jost JSK 34 Repair Instructions
Replacing sensor set
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Also See for JSK 34:
- Installation and operating instructions manual (24 pages) ,
- Repair instructions (16 pages)
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Summary of Contents for jost JSK 34
- Page 1 Replacing sensor set JSK 34/JSK 36/JSK 37C/ JSK 40/JSK 42 Repair instructions Member of JOST World www.jost-world.com...
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Page 2: Table Of Contents
This repair manual is designed to act as a guide to Use............4 completing repair work on our sensor set. 3 General............5 The use of JOST spare parts is essential. Changes or 4 Standard/special tools and auxiliary mate- modifications of any kind invalidate any warranty rials............. 6 claims and will lead to the component type approval being forfeited. -
Page 3: Safety Instructions
Safety instructions The relevant safety regulations in your country (Health & Safety at Work, for example) apply to work 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. -
Page 4: Intended Use
JOST fifth wheel couplings are specified to comply with Regulation ECE R55 in class 50 and may be used solely in conjunction with kingpins of class H50, steering wedges and mounting plates of class J, or com- parable licensed equipment. -
Page 5: General
General Conversion work must be carried out by trained personnel in suitable workshops. Repair work must be carried out using suitable tools and state of the art methods. Instructions for assembly are indicated by a diamond (◊). The assembly is in reverse order if not described separately. The torque values shown in the illustrations are required for the subsequent assembly process. -
Page 6: Standard/Special Tools And Auxiliary Materials
1/2´´ 1/2´´ Size 10 Diameter 5.5mm Size 18 150mm Special tools Workbench SKE00863000 – Multimeter/ohmmeter Auxiliary materials We recommend high-pressure grease (EP), e.g. JOST high-performance lubricant (JOST Art. No. SKE 013 440 000). ZDE 199 007 105 DE • 08-2023... -
Page 7: Sensor Function Test
Check the magnet and sensor of the fifth wheel coupling handle (see Sections 5.2 and 5.3.1). Replace worn and faulty components (see Section 6 and repair instructions for JSK 34/JSK 36/JSK 37/JSK 40/JSK 42 on Fifth wheel the JOST website at www.jost-world.com). -
Page 8: Basic Settings And Visual Inspection
Wearing part JSK 37C without plastic top plate liners and wearing part JSK 36. 150mm 19.0 -20.5 mm JSK_12_034 Wearing parts JSK 37 with plastic top plate liners and JSK 34/JSK 40/JSK 42 with and without plastic top plate liners. ZDE 199 007 105 DE • 08-2023... - Page 9 Before performing a sensor function test, the following components must first be inspected for visible mechanical damage: 1 Cover of semi-trailer sensor 2 Plug 3 Cable to sensor set JSK 40/JSK 42 JSK 34 JSK 37 JSK_12_064 4 Handle or latch 5 Handle magnet (secured with shrink-fit hose) 6 Locking sensor...
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Page 10: Diagnostic Tester
Measuring points Resistance If the magnet in the latch Plug pins 3 and 4 Infinite (JSK 34/JSK 36/JSK 37) or the shrink-fit Plug pins 3 and 5 Infinite Plug pins 4 and 5 Infinite hose securing the magnet is damaged or no longer present, the latch must be replaced. -
Page 11: Checking The Kingpin Sensor
Open the coupling (no kingpin engaged). ing the handle of JSK 40/JSK 42 fifth wheel cou- The LED on the back of the sensor must not plings or the latch of JSK 34/JSK 36/JSK 37 fifth light up brightly. wheel couplings:... -
Page 12: Checking The Semi-Trailer Sensor
Sensor function test 5.3.3 Checking the semi-trailer sensor The sensor's function LED points downwards when installed. The LED can then be observed with the help of a mirror. To do this, slide a mirror to left (arrow A) next to the right pedestal between the fifth wheel coupling plate and the mounting plate. -
Page 13: Repair Work
Repair work ATTENTION! Worn, damaged and cracked parts must always be replaced. Repair welds must not be used. After completing the repair work, the entire fifth wheel coupling lock- ing mechanism must be greased and its function tested. With the diagrams the work steps should be car- ried out in alphabetical order (e.g. -
Page 14: Removing Cable Fastenings And Connectors
Repair work Removing cable fastenings and Using a cable cutter, remove the cable ties securing the connection cable from the locking connectors sensor (1), the kingpin sensor (2) and the semi- trailer sensor (3) to the connector (3). Cable tie A is secured with a washer. ADVICE! Cable ties may be secured with a washer behind the main fin. -
Page 15: Removing The Semi-Trailer Sensor
Repair work Removing the semi-trailer sensor Installing the plug and semi-trailer sensor Components of the semi-trailer sensor unit: JSK_12_050 Position of semi-trailer sensor (1). JSK_12_009 1/2´´ Screw M6 x 10 mm with washer Holder 1/2´´ Semi-trailer sensor M30 Size 36 nut Size 4 Cable splice (optional) Protective cap... -
Page 16: Removing The Kingpin Sensor
The installation and operating instructions and repair instructions can be obtained from the JOST website at www.jost-world.com. JSK_12_013 Guide a new kingpin into the fifth wheel cou- pling and ensure that the locking mechanism is Undo the grub screw (14). - Page 17 Repair work Carefully screw in the grub screw (14) until it touches the kingpin sensor (A). Now screw the grub screw in by another quar- ter turn (B) to fix the kingpin sensor in place. Alternatively, tighten the grub screw to the A=x+75.5mm specified torque.
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Page 18: Removing The Locking Sensor Jsk 40/Jsk 42
Repair work Removing the locking sensor JSK 40/JSK 42 To remove the locking sensor, the handle must be removed. JSK_12_019 Remove the pull lever (19) from the fifth wheel coupling. JSK_12_017 1/2´´ Unhook the double spring (17). 1/2´´ Size 2.5 ATTENTION! Risk of injury! The double spring (17) is under tension! -
Page 19: Installing The Locking Sensor And Con- Nector Jsk 40/Jsk 42
Repair work 1/2´´ 1/2´´ 6.5 Nm Size 2.5 JSK_12_021 JSK_12_023 Undo the screws (20) With plastic top plate liner: – 2 x screw M6x16 (20) – 2 x washer D6 (21) Installing the locking sensor and The connector is installed in the reverse order. connector JSK 40/JSK 42 After this, use the supplied cable ties to refasten the The locking sensor is installed in the reverse order. - Page 20 Repair work Variant 1 Diameter 5.5mm Size 17 JSK_12_026 JSK_12_025 Drive the rivets (23) into the drill hole using a Remove the head of the blind rivets (23) using a pinpunch of diameter 3 mm. 5.5 mm drill bit Undo the hex bolt M10 (24). Remove the latch (25) and the sensor with holder (22).
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Page 21: Installing The Replacement Locking Sensor
Repair work 6.10 Installing the replacement locking sensor 30 Nm Add-on parts of locking sensor JSK 37C Size 17 JSK_12_063 Tighten the hex bolt (24) to the specified torque. ATTENTION! Next, check that the lock is functioning correctly. After it has been deflected to the open position, the latch (25) must move independently to the stop on the 22 Locking sensor with holder... -
Page 22: Replacement Latch
Installation is performed in the reverse order. ATTENTION! Only use a new lock bolt (33) and nut (35) for installation. ATTENTION! Also note the ‘Repair instructions for the JSK 34 fifth wheel coupling’. ZDE 199 007 105 DE • 08-2023... -
Page 23: Disposal Instructions
Disposal instructions Installed parts are valuable raw materials that can be recycled. They can be split into plastics, rubber and metal materials. Plastic and rubber are labelled in accordance with VDA recommendation 260. Before disposal, clean parts to remove any residual oil or grease. - Page 24 Member of JOST World JOST, Germany, Tel. +49 6102 295-0, tkd-technik@jost-world.com, www.jost-world.com ZDE 199 007 105 DE • 08-2023 • 2.3...
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