when changing linings and or drums on a vehicle equipped with Gunite automatic slack adjusters Following these procedures will ensure that the automalic slack adjuster is functioning correctly before returning the vehicle to service Block the vehicle s wheels If the vehicle is equipped with spring brake chambers manuallu cage the spring brakes following the manufacturer s recommended procedures Using a 7 16 wrench or socket rotate the hex extension counterclockwise Vou should have at least 15 ft lbs resistance and a ratcheting sound will be heard as the hex extension is rotated Do not use an air impact wrench on the 7 16 hex It can damage the clutch 14 Onlu back off the adjusting hex enough to allow the drum to clear the lining Remo
17. ing nuts the area in contact with hubs or drums and the area in contact with other wheels in dual position ii Any damage due to cleaning including damage from the use of abrasives abrasive brushes steel wool scouring pads or strong chemicals and iii Any damage to the wheel finish due to removal misuse or chipping whether by contact with road obstacles such as stones gravel curbs barriers signs or otherwise ACCU SHIELD products are not covered for corrosion AWES recommends cleaning wheels with mild soap and water ACCU FLANGE The Accu Flange treatment warranty covers original purchasers against sharp edges on the rim flange for two 2 years from the date of manufacture This warranty does not cover the following conditions i Any damage due to cleaning including damage from the use of abrasives abrasive brushes steel wool scouring pads strong chemicals or corrosives and ii Any damage due to removal misuse or chipping whether by contact with road obstacles such as stones gravel curbs barriers signs tire changing equipment or otherwise For Accu Flange Accu Shield or Accu Flange Accu Armor wheels AWES recommends cleaning with mild detergent and water only For Accu Flange only wheels AWES recommends cleaning with mild detergent and water and then apply a wheel polish or carnauba wax with 100 cotton cloth Standard Brake Drums Spoke Wheels Disc Wheel Hubs Automatic Slack Adjusters and Hardware The above war
18. ment a new push rod must be installed and cut to length Refer to the section on cutting a new push rod to length in this service manual The push rod may extend up to 1 16 past the clevis opening If the push rod extends more than 1 16 past the clevis opening mark the push rod and remove the clevis to allow the push rod to be cut to the proper length Gunite automatic slack adjusters using the collar lock clevis are available with either standard or extended clevis designs depending on the application On trailer applications an extended clevis can be used instead of replacing the push rod However you must still have full thread engagement inside the hex nut If you have less than full thread engagement a new push rod must be installed If you replace the push rod you must cut the new push rod to the proper length Refer to the section on cutting a new push rod to length in this service manual Do not use an extended clevis on tractor applications the extended clevis may interfere with the face of the air chamber WHEEL END SOLUTIONS NOTE On axles equipped with spring brake chambers be sure the chambers are fully caged before cutting the push rod If the spring brakes are not fullu caged the push rod can be cut too short Once the 1 1 4 collar nut has been properlu tightened to the clevis tighten the 15 16 jam nut against the collar lock nut using 40 to 50 ft lbs of torque NOTE Failure to tighten the jam n
19. ranty shall be void if i any goods have exceeded AWES acceptable wear limits or have been subjected to accidents or abnormal conditions of use temperature moisture dirt or corrosive matter or ii the product fails as the result of another manufacturer s product The TRU SET disc wheel hub requires the use of a seller approved hubcap and lubricant REMEDIES AND LIMITATIONS OF REMEDIES In the event of any material breach of the above limited warranties AWES agrees to repair or replace at its sole option without charge any and all of its warrantable product that fail during normal use and service due to defects in material and or workmanship all subject to the original purchaser providing written notice of the alleged breach within 3O daus of failure Time is of the essence herein and original purchaser s failure to provide written notice to AWES within the required time of any alleged breach of the foregoing warranty will release and discharge AWES from any obligation or liability for that breach of warranty In no event will AWES be liable for any other costs associated with the replacement or repair of product covered under this warranty including labor installation or other costs incurred bu customer The remedies set forth herein shall be the sole and exclusive remedies available to the original purchaser so that AWES repair or replacement is a fulfillment of all AWES obligations AWES SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTA
20. the distance between the face of the air chamber and the center of the large clevis pin B see Figure 3 The difference between the A measurement and the B measurement is the push rod stroke Check the charts located on the next page for the proper maximum stroke after adjustment of the brakes Using a ruler measure the distance from the face of the air chamber to the center of the large pin in the clevis A see Figure 3 11 jie GUNITE STANDARD CLAMP TYPE BRAKE CHAMBER DATA Maximum Outside Rated Diameter Stroke oke 9 5 1 4 1 75 1 3 8 12 5 11 16 173 1 3 8 16 6 3 8 2 25 1 3 4 20 6 25 32 225 1 3 4 24 7 7 32 2 25 1 3 4 30 8 3 32 2 50 2 36 9 3 00 2 1 4 Note If type 36 chamber is used slack length should be less than 6 LONG STROKE CLAMP TVPE BRAKE CHAMBER DATA i Maximum Diameter Stroke Legal ENS 16 6 3 8 2 50 2 20 6 25 32 2 50 2 24 7 7 32 2 50 2 Figure 3 Measuring Maximum Stroke 24 7 7 32 3 00 2 1 2 30 8 3 32 3 00 2 1 2 Note Identified bu square air port bosses Recommended Maintenance Every Three Months or 25 000 Miles 1 Check the condition of the foundation brakes including drums 3 After allowing the brake drum to cool to room temperature check shoes and linings cams rollers bushings etc for correct chamber stroke following the procedure on page 10 2 Check for structural damage of the housing worn clevis worn Due to different operating conditions
21. tomatic slack adjuster must be replaced 6 If the Gunite automatic slack adjuster passes the free stroke function test clockwise and counterclockwise torque tests and the brake does not meet the Maximum Legal Stroke Limit check the foundation brake Check for worn cam bushings pins rollers broken springs broken drums sprung linings worn quick connect clevises clevis pins and clevis bushings Repair as necessary and repeat the function test to see if the Gunite automatic slack adjuster meets the Maximum Legal Stroke Limit 7 Pins seizing are a result of corrosive environments If pins seizing are a problem they should be replaced with stainless steel pins WARNING Gunite automatic slack adjusters should not be manually adjusted in an effort to correct excessive pushrod stroke Excessive pushrod stroke indicates that a problem exists with the automatic slack adjuster with the installation of the automatic slack adjuster or with the related foundation brake components which manual adjustment will not fix Manual adjustment of Gunite automatic slack agjusters is a dangerous practice that could have serious consequences because it gives the operator a false sense of securitu about the effectiveness of brakes which are likely to go out of adjustment again soon If you need additional service manuals or installation gauges contact Gunite at the address listed on the back of this manual jie GUNITE ACCURIDE WHEEL END
22. ut will allow the air chamber push rod to rotate in the clevis and change the installed position of the Gunite automatic slack adjuster preventing proper automatic slack adjuster function After threading the 1 1 4 collar nut onto the clevis housing place the template over the large and small clevis pins as shown above Align the Gunite automatic slack adjuster bu adjusting the 3 4 hex nut on the push rod until the appropriate centering hole on the template aligns with the center hole on the camshaft The template is provided with centering holes for 5 5 5 6 and 6 5 inch arm Fullu applu the brakes and allow the chamber push rod to travel lengths Refer to page 4 for proper gauge its maximum stroke Clearance must exist between the Gunite automatic slack adjuster and all adjacent chassis components Release the brakes After completing this step refer to page 11 for Proper Brake Adjustment and Power Stroke Inspection Using a torque wrench tighten the 1 1 4 collar nut to the clevis using 40 to 50 ft lbs of torque jie GUNITE Threaded Clevis ASA Installation Procedure Apply anti seize to the chamber push rod threads before installing Align the clevis on the threaded push rod until the appropriate the new clevis centering hole on the template aligns with the center hole on the camshaft The template is provided with centering holes for 5 5 5 6 and 6 5 inch arm lengths Once the clevis has been properlu a
23. ve the brake drum After the brake drum has been removed rotate the hex extension clockwise until the cam turns over This will allow the brake rollers to be in the release position Proceed with the lining change and or brake drum replacement After completing this step refer to page 11 for proper brake adjustment uncage the spring brakes and refer to page 11 for power stroke inspection WHEEL END SOLUTIONS Troubleshooting 1 Gunite automatic slack adjusters should not have to be manuallu adjusted except for initial installation and at the time of brake reline If the power stroke with an 90 psi brake application is less than the Maximum Legal Stroke Limit shown in the chart on page 11 the Gunite automatic slack adjuster is functioning properly 2 If the chamber stroke exceeds the Maximum Legal Stroke Limit measure the free stroke 3 Free stroke is the amount of movement of the slack adjuster arm required to move the brake shoes against the drum With the brakes released measure from the face of the air chamber to the center of the large clevis pin see Figure 7 Apply pressure using a lever to activate the Gunite automatic slack adjuster until the brake shoes make contact with the brake drum surface The difference between the released and the applied measurements is the free stroke The free stroke should be 3 8 to 5 8 If the free stroke is less than 3 8 a dragging brake can occur If this situation oc
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