Repair fifth wheel couplings

Repair manual for
JSK 40, JSK 42 fifth wheel couplings
ZDE 199 002 111 GB 05/2004
Foreword
Fifth wheel couplings are connecting parts that must comply with very high safety requirements and must also undergo design approval tests. This repair manual is designed to act as a guide to completing repair work on our fifth wheel couplings. It is essential that you use JOST spare parts. Modifications of any kind will render both the warranty and the type approval void. Instructions for the operating and installation of the fifth wheel couplings and the permitted load data for them are provided in separate documents.
Table of contents
1 Safety information 2 Troubleshooting 3 Standard and special tools, auxiliary material 3.1 3.2 3.3 Standard tools Special tools Auxiliary material 3 4
5 5 5 5 18
4 Repair work 4.1 4.2
4.3
4.4 4.5 4.6
4.7 4.8 4.9
To remove and install the liner 6 To remove and install the bearing on the workbench 7 4.2.1 To remove and install the bearing for mounting plate installation 7 4.2.2 To remove and install the bearing with the traverse 10 To remove and install the bearing on the vehicle 13 4.3.1 To remove and install the bearing for mounting plate installation 13 4.3.2 To remove and install the bearing with the traverse 16 To remove and install the wearing part 18 To remove and install the lock jaw 19 To remove and install the locking mechanism 22 4.6.1 To remove and install the locking mechanism, handle at the front 22 4.6.2 To remove and install the locking mechanism, handle at the rear 26 To adjust the locking mechanism 29 Wear limits, adjustment and control dimensions 29 Function test 33
5 Spare parts for JSK 40/40 W Plate installation 6 Spare parts for JSK 40/40 W with traverse 7 Spare parts for JSK 42/42 W Plate installation 8 Spare parts for JSK 42/42 W with traverse 9 Disposal instructions
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36
38
40 42 2
1 Safety information
JSK 40/42
The relevant safety regulations in your country (for example Health & Safety at Work) apply for working with sliders, fifth wheel couplings, tractor units and semi-trailers. The appropriate safety information in the owners handbook for the tractor unit and the semi-trailer are valid and must be followed. Safety information, which are directly linked to the specific activity, are listed in the following sections for servicing and repair work. It is essential that you follow these safety information.
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2 Troubleshooting
0
JSK 40/42
Remedy to 1. The skid plate should be at the same height or max. 50 mm lower than the fifth wheel coupling.
Fault
Cause
Fifth wheel coupling will 1. The king pin is too high. not close.
2. The skid plate is uneven, thus to 2. Replace the skid plate. Maximum flatness causing the king pin to be in deviation 2 mm. the wrong position. 3. The king pin is not the correct to 3. Replace the king pin. size or is damaged. 4. Lock jaw deformed. 5. Poor servicing. 6. Double spring defective. 7 Lever and/or handle bent. . to 4. Replace lock jaw SK 3221-52Z. to 5. Ease the mechanism and grease it. to 6. Replace double spring SK 3105-20 or gas pressure spring SKE 001560000. to 7 Replace/Straighten handle SKE 001620020 . or SKE 001630020 and handle SKE 001390020 or SKE 001390120.
The fifth wheel coupling 1. Tractor unit not level or pulling. to 1. Relieve the pressure on the tractor units locking mechanism. cannot be opened. 2. Poor servicing, damage to the lock jaw or locking bar, or incorrect locking mechanism adjustment. to 2. The fifth wheel coupling can be opened by force as follows: Pull the handle until the locking edge is exposed, swing it forwards and secure it in this position using a suitable object (for example a screwdriver). Undo the lock nut on adjusting screw SKE 500740420 and screw in the adjusting screw until the jamming has been rectified. Then rectify the poor servicing, check the locking mechanism parts for signs of damage and repair or adjust the locking mechanism if necessary. to 1. Replace lock jaw SK 3221-52Z. to 2. Replace spring SK 847 . to 3. Clean and grease the area of the locking mechanism. to 1. Replace collar SKE 001370020 (see sections 4.1 and 4.2). to 2. Check king pin, replace it if it is worn. If the king pin is in good conditions but there is still play, adjust the locking mechanism (see section 4.9). If this does not produce the desired result, replace the lock jaw SK 3221-52Z, the wearing part SKE 001740020 and the locking bar SKE 001009720.
Fifth wheel coupling does not stay in the ready position.
1. Lock jaw deformed. 2. Spring defective. 3. Poor servicing.
Movement between 1. Bearing has excessive play. fifth wheel coupling and semi-trailer (knocking). 2. Locking mechanism has excessive play.
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3.1
0
Standard and special tools, auxiliary material JSK 40/42
Standard tools
0
3/4
3/4
1/2
1/2
3/4
1/2
1/2
Nm 1/2 1/2 1/2 1/2
Nm
100 mm 1/2
100 mm T45 1/2 3/4
SW18
SW24
SW7
SW8
SW10
SW14
SW14
150 mm
SW 10
SW 11
SW 13
SW 17
SW 22
SW 24
4 - 12
300 gr.
200 mm
JSK40/95
3.2
0
Special tools
0
SK 2702-10
3.3
Auxiliary material
High pressure grease (EP) with MoS2 or graphite additive, for example: Collgranit A3 paste Turmogeargrease B2 from Lubcon (www.lubcon.com)
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4 Repair work
JSK 40/42
Repair work must be carried out by trained personnel. Repair work is to be carried out using suitable tools and state of the art methods. The item numbers in the drawings refer to the spare parts lists in sections 5 8. Information for assembly work are marked with a diamond . If it is not described separately, assembly work must be carried out in reverse order. The torque values shown in the drawings are required for the subsequent assembly process. Clean all parts thoroughly before assembly. After completing the repair work, the fifth wheel coupling locking mechanism must be greased and its function tested.
0
The torque values shown in the drawings must be used at all times. Worn, damaged and cracked parts must always be replaced. Repair welds must not be used.
Version with handle at the front

0
Version with handle at the rear

0
9 Handle
JSK40/115
Note The position of handle must be noted for some of the work shown in the following sections.
4.1
0
To remove and install the liner

0
1/2
1/2
1/2
24 Liner
T45
SW8
45 Nm
24
JSK40/56
Undo the Allen bolts or inner round hex bolt. Remove the liner (24).
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4 Repair work
4.2 To remove and install the bearing on the workbench
JSK 40/42
Note On the low maintenance version, the liner must be removed first as described in section 4.1.
0 0
JSK40/50
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.
4.2.1 To remove and install the bearing for mounting plate installation
0 0
3/4
3/4
21 Bridge screw
SW14
450 Nm
21 21
JSK40/51
0
The bridge screws (21) must always be replaced after being removed. Undo the bridge screws (21).
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4 Repair work
JSK 40/42
4.2.1 To remove and install the bearing for mounting plate installation (continued)
0 0
23 Bridge
23
JSK40/52
Remove the bridge (23).

0 0
When installing the bridge (23) ensure that the side with the angled edges faces the outside and the JOST logo is legible.
0
22 Rubber bearing 25 Pedestal b Cam
22 b 25
JSK40/53
Remove the rubber bearing (22).

0 0
When installing the rubber bearing (22) ensure that the cam (b) on the rubber bearing (22) is installed in the corresponding gap in the pedestal (25).
0
25 Pedestal
25
Remove the pedestal (25).

0 0
When installing the pedestal (25) ensure that the JOST logo faces the outside.
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TS
JSK40/54
4 Repair work
JSK 40/42
Version JSK 40 only
0 0
22 Collar c Intermediate piece
22
JSK40/117
Remove the collar (22) and intermediate piece (c).
Version JSK 42 only

0 0
22 Collar
22
JSK40/55
Remove the collar (22).
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4 Repair work
4.2.2 To remove and install the bearing with traverse
0 0
JSK 40/42
1/2
1/2
1/2
26 Traverse screw 27 Traverse
100 mm
SW14
SW 24
280 Nm
26
27
JSK40/57
Undo the traverse screws (26) on both sides. Remove the traverse (27).
0 0
3/4
3/4
21 Bridge screw
SW14
450 Nm
21
21
JSK40/58
!
0
0
23 Bridge
23
JSK40/59
Remove the bridge (23).

0 0
When installing the bridge (23) ensure that the side with the angled edges faces the outside and the JOST logo is legible as shown.
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4 Repair work
4.2.2 To remove and install the bearing with traverse (continued)
0 0
JSK 40/42
22 Rubber bearing 25 Pedestal b Cam
25
22
b
JSK40/60
Remove the rubber bearing (22).

0 0
When installing the rubber bearing (22) ensure that the cam (b) on the rubber bearing (22) is installed in the corresponding gap in the pedestal (25).
0
25 Pedestal
25
JSK40/61
Remove the pedestal (25).

0 0
When installing the pedestal (25) ensure that the JOST logo faces the outside.
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4 Repair work
Version JSK 40 only
0 0
JSK 40/42
JSK 40 K1, K5
JSK 40 K2, K3, K4, K6
22
22
JSK40/116
Version JSK 42 only

0 0
22 Collar
22
JSK40/55
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4 Repair work
4.3 To remove and install the bearing on the vehicle
JSK 40/42
0 0
JSK40/104
Attach suitable lifting gear, for example a king pin with a holder, to the fifth wheel coupling.
Note The illustration shows the fifth wheel coupling for mounting plate installation.
4.3.1 To remove and install the bearing for mounting plate installation
0 0
3/4
3/4
21 Bridge screw
SW14
21
450 Nm
JSK40/105
0
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4 Repair work
JSK 40/42
0 0
22 Rubber bearing 23 Bridge
22 23
JSK40/106
Remove the bridge (23) and rubber bearing (22). Raise the fifth wheel coupling with lifting gear.
Version JSK 40 only

0 0
c 22
JSK40/118
Version JSK 42 only

0 0
22 Collar
22
JSK40/107
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4 Repair work
JSK 40/42
0 0
22 Rubber bearing 23 Bridge
150 mm
106.5 mm 62.5 mm 52.5 mm
22
23
JSK40/109
Secure the rubber bearing (22) to the bridge (23) as shown with Sellotape / insulating tape for later installation.
0 0
22 Rubber bearing 23 Bridge b Cam
23 22
JSK40/110
Slide in the bridge (23) on both sides as shown. Lower the fifth wheel coupling with lifting gear.
0 0
3/4
3/4
21 Bridge screw 23 Bridge i Gap
Nm
SW14
21 i
450 Nm
23
JSK40/111
0 0
When installing the bridge (22) ensure that the cam (b) on the rubber bearing (22) is installed in the corresponding gap (i) in the pedestal. Insert the bridge screws (21).
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4 Repair work
4.3.2 To remove and install the bearing with traverse
0 0
JSK 40/42
3/4
3/4
21 Bridge screw 23 Bridge
SW14
21 23
450 Nm
JSK40/112
0
The bridge screws (21) must always be replaced after being removed. Undo the bridge screws (21). Remove the bridge (23). Raise the fifth wheel coupling with lifting gear.
Version JSK 40 only

0 0
22 c
JSK40/108
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4 Repair work
Version JSK 42 only
0 0
JSK 40/42
22 Collar
22
JSK40/107

0 0
22 Rubber bearing 23 Bridge 25 Pedestal b Cam
b 22
23
25
JSK40/113
0 0
When installing the rubber bearing (22) ensure that the cam (b) on the rubber bearing (22) is installed in the corresponding gap in the pedestal (25). Slide in the rubber bearing (22) and bridge (23). Lower the fifth wheel coupling with lifting gear.
3/4
3/4
21 Bridge screw 23 Bridge
Nm
SW14
21
23
450 Nm
JSK40/114
Insert the bridge screws (21).
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4 Repair work
4.4
0
JSK 40/42
To remove and install the wearing part

0
1/2
1/2
Allen bolt
SW7
49 Nm 49 Nm
JSK40/66
Undo the Allen bolts (1).

0 0
Securing ring
JSK40/67
Lever out the securing ring (2) with a screwdriver.

0 0
1 2
Wearing part Securing ring
JSK40/85
Remove the wearing part (1).
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4 Repair work
4.5 To remove and install the lock jaw
JSK 40/42
Version with the handle at the front only

0 0
Double spring
JSK40/63
Release the double spring (7).

0 0
When installing the double spring (7) ensure that the installation is carried out as shown in the illustration.
Version with the handle at the rear only

0 0
13 Gas pressure spring 17 Ball head
SW 13
13
20 Nm
17
JSK40/78
Lever out the securing clips with a screwdriver. Remove the gas pressure spring (13). Remove the ball head (17).
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4 Repair work
4.5 To remove and install the lock jaw (continued)
JSK 40/42
All versions
0 0
4 Spring 5 Cable tie 19 Securing ring on the eye bolt
200 mm
19 4 5
JSK40/64
Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).
0 0
Lubrication tube
SW 10
40 Nm
JSK40/65
Undo the screw connector on the lubrication tube (5).
Note Remove the wearing part as described in section 4.4 and then continue the work in the section.
0 0
6 a
Bolt M14 screw (removal tool)
a 6
JSK40/68
Screw in the screw (a) and pull out the bolt (6).
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4 Repair work
4.5 To remove and install the lock jaw (continued)
JSK 40/42
Version with the handle at the front only

0 0
Handle
JSK40/69
Pull the handle (9) to the outside.
Version with the handle at the rear only

0 0
Handle
JSK40/89
Pull the handle (9) to the outside.
All versions
0 0
5 6
Lubrication tube Lock jaw
SW 10
SW 11
3 Nm
5
JSK40/90
Turn the lock jaw (6) as shown and remove it. Unscrew the lubrication tube (5) from the lock jaw (6).
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4 Repair work
4.6 To remove and install the locking mechanism
JSK 40/42
4.6.1 To remove and install the locking mechanism, handle at the front
0 0
Double spring
JSK40/63
Release the double spring (7)

0 0
When installing the double spring (7) ensure that the installation is carried out as shown in the illustration.
0
200 mm
19 4 5
JSK40/64
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4 Repair work
JSK 40/42
4.6.1 To remove and install the locking mechanism, handle at the front (continued)
0 0
Lubrication tube
SW 10
40 Nm
JSK40/65
Note Remove the wearing part as described in section 4.4 and the lock jaw as described in 4.5. Then carry on with the work in the section.
0 0
1/2
1/2
1/2
3 Securing bolt 10 Intermediate lever 11 Lever spring
100 mm
SW14
d 11 10
110 Nm
3
JSK40/71
Release the lever spring (11) and undo the securing bolt (3). Push the intermediate lever (10) in the direction indicated by the arrow until the two holes (d) and (e) line up.
0 0
1/2
1/2
10 Intermediate lever 12 Lever screw
SW14
12 10
110 Nm
JSK40/72
Undo the lever screw (12) from the underside through the hole (e). Remove the intermediate lever (10).
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4 Repair work
JSK 40/42
0 0
Locking bar
JSK40/73
Remove the locking bar (3).

0
1/2
1/2
12 Lever screw
SW10
45 Nm
12
JSK40/74
0
Undo the lever screw (12).

0
1/2
1/2
15 Hexagonal nut
SW18
SW 24
15
65 Nm
JSK40/75
0
Undo the hexagonal nut (15).
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4 Repair work
JSK 40/42
0 0
10 Lever 14 Pull lever
14
10
JSK40/76
0
Remove the pull lever (14) and lever (10).
Note When installing the locking unit grease all the moving parts (lock jaw, locking bar, wearing ring, pull lever and all joints). Adjust the locking mechanism as described in section 4.7.
0 0
3 Locking bar and securing screw 4 Spring 6 Lock jaw 9 Handle
14 11 3 10 12
15
10 Intermediate lever and lever 11 Lever spring 12 Lever screws 14 Pull lever
15 6 4 19 12 3
JSK40/77
15 Pull lever screw with hexagonal nut 19 Eye bolt, complete
10
The screws (3) and (12) must always be replaced after being removed.
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4 Repair work
JSK 40/42
4.6.2 To remove and install the locking mechanism, handle at the rear
0 0
13 Gas pressure spring 17 Ball head
SW 13
13
20 Nm
17
JSK40/78
Lever out the securing clips with a screwdriver. Remove the gas pressure spring (13). Remove the ball head (17).
0 0
200 mm
19 4 5
JSK40/64
0 0
Lubrication tube
SW 10
40 Nm
JSK40/65
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4 Repair work
JSK 40/42
4.6.2 To remove and install the locking mechanism, handle at the rear (continued)
Note Remove the wearing part as described in section 4.4 and the lock jaw as described in 4.5. Then carry on with the work in the section.
0 0
1/2
1/2
3 Securing bolt 16 Pull lever
SW14
110 Nm
3 16 f
JSK40/79
Move the pull lever (16) in the direction indicated by the arrow until the screw head is over the hole (f). Undo the securing screw (3) from the underside through the hole.
0 0
1/2
1/2
3 Locking bar 15 Hexagonal nut 16 Pull lever
SW14
SW 24
16
65 Nm
15 f
JSK40/80
Remove the locking bar (3). Move the pull lever (16) in the direction indicated by the arrow until the screw head is over the hole (f). Remove the hexagonal nut (15).
0 0
16 Pull lever
16
JSK40/81
Remove the pull lever (16).

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4 Repair work
JSK 40/42
4.6.2 To remove and install the locking mechanism, handle at the rear (continued)
0 0
1/2
1/2
1/2
10 Lever 12 Lever screw
100 mm
SW10
12 10
45 Nm
JSK40/82
Undo the lever screw (12) and remove the lever (10).
Note When installing the locking unit grease all the moving parts (lock jaw, locking bar, wearing ring, pull lever and all joints). Adjust the locking mechanism as described in section 4.7.
0 0
12
3 Locking bar and securing screw 4 Spring 6 Lock jaw 9 Handle
10
10 Lever 12 Lever screw 13 Gas pressure spring
13 17 15 3 4 15 9 16 3 19
JSK40/83
0
15 Pull lever screw with hexagonal nut 16 Pull lever 17 Ball head 19 Eye bolt, complete
The screws (3) and (12) must always be replaced after being removed.
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4 Repair work
4.7
0
JSK 40/42
To adjust the locking mechanism

0
1/2
1/2
3 Locking bar 6 Lock jaw 9 Handle 20 Adjusting screw g Lock nut
SW24
SW 24
6 9
20 g
JSK40/96
Note The locking mechanism must be adjusted as follows using a semi-trailer without forced steering with a new king pin:
Uncouple the tractor unit on a flat, firm piece of ground. Undo the lock nut (g). Unscrew the adjusting screw (20) by approximately 15 turns. Couple the tractor unit up again. Tighten the adjusting screw (20) again until the handle (9) starts to move (have an assistant check this). To se t the recommended basic play of 0.3 mm, tighten the adjusting screw (20) by a further 1.5 turns and secure it with the lock nut (g). If there is still excessive play, the wearing ring and the lock jaw must be replaced as described in the repair manual.
4.8
Wear limits, adjustment and control dimensions
Lock jaw
0 0
Lock jaw
150 mm
17.5 - 19.0 mm
JSK40/86
Replace the lock jaw (6) when the wear limit is reached.
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4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)
JSK 40/42
Wearing part
0 0
Wearing part
150 mm
17.5 - 20.5 mm 1
JSK40/87
Replace the wearing part (1) when the wear limit is reached.
Collar
0 0
22 Collar
150 mm
22
3.0 - 8.0 mm
JSK40/97
Replace the collars (22) when the wear limit is reached.
King pin
0 0
150 mm
71.0 - 73.0 mm
84-82.5 mm
JSK40/88
49-50.8 mm
Replace the king pin when the wear limit is reached.

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4 Repair work
JSK 40/42
Coupling plate
0 0
A B
150 mm
Lubricating groove depth Exterior
100 mm
JSK 40
JSK 42
100 mm
A
110 mm
A B
110 mm
JSK40/98
70 mm
The fifth wheel coupling must be replaced if:

0
The top of the plate is worn to the bottom of the lubricating groove depth (A) at any point. Material wear of up to approx. 8 mm or up to the surface of the bearing screws, in other words up to approx. 3 mm lower than the bottom of the lubricating groove, is permitted on the exterior part (B) over the bearings. This does not apply to the W version.
Top plate liner

0 0
24 Liner h Securing screws
150 mm
24
h h
0 -3 mm
45 Nm
24
JSK40/103
h
Replace the liner (24) when it has worn down to the surface of the securing screws (h).
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4 Repair work
JSK 40/42
Locking mechanism (handle at the front)

0 0
150 mm
10 Intermediate lever and lever
0 mm
0 mm
10
0 mm
0 mm
JSK40/99
The lock jaw is worn when the space between the coupling plate and the lever (10) or between the coupling plate and the intermediate lever (10) is 0 mm. The locking mechanism cannot be adjusted any further at this point.
Locking mechanism (handle at the rear)

0 0
16 Pull lever
150 mm
0m
16
0m m
JSK40/100
The locking mechanism is worn when the space between the pull lever (16) and the edge of the coupling plate is 0 mm. The locking mechanism cannot be adjusted any further at this point.
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4 Repair work
4.9 Function test
JSK 40/42
Locking mechanism (handle at the front)

0 0
3 Locking bar 9 Handle 10 Lever A King pin B Locking bar tip
150 mm
min 4
mm
10 B 3
A
Locking mechanism (handle at the rear)
0
JSK40/101
3 Locking bar 9 Handle 10 Lever
150 mm
mm min 4
10 B
A King pin B Locking bar tip
3 A 9
JSK40/102
During the uncoupling process the engaging edge must be raised by at least 4 mm. The test is made when the king pin (A) (new condition) is pressed on the bar tip (B) and the handle (9) is held in the direction indicated by the arrow. If the gap is less than 4 mm, the lever (10), the handle (9) or the locking bar (3) must be checked for signs of deformation and wear.
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5 Spare parts for JSK 40/40 W Mounting plate installation

0
21
24 20 (8x) 01 02 03
22 04 05 19 06 07
08 L 25 13 23 16 17 15 14 12 11
JSK40/91
0
09
18 10
Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Gas pressure spring Pull lever, complete with item 15 Pull lever screw Pull lever, complete with items 15 and 17 Ball head Lever set with item 12 Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with intermediate piece and item 21 Liner with screws
Quantity Serial No./Note Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE 001560000 SKE001620020 SKE 001650020 SKE 001630020 SKE 001007800 SKE 001006820 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530020 SKE 001007020 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 2 2 1
L = 220 mm L = 390 mm for front handle
for rear handle for front handle for rear handle for rear handle for rear handle
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Item Description 25 Pedestal height 150 with item 21 Pedestal height 185 with item 21 Pedestal height 225 with item 21 Pedestal height 250 with item 21 Quantity Serial No./Note Article number per JSK SKE 001005620 SKE 001005720 SKE 001005820 SKE 001005920 2 2 2 2
Item Repair and retrofit kits 1, 2, 3, 4, 5, 6, 19

0
Article number SKE 001640020
Locking mechanism, complete
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6 Spare parts for JSK 40/40 W with traverse

0
21 20 22
24 (8x) 01 02 03
04 05
19 06
07
27 26
08 L 09
25
18 23 17 16 15 14 13 12 11
JSK40/92
0
10
Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Gas pressure spring Pull lever, complete with item 15 Pull lever screw Pull lever, complete with items 15 and 17 Ball head Lever set with item 12 Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with intermediate piece and item 21 Liner with screws
Quantity Serial No./Note Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE 001560000 SKE001620020 SKE 001650020 SKE 001630020 SKE 001007800 SKE 001006820 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530020 SKE 001007020 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 2 2 1
L = 220 mm L = 390 mm for front handle
for rear handle for front handle for rear handle for rear handle for rear handle
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Quantity Serial No./Note Article number per JSK SKE 001500020 SKE 001500120 SKE 001500220 SKE 001500320 SKE 001510020 SKE 001510120 SKE 001510220 SKE 001510320 SKE 001520020 SKE 001520120 SKE 001520220 SKE 001520320 SKE 002770020 SKE 001010020 SKE 001570020 SKE 001590020 SKE 001010120 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1
Item Description Pedestal height 150 LB K1/K2 with item 21 Pedestal height 150 LB K3 with item 21 Pedestal height 150 LB K4/K5 with item 21 Pedestal height 150 LB K6 with item 21 Pedestal height 190 LB K1/K2 with item 21 Pedestal height 190 LB K3 with item 21 Pedestal height 190 LB K4/K5 with item 21 Pedestal height 190 LB K6 with item 21 Pedestal height 225 LB K1/K2 with item 21 Pedestal height 225 LB K3 with item 21 Pedestal height 225 LB K4/K5 with item 21 Pedestal height 225 LB K6 with item 21 Traverse screws set Traverses LB K1/K5 with item 26 Traverses LB K2/K5 height 150 with item 26 Traverses LB K2/K5 height 190/225 with item 26 Traverses LB K3/K6 with item 26
25
26 27
Item Repair and retrofit kits 1, 2, 3, 4, 5, 6, 19 Locking mechanism, complete
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0
21
24 20 (8x) 01 02 03
22 04 05 19 06 07
08 L 25 09
23
15 14 12 11
JSK40/93
10
Item Description 1 2 3 4 5 6 7 8 9 10 11 12 14 15 19 20 21 22 23 24 25 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Pull lever, complete with item 15 Pull lever screw Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with item 21 Liner with screws Pedestal height 150 with item 21 Pedestal height 185 with item 21 Pedestal height 225 with item 21 Pedestal height 250 with item 21
Quantity Serial No./Note Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE001620020 SKE 001650020 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530220 SKE 001007020 SKE 001005620 SKE 001005720 SKE 001005820 SKE 001005920 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 2 1 2 2 2 2
L = 220 mm L = 390 mm
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0
ZDE 199 002 111 GB 05/2004
39

0
21 20 22
24 (8x) 01 02 03
04 05 27
26
19 06
07
08 L 09
25
23 15
14
12 11
10
JSK40/94
0
Item Description 1 2 3 4 5 6 7 8 9 10 11 12 14 15 19 20 21 22 23 24 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Pull lever, complete with item 15 Pull lever screw Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with item 21 Liner with screws
Serial No./Note
Quantity Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE001620020 SKE 001650020 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530220 SKE 001007020 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 2 1
L = 220 mm L = 390 mm
for front handle
ZDE 199 002 111 GB 05/2004
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Serial No./Note Quantity Article number per JSK SKE 001500020 SKE 001500120 SKE 001500220 SKE 001500320 SKE 001510020 SKE 001510120 SKE 001510220 SKE 001510320 SKE 001520020 SKE 001520120 SKE 001520220 SKE 001520320 SKE 002770020 SKE 001570020 SKE 001590020 SKE 001010120 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1
Item Description Pedestal height 150 LB K2 with item 21 Pedestal height 150 LB K3 with item 21 Pedestal height 150 LB K4 with item 21 Pedestal height 150 LB K6 with item 21 Pedestal height 190 LB K2 with item 21 Pedestal height 190 LB K3 with item 21 Pedestal height 190 LB K4 with item 21 Pedestal height 190 LB K6 with item 21 Pedestal height 225 LB K2 with item 21 Pedestal height 225 LB K3 with item 21 Pedestal height 225 LB K4 with item 21 Pedestal height 225 LB K6 with item 21 Traverse screw set Traverses LB K2/K5 height 150 with item 26 Traverses LB K2/K5 height 190/225 with item 26 Traverses LB K3/K6 with item 26
25
26 27
ZDE 199 002 111 GB 05/2004
41
9 Disposal instructions
The mounted parts are valuable raw materials that can be recycled. They can be split into plastics, rubber and metallic materials. The plastics and rubber materials are identified pursuant to VDA Recommendation 260. All oil and grease is to be cleaned off the parts before their disposal.
ZDE 199 002 111 GB 05/2004
42

Repair fifth wheel couplings

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Repair fifth wheel couplings

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Repair manual for

JSK 40, JSK 42 fifth wheel couplings

ZDE 199 002 111 GB 05/2004

4 Repair work 4.1 4.2

4.4 4.5 4.6

4.7 4.8 4.9

ZDE 199 002 111 GB 05/2004

Fifth wheel coupling does not stay in the ready position.

1. Lock jaw deformed. 2. Spring defective. 3. Poor servicing.

ZDE 199 002 111 GB 05/2004

Standard and special tools, auxiliary material JSK 40/42

Nm 1/2 1/2 1/2 1/2

100 mm T45 1/2 3/4

ZDE 199 002 111 GB 05/2004

Version with handle at the front

Version with handle at the rear

To remove and install the liner

ZDE 199 002 111 GB 05/2004

ZDE 199 002 111 GB 05/2004

Remove the bridge (23).

22 Rubber bearing 25 Pedestal b Cam

Remove the rubber bearing (22).

Remove the pedestal (25).

22 Collar c Intermediate piece

Remove the collar (22) and intermediate piece (c).

Version JSK 42 only

Remove the collar (22).

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26 Traverse screw 27 Traverse

Remove the bridge (23).

ZDE 199 002 111 GB 05/2004

22 Rubber bearing 25 Pedestal b Cam

Remove the rubber bearing (22).

Remove the pedestal (25).

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22 Collar c Intermediate piece

JSK 40 K2, K3, K4, K6

Remove the collar (22) and intermediate piece (c).

Version JSK 42 only

Remove the collar (22).

ZDE 199 002 111 GB 05/2004

ZDE 199 002 111 GB 05/2004

22 Rubber bearing 23 Bridge

Version JSK 40 only

22 Collar c Intermediate piece

Remove the collar (22) and intermediate piece (c).

Version JSK 42 only

Remove the collar (22).

ZDE 199 002 111 GB 05/2004

22 Rubber bearing 23 Bridge

106.5 mm 62.5 mm 52.5 mm

22 Rubber bearing 23 Bridge b Cam

21 Bridge screw 23 Bridge i Gap

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21 Bridge screw 23 Bridge

Version JSK 40 only

22 Collar c Intermediate piece

Remove the collar (22) and intermediate piece (c).

ZDE 199 002 111 GB 05/2004

Remove the collar (22).

22 Rubber bearing 23 Bridge 25 Pedestal b Cam

21 Bridge screw 23 Bridge