jost JSK 34 Setup guide

Replacing the JSK 34
locking sensor
EN Repair instructions
www.jost.world.com
Replacing the JSK 34
locking sensor
EN Repair instructions
www.jost.world.com

Preface
Sensor-enabled fifth wheel couplings are parts that
must comply with very high safety requirements.
This repair manual is designed to act as a guide to
completing repair work on our sensor set.
The use of JOST spare parts is essential. Changes
or modifications of any kind invalidate any warranty
claims and will lead to the component type approval
being forfeited.
Operation and installation are described separately
in dedicated publications.
Explanation of symbols
WARNING!
Means that death, serious physical injury
or significant material damage can occur if
the relevant safety instructions are not fol-
lowed.
ATTENTION!
Means that slight physical injury or mater-
ial damage can occur if the relevant safety
instructions are not followed.
ADVICE!
Contains additional important information.
Contents
1 Safety instructions...................................... 3
2 Intended use................................................ 4
2.1 Use...................................................... 4
3 General......................................................... 5
4 Standard/special tools and auxiliary
materials....................................................... 6
4.1 Standard tools..................................... 6
4.2 Special tools........................................ 6
4.3 Auxiliary materials............................... 6
5 Sensor function test.................................... 7
6 Repair work.................................................. 8
6.1 Preparing the fifth wheel coupling....... 8
6.2 Removing cable fastenings and con-
nectors................................................. 8
6.3 Removing the locking sensor.............. 9
6.4 Removing contacts.............................. 9
6.5 Installation........................................... 10
6.5.1 Installing contacts................ 10
6.5.2 Installing the connector........ 11
7 Disposal instructions.................................. 12
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1 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.
The permitted load data and safety information must be complied with during operation and installation.
For maintenance and repair work, the following sections contain safety information that is directly related
to each specific activity. It is essential that you follow this safety information.
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2 Intended use
2.1 Use
JOST fifth wheel couplings are mechanical connecting devices and establish a connection between the
tractor unit and the semi-trailer. They are designed for mounting on a tractor unit.
Fifth wheel couplings, mounting plates and kingpins are vehicle-connecting parts that must comply with
very high safety requirements and must also undergo design approval tests. Modifications of any kind will
render both the warranty and the type approval void and therefore also invalidate the vehicle operating
licence.
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
comparable licensed equipment. The sensors conform to Regulation ECE R10.
JOST fifth wheel couplings are suitable for use in power steering systems.
ADVICE!
Technical modifications reserved.
You can find the latest information at www.jost-world.com
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3 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.
Clean all parts thoroughly before assembly.
After completing the repair work, the fifth wheel coupling locking mechanism must be greased and its
function tested.
ATTENTION!
The prescribed tightening torques must be adhered to!
Always replace worn, damaged and cracked parts.
Repair welds must not be used.
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4 Standard/special tools and auxiliary materials
4.1 Standard tools
1/2´´
Size 10
1/2´´
Size 10
4.2 Special tools
Workbench
– Hot air blower
– Ejector tool for Tyco HDSCS flat connector 1.6 (Tyco article number 0-0539960-1)
– Ejector tool for Tyco HDSCS flat connector 2.8 (Tyco article number 1-1579007-6)
4.3 Auxiliary materials
We recommend high-pressure grease (EP), e.g. JOST high-performance lubricant (JOST Art. No. SKE
013 440 000).
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5 Sensor function test
Before replacing the locking sensor, all sensors must first undergo a function test to ensure that only the
locking sensor is faulty.
To do this, see the repair instructions "Replacing sensor set JSK 34/JSK 36/JSK 37/JSK 40/JSK 42".
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6 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 locking
mechanism must be greased and its func-
tion tested.
With the diagrams the work steps should be car-
ried out in alphabetical order (e.g. a, b, c). Assem-
bly is carried out correspondingly in reverse order.
Instructions for assembly are identified in the dia-
gram number or in the diagram itself with a diamond
◊. The torque values shown in the illustrations are
required for the subsequent assembly process. The
prescribed tightening torques must be adhered to!
6.1 Preparing the fifth wheel cou-
pling
Disconnect the electrical connection to the trac-
tor unit.
1
JSK/45-1
ATTENTION!
The fifth wheel coupling may only be raised
using suitable lifting gear.
Remove the fifth wheel coupling from the tractor
unit and place on a suitable surface, e.g. work-
bench. Also see the repair instructions for the
fifth wheel coupling in question.
6.2 Removing cable fastenings and
connectors
1
JSK34_101
1
2
ADVICE!
Depending on the design, the cable rout-
ing, position and number of cable ties and
cable clamps may vary.
ADVICE!
Make sure the cable sleeve is not damaged
during the following step.
Using a cable cutter, remove the cable ties
securing the connection cable from the locking
sensor (1) to the connector (2).
2
11
C
D
10
JSK_12_011
Slide the safety slide (10) in the direction of the
arrow (C) away from the plug.
Pull the plug (11) out of the retaining plate
towards the centre of the fifth wheel coupling
plate (D).
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6 Repair work
ADVICE!
Installation is performed in the reverse
order.
6.3 Removing the locking sensor
1
JSK34_102
1
Position of locking sensor (1).
2
1/2´´
1/2´´
Size 10
Size 10
JSK34_103
34
33
35
Undo the bolt (33) and M6 nut (35).
Remove the sensor (34).
3
JSK34_104
A
33
34
6,5 Nm
Insert the sensor (34) in the cutout in the fifth
wheel coupling, paying attention to the two con-
tact points A.
Screw on the sensor (34) using a new bolt (33)
and lock nut (35).
ADVICE!
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".
6.4 Removing contacts
1
33
31
32
JSK37C_05
ATTENTION!
Take care not to damage the cable during
the next step.
Cut open the cable tie (31) on the connector
cap (32).
Using a flat screwdriver, open the locking clip
(33) of the connector cap and remove the cap.
2
JSK37C_06
E
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6 Repair work
Unlock the second contact lock of the connec-
tor.
To do so, insert a flat screwdriver into the hole
provided. Light pressure moves the contact lock
into the pre-detent position.
3
JSK37C_07
ATTENTION!
Never pull the wire before unlocking the
contact. Light pressure against the cable
lead-out direction facilitates unlocking.
Press the contact out of pin 3 using the ejector
tool for Tyco flat connector 2.8.
Press the contacts out of pins 4 and 5 using the
ejector tool for Tyco flat connector 1.6.
To press out the contacts, push the blades of
the ejector tool into the two slots in the corre-
sponding contact chamber as far as they will
go.
Once you have inserted the ejector tool and
unlocked the contact, you can remove the con-
tact from the wire.
4
A
B
JSK37C_08
Nip off the pushed-out contacts directly behind
the seal using a cable cutter (A).
Next, pull the sensor cable out of the shrink-fit
hose (B).
6.5 Installation
6.5.1 Installing contacts
1
04
05
03
JSK_12_056
ATTENTION!
When inserting the contacts, make sure
they are aligned correctly. The contacts
must click audibly into place in the connec-
tor.
Insert the contacts of the new locking sensor
Pin 3 = black
Pin 4 = red
Pin 5 = brown
Close the contact lock on the connector.
2
3135
3234
JSK37C_10
ATTENTION!
It is clear when contacts are in their end
position due to the following:
– The contacts have audibly clicked into
place.
– The single-wire seal is fully inserted in
the connector hole.
– The second contact lock (yellow clip)
can be engaged effortlessly after the
contacts have been pinned.
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6 Repair work
ATTENTION!
The shrink-fit hose, cable sleeve and wire
insulation can be damaged by the heat
from the hot air blower.
Re-shrink the shrink-fit hose around the remain-
ing two cables using a hot air blower.
Next, secure the jacket cable of the new locking
sensor (34) to the two other jacket cables using
a cable tie (35).
Put on the connector cap (32).
Secure the cable to the connector cap (32) with
another cable tie (31).
6.5.2 Installing the connector
The connector is installed in the reverse order.
After this, use the supplied cable ties to refasten the
cable at the points indicated in Section 6.2. Don’t for-
get to also secure cables and hoses that were unfas-
tened during the removal of cable ties.
ATTENTION!
When repair is complete, a function test of
the fifth wheel coupling must be performed
(see the repair instructions of the fifth wheel
coupling in question).
Sensor installation and cable routing must
not have disturbed/influenced the function
of the fifth wheel coupling. On the other
hand, cables and lines must not be dis-
turbed/damaged by the mechanisms of the
fifth wheel coupling.
ATTENTION!
When repair is complete, a function test
of all sensors must be performed, see the
repair instructions "Replacing sensor set
JSK 34/JSK 36/JSK 37/
JSK 40/JSK 42".
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7 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.
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JOST, Germany, Tel. [phone], [email protected], www.jost-world.com
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