jost R 403 FR User manual
2MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
Table of contents
1 Explanation of symbols................................................. 4
2 Intended use................................................................. 5
2.1 General..................................................................... 5
2.2 Technical data and spare parts................................. 5
3 Installation.................................................................... 6
3.1 Installation suggestions............................................ 6
4 Operation...................................................................... 9
4.1 Operating equipment............................................... 9
4.2 Mounting and locking the container........................ 10
4.3 Tipping process......................................................... 12
4.4 Unlocking the container........................................... 12
5 Maintenance................................................................. 13
5.1 Inspection instructions............................................. 13
5.2 Disposal instructions................................................. 15
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 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.
4MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
2 Intended use
2.1 General
Locks R 403 FR and R 403 FL are not independently functioning
units. They are intended for mounting on a semi-trailer for trans-
porting ISO containers.
They must not be brought onto the market until it has been
established that the semi-trailer fitted with the locks satisfies the
domestic road traffic regulations.
The locks may only be brought into operation together with the
instructions in the owner’s manual of the tractor unit and trailer,
and the instructions for the locks themselves.
Locks R 403 FL and R 403 FR are used on the rear of a tipping con-
tainer chassis, for securing ISO containers. The R 403 FL is installed
on the left in the direction of travel, the R 403 FR on the right.
The lock components are reinforced, so that they can absorb the
loads acting on the tipping chassis during tipping.
The admissible loads can be found in the technical data, see
Chapter 2.2, "Technical data and spare parts".
We recommend fitting additional rear stabilisers, for use during
the tipping process.
2.2 Technical data and spare parts
ADVICE!
Test report 8109405693 from TÜV Nord Mobilität grants
approval based on ADR 2011 for a container weight of
34t.
WARNING!
The tipping angle must not exceed 55°. The maximum
admissible container weight when using this lock is 34t.
ADVICE!
Other combinations of container weight and tipping
angle may be approved following consultation with
JOST-Werke GmbH.
For spare parts numbers, please refer to the parts lists
of the latest product catalogue.
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 07-2020 5
3 Installation
The R 403 FR is for mounting on the rear right in the direction of
travel; the R 403 FL on the rear left.
3.1 Installation suggestions
Both locks must be welded to a rotating axle extending right
through the vehicle, to ensure a torsionally rigid coupling between
them.
WARNING!
Rotating axles that are not coupled and are independent
from one another lead to a high risk of accident when
the container is tipped, and must be avoided.
1
max. 80
TL403/001
The rotating axle (1) should be positioned at the same height as
the pivot in the direction of travel, and no more than 80 mm below
the support surface (see Fig. TL403/001).
ATTENTION!
Exceeding this distance or positioning the rotating axle
further forward in the direction of travel considerably
heighten the load on components during operation,
increasing the risk of accident.
6MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
3 Installation
ADVICE!
Extending the support surface in the direction of travel
is permitted and can reduce the load on components.
The vehicle manufacturer is responsible for the specification and
strength of the weld seams and any positioning of the rotating axle
outside the recommended zone.
All welding work must be performed solely by expert personnel.
The relevant, currently valid standards and codes of practice must
be observed.
See the following table for approved filler metals and welding con-
sumables.
Approved filler metals
Welding process EII MAG C, MAG M
Filler metal Electrode rod Welding wire
Name of stan-
dard
ISO 2560 - A -
E 35 0 A5
ISO 14341 - A -
G 42 0 M(C) G3Si1
ISO 14341 - A -
G 42 0 M(C) G4Si1
Approved welding consumables
Welding process EII
Welding consum-
ables
Electrode rod
Name of stan-
dard
ISO 14175 -C1
ISO 14175 -M21
ISO 14175 -M24
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 07-2020 7
3 Installation
2
1
4
3
TL403/002
1Pivot position indicator
2Bolt
3Safety catch
4Dowel pins
ADVICE!
If you first need to dismantle the lock, when finally
installing the pivot position indicator make sure it is
positioned correctly, to ensure it functions properly,
also see Chapter 2.2, "Technical data and spare parts".
The screw in the safety latch must be tightened to a
torque of 25 Nm. A medium-firm screw locking agent
can also be used.
If installed incorrectly, all warranty claims against the manufac-
turer and the supplier of the lock will be rendered void. If the
dimensions or shape of the lock are subsequently modified by the
vehicle manufacturer, the latter shall bear responsibility for the
modified shape of the product.
8MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
4 Operation
4.1 Operating equipment
3
6
1
2
5
4
TL403/003
1Pivot position indicator
2Thrust plate
3Safety catch
4Clamping nut
5Pivot
6Rear panel
The diagram above shows the parts of the R 403 FR, which are also
found on the R 403 FL.
Operation of the R 403 FR as described below can also be applied
to the R 403 FL.
The integrated thrust plate provides additional security to prevent
the container from slipping; when used as intended it does not
absorb any forces.
A gap must be visible between the thrust plate and the corner fit-
ting of the container.
WARNING!
If the corner fitting is lying against the thrust plate (dur-
ing tipping), inspect the lock immediately for compli-
ance with the criteria set out in Chapter 5.1, "Inspection
instructions".
A faulty corner fitting – with an excessively worn hole in the base,
for example – can cause the components to come into contact in
this way.
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 07-2020 9
4 Operation
4.2 Mounting and locking the container
1
2
3
TL403/004
1Corner fitting of container
2Pivot head
3Guide bush
Before putting on the container, make sure the locks are in the
correct position for mounting.
For this, the pivot head and guide bush must be facing the same
way, as shown in Fig. TL403/004.
The container can now be mounted.
Its corner fittings must not show any inadmissible deformations or
inadmissible wear.
4
6
5
7
TL403/005
4Pivot position indicator
5Pivot
6Safety catch
7Clamping nut
After loading, the corner fitting must lie flush against the lock.
As shown on the left in Fig. TL403/004, the pivot position indica-
tor projects over the side of the housing when the container is
unlocked.
Next, open the safety catch. To do so, push the catch up, turn it 90°
and, with it now horizontal, pull it sideways.
The clamping nut can now be rotated; first slacken it a few turns.
10 MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
4 Operation
You can now lift the pivot and clamping nut together, turn them
90° and then deposit them again.
WARNING!
If the pivot position indicator shows that the pivot is
open when the container is mounted, it is vital that you
close the lock properly before commencing a journey.
8
9
10
11
12
13
TL403/006
8Safety catch
9Pivot position indicator
10 Corner fitting of container
11 Pivot head
12 Clamping nut
13 JOST operating key 915.259.000
When the pivot is rotated 90°, the underside of its head must
lie against the base panel of the corner fitting, as shown in Fig.
TL403/006.
WARNING!
Perform a visual inspection through the hole in the side
of the corner fitting, and make sure the pivot is correctly
positioned.
The pivot position indicator is now in the direction of travel, as
shown on the left in of Fig. TL403/006, and no longer projects
above the side of the housing. Next, tighten the clamping nut by
hand until it comes into contact with the underside of the housing.
ATTENTION!
If the container is to be tipped as well as transported
normally on roads, tighten the nut to approx. 100 Nm
using a suitable tool (e.g. JOST universal operating key
915.259.000). We also recommend using this tool if the
container is simply to be loaded and its further use is
unknown.
Next, secure the clamping nut with the safety catch so that it can-
not work loose. To do so, fold the catch down. If you cannot bring
the catch into its locked position because of the position of the nut,
slacken the nut until this is possible.
ATTENTION!
Before commencing a journey, make sure the safety
catch is closed and the clamping nut is secured so it can-
not turn.
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 07-2020 11
4 Operation
4.3 Tipping process
Inspect all locks securing the container to make sure they are
closed.
In particular, look through the hole in the side of the corner fitting
to check that the pivot covers the base panel of the corner fitting
as intended.
The pivot position indicator must show that the locks are closed;
the safety catch must secure the clamping nut so it cannot turn.
WARNING!
Check that all locks are correctly closed before tipping.
ATTENTION!
We recommend tightening the nuts once again with a
suitable tool as described in section 3.2., as the preload
may have decreased due to settling during transport.
WARNING!
To additionally stabilise the vehicle, use the rear sta-
bilisers attached to the vehicle as per their operating
instructions.
WARNING!
Do not remain in the danger zone during the tipping
process, and make sure that other persons also stay out
of this area.
4.4 Unlocking the container
The basic procedure for unlocking and lifting off the container is
the reverse of that described in Chapter 4.2, "Mounting and locking
the container".
Bring the safety catch into a horizontal position so that you can
then slacken the clamping nut.
Using a suitable tool such as the JOST universal operating key
915.259.000 mentioned above can facilitate this task.
After this, you will easily be able to lift the pivot and clamping nut
and turn them 90°.
The pivot position indicator now faces outwards; the container can
be removed.
ATTENTION!
For empty trips, bring the locks into closed position as
described in the work steps in Chapter 4.2, "Mounting
and locking the container".
Then, the pivot position indicator does not project
beyond the side of the housing, preventing danger to
other road users.
12 MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
5 Maintenance
5.1 Inspection instructions
When containers are tipped, locks – particularly at the rear – are
subjected to greater wear than during simple transport; there is
also a considerably greater risk of accident due to component fail-
ure.
WARNING!
If locks are faulty, the higher forces exerted while tipping
pose a risk of the container falling off. Therefore, replace
faulty parts with genuine spare parts immediately.
ADVICE!
You or the operator must visually inspect all locks to
ensure they are complete, undamaged and in perfect
working order every day before driving commences.
At least every six weeks, have the following tests performed by a
qualified specialist:
Housing
Function test of internal lock parts (all operating positions
described in the instructions for use can be reached).
Check housing for abnormal deformation (minor deformation
due to operation, e.g. of the upper panel, is admissible).
Check guide bush for deformations that adversely affect func-
tion (the pivot can be clamped between the two cams of the
guide bush with the clamping nut without problem).
Check for visible cracks.
Safety catch
Check that the safety catch is present, is not damaged and
functions correctly (when tightened, the clamping nut is
secure so it cannot work loose).
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 07-2020 13
5 Maintenance
Pivot and clamping nut
General: Check for damage, deformations or wear that are
abnormal or adversely affect function (strike marks on the
cams of the clamping nut are admissible).
Check pivot and clamping nut threads. These must not display
any visible signs of wear along their entire length, or any signs
of damage or deformation. The check should preferably be
performed with the components removed.
JSMTL/012
Examples of inadmissible thread wear.
Check the pivot head (especially the underside) for visible
abnormal (local) wear, abnormal deformations and damage
that adversely affects function.
JSMTL/013
Examples of inadmissible wear on the pivot head.
Pivot position indicator
Check that the indicator itself and the two dowel pins are
present (the clamping nut is secured so it cannot come off the
pivot).
14 MUB 013 005 M30 (REV-B) 07-2020 Twist Locks R 403 Fx
5 Maintenance
5.2 Disposal instructions
The installed parts are valuable raw materials that can be recycled.
Before disposal, clean parts to remove any residual oil or grease.
EN
Twist Locks R 403 Fx MUB 013 005 M30 (REV-B) 07-2020 15
Member of JOST World
JOST, Germany, Tel. +49 6102 295-0, [email protected], www.jost-world.com
MUB 013 005 M30 (REV-B) 07-2020 • 2.2
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