jost JSK Series User manual

Sensor JSK
EN Installation and operating instructions
Sensor JSK
EN Installation and operating instructions

2MUB 007 001 M01 (REV-C) 07/2020 Sensor JSK

Table of contents
1 Explanation of symbols................................................. 4
2 Safety information........................................................ 5
2.1 Safety information for operation.............................. 5
2.2 Safety information for installation............................ 6
3 Intended use................................................................. 7
4 Installation.................................................................... 8
4.1 List of components................................................... 8
4.2 Display....................................................................... 9
4.3 Connecting connection cable................................... 10
5 Operation...................................................................... 11
5.1 Self-diagnostic........................................................... 11
5.2 Operating indicator (fifth wheel coupling open/
ready for coupling).................................................... 11
5.3 Operating indicator (fifth wheel coupling closed/
ready to drive)........................................................... 11
5.4 Operating indicator (faults)...................................... 12
5.5 Sensor coupling process........................................... 13
5.6 Sensor uncoupling process....................................... 15
6 Troubleshooting............................................................ 17
6.1 General malfunctions............................................... 17
6.2 Malfunctions during coupling up.............................. 20
6.3 Malfunctions during uncoupling............................... 21
7 Maintenance................................................................. 22
7.1 Cleaning the sensor fifth wheel coupling................. 22
EN
Sensor JSK MUB 007 001 M01 (REV-C) 07/2020 3

1 Explanation of symbols
WARNING!
Means that death, serious physical injury or significant
material damage can occur if the relevant safety instruc-
tions are not followed.
ATTENTION!
Means that slight physical injury or material damage
can occur if the relevant safety instructions are not fol-
lowed.
ADVICE!
Contains additional important information.
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2 Safety information
ATTENTION!
The safety information is compiled in this section.
Where the user or others are in danger, the safety
instructions are repeated in the individual sections and
highlighted with the danger warning sign shown here.
The relevant safety regulations in your country (for example Health
& Safety at Work) apply for working with fifth wheel couplings,
tractor units and semi-trailers. The appropriate safety instructions
in the operating manual for the tractor unit and the semitrailer are
applicable and must be followed.
The following safety information applies to the installation and
mounting work. Safety instructions directly linked to the activity
are listed again individually.
2.1 Safety information for operation
The sensor coupling may only be used by authorised persons.
Only use the fifth wheel coupling and skid plate on the semi-
trailer if they are in perfect technical condition.
Ensure that the material wear does not exceed the wear lim-
its for the lock jaw and the king pin set out in the installation
and operating instructions for class G50 JOST fifth wheel cou-
plings. Otherwise this will result in the king pin sensor being
damaged.
Comply with the relevant safety regulations when connecting
a semi-trailer, for example the Health and Safety at Work Reg-
ulations.
Before starting any journey and each time couple a trailer,
check that the locking mechanism is in good condition and
that it is properly secure. Only drive the vehicle with the lock-
ing mechanism locked and secured.
WARNING!
If the fifth wheel coupling is not correctly closed and
secured, the semi-trailer can work loose. This can cause
an accident and injure you and other people. Always
check that the fifth wheel coupling is in good condition
and locked after connecting a semi-trailer. A pre-depar-
ture inspection is always to be performed, even if the
display indicates “Fifth wheel coupling closed (green)”.
The sensor coupling is only an assistance function which
helps you to couple and uncouple trailers.
EN
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2 Safety information
2.2 Safety information for installation
The assembly work may only be completed by authorised
specialists.
Follow the safety instructions for working on the vehicle’s
electrical system as set out in the assembly and modification
instructions issued by the vehicle’s manufacturer.
The battery must be disconnected before starting any work
on the vehicle’s electrical system.
The earth return of the electrical consumers is not through
the chassis but through the cabling via the earth post on the
fuse holder.
Install all the cables so that they cannot be crushed or chafed.
Do not fasten cables to brake lines.
Route cables at an adequate distance from heat sources, such
as the exhaust system.
When installing the cables ensure that there is a sufficient
length of cable between the fifth wheel coupling and the
vehicle body.
Install the electronic display equipment within the view of the
driver.
Make the connection for the power supply to the sensor cou-
pling at a point approved by the vehicle manufacturer.
The sensor coupling must be protected by a conventional 1 A
automotive fuse.
Follow the ADR / GGVS regulations and national legislation
and regulations relating to ADR / GGVS vehicles.
The connection may only be made using an ADR extension
cable on ADR / GGVS vehicles. This must be specified in the
order.
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3 Intended use
ATTENTION!
The JOST sensor coupling is only an assistance function
which helps you to couple and uncouple trailers. The
pre-departure inspection mentioned in section 2.1 must
therefore be conducted in full and is not replaced or
rendered unnecessary by the sensor coupling.
The JOST sensor coupling provides the driver with information
relating to the locking status of the fifth wheel coupling.
The individual components must be used only in combination with
the specially intended JOST fifth wheel coupling.
Information on this subject is provided in the sales documentation
supplied by JOST.
Modifications of any kind will render both the warranty and the
design approval void and therefore also cancel the vehicle's oper-
ating licence.
The sensor coupling display can be shown on the JOST display or
on a display integrated in the instrument panel of the vehicle.
JSKC/38
Sensor coupling with 3 sensors.
JSKC/48
Sensor coupling with 2 sensors.
The operational status of the fifth wheel coupling is shown with
the following symbols (under ISO 2575).
Open (red) Closed (green)
Closed (red) Malfunction
(red)
Level reached
(only for variant
with 3 sensors)
The JOST display is described below. The descriptions apply accord-
ingly to the display on the instrument panel.
EN
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4 Installation
4.1 List of components
8
2
4
5*
1
2
8
5*
6
7
6
4
1
7
3
JSKC/02
1Display
2Plug (display)
3Connection cable
4Plug (fifth wheel coupling)
5* Semi-trailer sensor, only with sensor coupling model with 3 sensors
6Locking sensor, switch magnet
7King pin sensor
8Power supply connection
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4 Installation
4.2 Display
JSKC/28
11
ADVICE!
Install the display (1) in the driver’s field of vision. The
display's installation foot has an adhesive surface and
can be affixed into position. The affixing area in the vehi-
cle must be dry and free of dust and grease. Alterna-
tively the installation foot may be screwed into position.
There are markings on the underside of the foot to make
it easier to install it.
EN
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4 Installation
4.3 Connecting connection cable
2Plug (display)
3Connection cable
4Plug (fifth wheel coupling)
8Power supply connection
– Black cable
Terminal 31 (negative) connection
– White cable
Terminal 15 connection (positive when ignition ON)
ATTENTION!
The safety information set out in section 2.2 must be
observed to prevent damaging the vehicle's electrical
system.
Connect the plug (2) to the display.
Route the power supply connection (8) to the point approved
by the vehicle manufacturer and connected there (see con-
nection diagram in section 4.1).
ATTENTION!
In order to avoid damage to the vehicle’s electrical and
sensor systems in the case of a short circuit, a commer-
cially available 1 A blade-type fuse must be installed in
the connection supply line (8). When making the con-
nection ensure that the display is suitable for the volt-
age of the vehicle (12 V or 24 V). Further information is
provided in the sales documentation.
Route the connection cable (3) to the fifth wheel coupling
and connect the plug (4) to the existing mating plug. The plug
must be locked with the yellow slide.
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5 Operation
ADVICE!
The figures partially show sensor couplings with 2 or 3 sensors, however, descriptions apply to both versions.
5.1 Self-diagnostic
The sensor coupling carries out a self-diagnostic test when the igni-
tion is switched on. This process checks the system’s sensors.
Switch on the ignition.
The entire display will light up.
After flashing several times, the
current operating status will be
displayed.
ADVICE!
Each time you start the system, check for lit-up indica-
tors to detect any defect in the display system in good
time.
5.2 Operating indicator (fifth wheel coupling open/
ready for coupling)
The red LED will be lit. The fifth
wheel coupling is open and
ready to couple.
ADVICE!
The display will switch off
after 5 seconds.
5.3 Operating indicator (fifth wheel coupling closed/
ready to drive)
The green LED will be lit. The
fifth wheel coupling is closed
and ready to drive away.
ADVICE!
The display will go dark
after 5 seconds.
EN
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5 Operation
5.4 Operating indicator (faults)
The red "Fifth wheel coupling
closed" indicator will flash and
an alarm will sound.
The JOST fifth wheel coupling
is not correctly locked, i.e. the
fifth-wheel coupling is closed,
but the king pin is not engaged
or not detected by the system.
The red LEDs will flash and an
alarm will sound. The fifth wheel
coupling is not correctly closed.
The king pin is engaged.
The entire display will light up
permanently in red.
A system error has occurred.
ADVICE!
Other errors and how to rectify them are set out in the
table (diagnostic table for faults) in section 6.
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5 Operation
5.5 Sensor coupling process
JSKC/38
The fifth wheel coupling is open and ready to cou-
ple.
Drive the tractor unit under the semi-trailer.
Raise the fifth wheel using the air suspension
until the fifth wheel coupling plate contacts the
skid plate.
For a sensor coupling with skid plate detection
(3 sensors), the display now switches on
automatically.
ADVICE!
For a sensor coupling with skid plate detec-
tion (3 sensors), the “Open (red)” display
starts flashing and a signal tone sounds
if the fifth wheel plate loses contact with
the skid plate during the coupling process.
Restore contact to the skid plate within 10
seconds, otherwise the system will switch
off and you should restart the coupling
process.
EN
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5 Operation
Reverse the tractor unit until the fifth wheel cou-
pling closes.
The green "Fifth wheel coupling closed" display
will be lit. The fifth wheel coupling is correctly
closed.
ADVICE!
The display will go dark after 2 minutes.
WARNING!
The driver must check that the semi-trailer
has been connected properly. The skid plate
must rest on the fifth wheel coupling with-
out a gap. The fifth wheel coupling must
be closed and locked, see installation and
operating manual for the JSK 34, JSK 36,
JSK 37C, JSK 40 and JSK 42.
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5 Operation
5.6 Sensor uncoupling process
The fifth wheel coupling is correctly closed
and locked.
Open the fifth wheel coupling locking mech-
anism.
“JOST lettering” and “Open” are flashing red.
ADVICE!
After a time limit of 2 minutes has
elapsed the alarm will stop and the
red LEDs will be constantly lit until the
tractor unit has been driven out. Igni-
tion Off/On required to restart.
Drive the tractor unit forwards.
For a sensor coupling with skid plate detec-
tion (3 sensors), the display continues to
show an open fifth wheel coupling as long
as there is contact between the fifth wheel
plate and the skid plate.
EN
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5 Operation
Drive out the tractor unit as usual, lowering
the air suspension.
The red indicators go out.
ADVICE!
The display will switch off completely
after approx. 10 seconds.
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6 Troubleshooting
ADVICE!
In order to remedy malfunctions, see also the repair instructions for the sensor set.
6.1 General malfunctions
Fault Cause Remedy
Plug connections loose or not connected
correctly.
Check the plug connections for the cabling between
the fifth wheel coupling and the electronic display.
ADVICE!
All the contacts must be engaged uniformly
in the plugs. Ensure that the plug connec-
tions are engaged correctly.
1 A automotive fuse defective. Replace 1 A automotive fuse.
Connection cable not connected correctly. Check voltage supply:
•White cable = terminal 15 (+12 V or +24 V
ignition ON)
•Black cable = Terminal 31 (earth)
Display non-functional after
starting (ignition “ON”).
Vehicle battery too weak. Charge/Replace the battery.
EN
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6 Troubleshooting
Fault Cause Remedy
Plug connections loose or not connected cor-
rectly.
Check the plug connections for the cabling between the
fifth wheel coupling and the electronic display.
ADVICE!
All the contacts must be engaged uniformly in
the plugs. Ensure that the plug connections are
engaged correctly.
JSK 34 - latch defective:
Magnet no longer present in latch.
Replace latch.
If the magnet is no longer present in the latch, also
remove magnet from detection field of the locking sen-
sor.
JSK 36/JSK 37 - latch defective:
Shrink-fit hose no longer present and the
magnet beneath it no longer adheres to the
intended position in the latch.
Replace the latch if the shrink-fit hose is missing.
If the magnet is no longer present in the latch, also
remove magnet from detection field of the locking sen-
sor.
JSK 42 - handle defective:
Magnet in handle no longer present or bro-
ken.
Replace the safety latch with magnet.
If the magnet is no longer present in the lever, also
remove magnet from detection field of the locking sen-
sor.
Sensor set defective
(cable break on sensor set or defective sen-
sor).
Check the sensor set according to the repair instructions
“Replacing the sensor set” and replace the sensor set if
necessary.
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6 Troubleshooting
Fault Cause Remedy
The fifth wheel coupling is not adjusted cor-
rectly or is worn.
Check fifth wheel coupling and adjust according to instal-
lation and operating instructions of fifth wheel coupling.
The king pin is worn to below the maximum
wear limit.
Replace the king pin and check the locking mechanism
setting on the fifth wheel coupling.
The king pin sensor is not installed correctly. The king pin sensor must be readjusted according to the
sensor system repair instructions.
When driving
or after ignition
ON with cou-
pled semi-trailer,
the indicator on
the display
changes as shown
Plug connections loose or not connected cor-
rectly.
Check the plug connections for the cabling between the
fifth wheel coupling and the electronic display.
ADVICE!
All the contacts must be engaged uniformly in
the plugs. Ensure that the plug connections are
engaged correctly.
EN
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6 Troubleshooting
6.2 Malfunctions during coupling up
Fault Cause Remedy
The fifth wheel coupling is not closed cor-
rectly or the king pin is not in the correct
position.
Check the status of the locking mechanism, adjust the
locking mechanism if necessary and reconnect the semi-
trailer.
JSK 42:
Handle not secured/not in end position
Check the functionality of the handle. If necessary, clean
and re-lubricate it (handle must move independently and
fully into the secured position - see MuB for fifth wheel
coupling JSK 40/42).
JSK 34 - latch defective:
Magnet no longer present in latch.
Replace latch.
If the magnet is no longer present in the latch, also
remove magnet from detection field of the locking sen-
sor.
JSK 36/JSK 37 - latch defective:
Shrink-fit hose no longer present and the
magnet beneath it no longer adheres to the
intended position in the latch.
Replace the latch if the shrink-fit hose is missing.
If the magnet is no longer present in the latch, also
remove magnet from detection field of the locking sen-
sor.
JSK 42 - handle defective:
Magnet in handle no longer present or bro-
ken.
Replace the safety latch with magnet.
If the magnet is no longer present in the lever, also
remove magnet from detection field of the locking sen-
sor.
Locking sensor defective Check the functionality of the locking sensor according
to the repair instructions “Replacing the sensor set” and
replace the sensor set if necessary.
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