jost JSK 40 Page 1 Repair Instructions Download

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Repair instructions

Replacing the sensor set

JSK 37/JSK 40/JSK 42

Daimler version

JSK_12_032

Summary of Contents for JSK 40

Page 1: ...Repair instructions Replacing the sensor set JSK 37 JSK 40 JSK 42 Daimler version JSK_12_032 ...

Page 2: ...iliary materials 7 4 1 Standard tools 7 4 2 Special tools 7 4 3 Auxiliary materials 7 5 Checking the function of the sensors 8 5 1 Troubleshooting 8 5 2 Basic settings and visual inspection 9 5 3 Diagnostic tester 11 6 Repair work 14 6 1 Preparing the fifth wheel coupling 13 6 2 Removing the cable ties 14 6 3 Removing the semi trailer sensor 16 6 4 Fitting the semi trailer sensor 17 6 5 Removing t...

Page 3: ...ur country for example Health Safety at Work apply for working with sensor enabled fifth wheel couplings and vehicles The relevant safety instructions included in the vehicle and semi trailer s operating instructions must also be complied with 1 Safety information ...

Page 4: ...y in conjunction with kingpins of class H50 and class J mounting plates or comparable licensed equipment JOST fifth wheel couplings are suitable for use in power steering systems Technical modifications reserved The latest information can be found at www jost world com 2 2 Specification The fifth wheel coupling is specified with the vehicle by the vehicle manufacturer the design must comply with D...

Page 5: ...tronic components e g plugs with bare fingers Do not allow the wiring harness to drop Check any worn components particularly the wearing ring and replace if necessary Only use the new screws and nuts provided with the repair kit Before commencing work adjust the fifth wheel coupling as per the operating instructions with the new wearing ring and new kingpin Always tighten the kingpin sensor clampi...

Page 6: ...ndard tools 0 4 2 Special tools 0 Multimeter resistance measuring device 4 3 Auxiliary materials We recommend high pressure grease EP e g JOST high performance lubricant Art No SKE 005 670 000 SK2702 10 SKE00863000 1 2 1 2 SW2 5 1 2 SW4 1 2 SW18 SW 17 SW 24 SW 36 D4 2 D5 5 M5 150 mm ...

Page 7: ...e Section 5 2 and the installation and operating instructions for JSK 36 JSK 37 and JSK 40 JSK 42 Section 3 Operation and Section 4 Maintenance and testing on the JOST website at www jost world com Replace worn and faulty components Adjust the fifth wheel coupling s locking play see Section 6 and repair instruc tions JSK 36 37 and JSK 40 JSK 42 on the JOST website at www jost world com Kingpin sen...

Page 8: ...lty or worn components must be replaced For fifth wheel couplings with sensors different wear dimensions apply to the fifth wheel coupling wear part 1 0 0 1 0 0 2 0 0 0 0 0 Wear part JSK 37C without plastic liner Wear part JSK 37 with plastic liners and JSK 40 JSK 42 with and without plastic liners 32 0 33 5 mm 1 1 JSK_12_033 19 0 20 5 mm 2 2 1 1 1 JSK_12_034 150 mm 150 mm 5 Checking the function ...

Page 9: ...tion sensor cover 2 Plug 3 Cable to the sensor set 0 4 Handle or trap 5 Handle magnet 6 Wear sensor 0 7 Kingpin abutting face sensor Remove grease deposits on items 1 2 4 5 6 7 and re grease the areas 2 3 3 1 JSK_12_035 3 2 3 1 JSK 40 JSK 42 JSK 37 4 5 6 JSK 40 JSK 42 JSK 37 4 5 6 JSK_12_036 7 7 JSK 40 JSK 42 JSK 37 JSK_12_037 5 Checking the function of the sensors ...

Page 10: ...ngs of type JSK 40 JSK 42 as follows right and left up and down rotate 0 0 Close the coupling Measure the contact resistance on the plug un der the fifth wheel coupling as follows moving the handle on fifth wheel couplings of type JSK 40 JSK 42 and the traps on fifth wheel cou plings of type JS 37 as follows right and left up and down only for JSK 40 42 rotate only for JSK 40 42 0 0 0 The sensor s...

Page 11: ... installed Consequently the LED can be observed with the help of a mirror To do this slide a mirror directly on the left arrow A next to the right pedestal between the coupling plate and the mounting plate The mirror must be slid to around the middle of the coupling see arrow B Switch the vehicle s ignition on Open the coupling no semi trailer coupled The LED on the back of the sensor must not lig...

Page 12: ...bsequent assembly process The prescribed tightening torques must be adhered to 6 1 Preparation of the fifth wheel coupling Disconnect the electrical connection to the tractor 0 The fifth wheel coupling may only be raised using suitable lifting gear Take the fifth wheel coupling off the tractor unit and place it on workbench SK 2702 10 0 The setting of the fifth wheel coupling and kingpin sensor mu...

Page 13: ...g the cable ties Depending on the design the cable routing the position and number of the cable ties and cable clamps may vary You can see different designs in Fig A 0 Trim and remove the cable tie Cable tie A is secured with a washer 1 0 0 A JSK_12_047 ...

Page 14: ...15 ZDE 199 007 105 03 2013 0 To secure the line during installation use the positions shown in Fig 1 and 2 see previous page 2 0 0 0 JSK_12_005 6 Repair work ...

Page 15: ...ning plate 4 To ensure better accessibility loosen the hook spring 2 on the eye bolt 3 Take care not to damage any lubricating line 5 in the vicinity 0 Loosen the securing nuts 7 on the semi trailer sensor 6 1 0 0 0 1 JSK_12_006 2 0 0 0 6 5 Nm 2 3 5 4 1 JSK_12_007 1 2 1 2 SW4 3 0 0 0 6 7 16 mm 30 Nm JSK_12_008 SW 36 ...

Page 16: ...unit 0 1 Screw M16x10 with washer 4 Holders 6 Semi trailer sensor M30 7 Nut SW36 8 Cable splice optional 9 Protective cap Installation is carried out correspondingly in the reverse order Note the installation measures see Fig 3 on page 16 Use a securing agent e g Loctite for the M30 nuts 7 1 0 4 7 7 6 1 8 9 JSK_12_009 ...

Page 17: ... the fifth wheel coupling this must be removed 0 1 0 0 0 1 JSK_12_010 0 Slide the safety slide 10 in the direction of the arrow C away from the plug Pull the plug 11 towards the centre of the coupling D out of the retaining plate Installation is carried out correspondingly in the reverse order 0 2 0 0 0 11 C D 10 JSK_12_011 ...

Page 18: ...rating instructions or repair instructions The installation and operating instructions and repair instructions can be obtained from the JOST website www jost world com Guide a new kingpin into the fifth wheel coupling and ensure that the lock is closed and secured as shown in the installation and operating in structions 0 Using a gauge 16 measure the distance X from position C on the fifth wheel c...

Page 19: ... not to damage any lines when the cable ties are tightened 6 8 Removing the locking sensor JSK 40 JSK 42 To remove the locking sensor the handle must be removed 0 Unhook the double spring 17 Caution Risk of injury When installing the double spring ensure that this is carried out as shown in the figure 0 Undo the hexagon nut 18 During installation use the hexagon nut supplied with the repair kit 3 ...

Page 20: ...lings without plastic liners 6 9 Fitting the locking sensor JSK 42 Installation is carried out correspondingly in the reverse order Note the difference between Figures 1 and 2 0 Without plastic liners 2 x screw M6x16 20 2 x washer D6 21 2 x sleeve 22 0 With plastic liners 2 x screw M6x10 20 2 x washer D6 3 0 0 0 0 4 0 0 0 5 0 0 0 19 JSK_12_019 1 JSK_12_020 1 2 1 2 SW2 5 6 5 Nm 20 JSK_12_021 1 2 1 ...

Page 21: ...e trap 25 and the sensor with holder 22 6 11 Fitting the spare part creating a repair drill hole 0 Drive the rivet 23 using a pin punch of diameter 3 mm into the drill hole 1 0 0 0 1 JSK_12_048 2 0 0 0 23 24 25 22 JSK_12_025 D5 5 SW 17 3 0 0 0 23 JSK_12_026 6 Repair work 6 10 Removing the locking sensor JSK 37 ...

Page 22: ...both sides 0 Fit the locking sensor with a sensor holder 22 and trap 25 as shown above Also note the Repair instructions for the JSK 37 fifth wheel coupling Tighten the securing nut 28 to hand tight ness Only use a new securing nut 28 for installation 0 To secure the retaining plate insert the M5 x 10 screw 29 included with the repair kit and tighten it to the specified torque Tighten the hexagona...

Page 23: ...0 Washer D10 31 Sleeve 32 Spring The mounted parts are valuable raw materials that can be recycled They can be split into plastic rubber and metallic materials Plastic and rubber is labelled in accordance with VDA recommendation 260 Before disposal parts may need to be cleaned of any residual oil or grease 1 0 0 0 0 22 24 25 30 31 32 28 29 JSK_12_031 6 Repair work 7 Disposal instructions ...

Page 24: ...Siemensstraße 2 D 63263 Neu Isenburg Telefon 49 6102 295 0 Fax 49 6102 295 298 www jost world com ZDE 199 007 105 03 2013 ...

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