Post on 14-Sep-2014
1ZDE 199 002 111 GB 05/2004
Repair manual for
JSK 40, JSK 42 fifth wheel couplings
2ZDE 199 002 111 GB 05/2004
Foreword Table of contents
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.
1 Safety information 3
2 Troubleshooting 4
3 Standard and special tools, auxiliary material 5
3.1 Standard tools 53.2 Special tools 53.3 Auxiliary material 5
4 Repair work 18
4.1 To remove and install the liner 64.2 To remove and install the bearing
on the workbench 74.2.1 To remove and install the bearing
for mounting plate installation 74.2.2 To remove and install
the bearing with the traverse 104.3 To remove and install the bearing
on the vehicle 134.3.1 To remove and install the bearing
for mounting plate installation 134.3.2 To remove and install
the bearing with the traverse 164.4 To remove and install the wearing part 184.5 To remove and install the lock jaw 194.6 To remove and install
the locking mechanism 224.6.1 To remove and install the locking
mechanism, handle at the front 224.6.2 To remove and install the locking
mechanism, handle at the rear 264.7 To adjust the locking mechanism 294.8 Wear limits, adjustment and
control dimensions 294.9 Function test 33
5 Spare parts for JSK 40/40 W – Plate installation 34
6 Spare parts for JSK 40/40 W – with traverse 36
7 Spare parts for JSK 42/42 W – Plate installation 38
8 Spare parts for JSK 42/42 W – with traverse 40
9 Disposal instructions 42
3ZDE 199 002 111 GB 05/2004
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 owner’s 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.
4ZDE 199 002 111 GB 05/2004
2 Troubleshooting
0
Fault Cause Remedy
Fifth wheel coupling will not close.
1. The king pin is too high.
2. The skid plate is uneven, thus causing the king pin to be in the wrong position.
3. The king pin is not the correct size or is damaged.
4. Lock jaw deformed.5. Poor servicing.6. Double spring defective.
7. Lever and/or handle bent.
to 1. The skid plate should be at the same height or max. 50 mm lower than the fifth wheel coupling.
to 2. Replace the skid plate. Maximum flatness deviation 2 mm.
to 3. Replace the king pin.
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 cannot be opened.
1. Tractor unit not level or pulling.
2. Poor servicing, damage to the lock jaw or locking bar, or incorrect locking mechanism adjustment.
to 1. Relieve the pressure on the tractor unit’s locking mechanism.
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.
Fifth wheel coupling does not stay in the ready position.
1. Lock jaw deformed.2. Spring defective.3. Poor servicing.
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.
Movement between fifth wheel coupling and semi-trailer (knocking).
1. Bearing has excessive play.
2. Locking mechanism has excessive play.
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.
JSK 40/42
5ZDE 199 002 111 GB 05/2004
3 Standard and special tools, auxiliary material
3.1 Standard tools
0
3.2 Special tools
0
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)
0
0
1/2´´
Nm
1/2´´ 1/2´´
100 mm
3/4´´ 3/4´´
100 mm
1/2´´
SW18
SW 10 SW 11 SW 17 SW 24
300 gr. 200 mm4 - 12
3/4´´
SW14
1/2´´
SW14
1/2´´
SW7
JSK40/95
3/4´´
Nm
SW 13 SW 22
1/2´´
SW8
1/2´´
SW10
150 mm
1/2´´
SW24
1/2´´
T45
SK 2702-10
JSK 40/42
6ZDE 199 002 111 GB 05/2004
4 Repair work
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
Version with handle at the front Version with handle at the rear0
Note
The position of handle must be noted for some of the work shown in the following sections.
4.1 To remove and install the liner
0
Undo the Allen bolts or inner round hex bolt. Remove the liner (24).
! 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.
0 9 Handle
0 24 Liner
9 9
JSK40/115
1/2´´ 1/2´´
T45
24
45 Nm
JSK40/56
1/2´´
SW8
JSK 40/42
7ZDE 199 002 111 GB 05/2004
4 Repair work
4.2 To remove and install the bearing on the workbench
Note
On the „low maintenance“ version, the liner must be removed first as described in section 4.1.0
0
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
Undo the bridge screws (21).
0
! The fifth wheel coupling may only be raised using suitable lifting gear.
0 21 Bridge screw
! The bridge screws (21) must always be replaced after being removed.
JSK40/50
3/4´´ 3/4´´
SW14
2121
450 Nm
JSK40/51
JSK 40/42
8ZDE 199 002 111 GB 05/2004
4 Repair work
4.2.1 To remove and install the bearing for mounting plate installation (continued)0
Remove the bridge (23).0
0
Remove the rubber bearing (22).0
0
Remove the pedestal (25).0
0 23 Bridge
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
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
0 When installing the pedestal (25) ensure that the JOST logo faces the outside.
23
JSK40/52
22
b
25JSK40/53
25
JSK40/54
JOST
JSK 40/42
9ZDE 199 002 111 GB 05/2004
4 Repair work
4.2.1 To remove and install the bearing for mounting plate installation (continued)
Version JSK 40 only0
Remove the collar (22) and intermediate piece (c).
Version JSK 42 only0
Remove the collar (22).
0 22 Collar
c Intermediate piece
0 22 Collar
22c
JSK40/117
22
JSK40/55
JSK 40/42
10ZDE 199 002 111 GB 05/2004
4 Repair work
4.2.2 To remove and install the bearing with traverse
0
Undo the traverse screws (26) on both sides. Remove the traverse (27).0
0
Undo the bridge screws (21).0
Remove the bridge (23).0
0
0 26 Traverse screw
27 Traverse
0 21 Bridge screw
! The bridge screws (21) must always be replaced after being removed.
0 23 Bridge
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.
1/2´´ 1/2´´
100 mm
1/2´´
SW14
1/2´´
SW14
26
27JSK40/57
280 Nm
SW 24
3/4´´ 3/4´´
SW14
2121
450 Nm
JSK40/58
23
JSK40/59
JSK 40/42
11ZDE 199 002 111 GB 05/2004
4 Repair work
4.2.2 To remove and install the bearing with traverse (continued)0
Remove the rubber bearing (22).0
0
Remove the pedestal (25).0
0 22 Rubber bearing
25 Pedestal
b Cam
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
0 When installing the pedestal (25) ensure that the JOST logo faces the outside.
22
25
bJSK40/60
25
JSK40/61
JSK 40/42
12ZDE 199 002 111 GB 05/2004
4 Repair work
4.2.2 To remove and install the bearing with traverse (continued)
Version JSK 40 only0
Remove the collar (22) and intermediate piece (c).
Version JSK 42 only0
Remove the collar (22).
0 22 Collar
c Intermediate piece
0 22 Collar
22 c 22c
JSK40/116
JSK 40 K1, K5 JSK 40 K2, K3, K4, K6
22
JSK40/55
JSK 40/42
13ZDE 199 002 111 GB 05/2004
4 Repair work
4.3 To remove and install the bearing on the vehicle
Note
On the „low maintenance“ version, the liner must be removed first as described in section 4.1.00
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
Undo the bridge screws (21).
0
0 21 Bridge screw
! The bridge screws (21) must always be replaced after being removed.
JSK40/104
3/4´´ 3/4´´
SW14
21
450 Nm
JSK40/105
JSK 40/42
14ZDE 199 002 111 GB 05/2004
4 Repair work
4.3.1 To remove and install the bearing for mounting plate installation (continued)0
Remove the bridge (23) and rubber bearing (22). Raise the fifth wheel coupling with lifting gear.
Version JSK 40 only0
Remove the collar (22) and intermediate piece (c).
Version JSK 42 only0
Remove the collar (22).
0 22 Rubber bearing
23 Bridge
0 22 Collar
c Intermediate piece
0 22 Collar
2322
JSK40/106
c22
JSK40/118
22
JSK40/107
JSK 40/42
15ZDE 199 002 111 GB 05/2004
4 Repair work
4.3.1 To remove and install the bearing for mounting plate installation (continued)0
Secure the rubber bearing (22) to the bridge (23) as shown with Sellotape / insulating tape for later installation.
0
Slide in the bridge (23) on both sides as shown. Lower the fifth wheel coupling with lifting gear.
0
0
Insert the bridge screws (21).
0 22 Rubber bearing
23 Bridge
0 22 Rubber bearing
23 Bridge
b Cam
0 21 Bridge screw
23 Bridge
i Gap
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.
150 mm
b 2322
106.5 mm
62.5 mm
52.5 mm
JSK40/109
23 b22
JSK40/110
21
450 Nm
23
JSK40/111
i
3/4´´
Nm
3/4´´
SW14
JSK 40/42
16ZDE 199 002 111 GB 05/2004
4 Repair work
4.3.2 To remove and install the bearing with traverse
0
0
Undo the bridge screws (21). Remove the bridge (23). Raise the fifth wheel coupling with lifting gear.
Version JSK 40 only0
Remove the collar (22) and intermediate piece (c).
0 21 Bridge screw
23 Bridge
! The bridge screws (21) must always be replaced after being removed.
0 22 Collar
c Intermediate piece
3/4´´ 3/4´´
SW14
21
23
450 Nm
JSK40/112
22c
JSK40/108
JSK 40/42
17ZDE 199 002 111 GB 05/2004
4 Repair work
4.3.2 To remove and install the bearing with traverse (continued)
Version JSK 42 only0
Remove the collar (22).0
00
Slide in the rubber bearing (22) and bridge (23). Lower the fifth wheel coupling with lifting gear.
0
Insert the bridge screws (21).
0 22 Collar
0 22 Rubber bearing
23 Bridge
25 Pedestal
b Cam
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 21 Bridge screw
23 Bridge
22
JSK40/107
23b 22
25
JSK40/113
21
450 Nm23
JSK40/114
3/4´´
Nm
3/4´´
SW14
JSK 40/42
18ZDE 199 002 111 GB 05/2004
4 Repair work
4.4 To remove and install the wearing part
0
Undo the Allen bolts (1).0
Lever out the securing ring (2) with a screwdriver.0
Remove the wearing part (1).
0 1 Allen bolt
0 2 Securing ring
0 1 Wearing part
2 Securing ring
1/2´´ 1/2´´
SW7
1
49 Nm49 Nm
JSK40/66
JSK40/67
2
1
2
JSK40/85
JSK 40/42
19ZDE 199 002 111 GB 05/2004
4 Repair work
4.5 To remove and install the lock jaw
Version with the handle at the front only0
Release the double spring (7).0
Version with the handle at the rear only0
Lever out the securing clips with a screwdriver. Remove the gas pressure spring (13). Remove the ball head (17).
0 7 Double spring
0 When installing the double spring (7) ensure that the installation is carried out as shown in the illustration.
0 13 Gas pressure spring
17 Ball head
7
JSK40/63
20 Nm
13
17
JSK40/78
SW 13
JSK 40/42
20ZDE 199 002 111 GB 05/2004
4 Repair work
4.5 To remove and install the lock jaw (continued)
All versions0
Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).0
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
Screw in the screw (a) and pull out the bolt (6).
0 4 Spring
5 Cable tie
19 Securing ring on the eye bolt
0 5 Lubrication tube
0 6 Bolt
a M14 screw (removal tool)
45
19
JSK40/64
200 mm
5
JSK40/65
40 Nm
SW 10
6a
JSK40/68
JSK 40/42
21ZDE 199 002 111 GB 05/2004
4 Repair work
4.5 To remove and install the lock jaw (continued)
Version with the handle at the front only0
Pull the handle (9) to the outside.
Version with the handle at the rear only0
Pull the handle (9) to the outside.
All versions0
Turn the lock jaw (6) as shown and remove it. Unscrew the lubrication tube (5) from the lock jaw (6).
0 9 Handle
0 9 Handle
0 5 Lubrication tube
6 Lock jaw
9
JSK40/69
9
JSK40/89
6
5
JSK40/90
3 Nm
SW 10 SW 11
JSK 40/42
22ZDE 199 002 111 GB 05/2004
4 Repair work
4.6 To remove and install the locking mechanism
Note
On the „low maintenance“ version, the liner must be removed first as described in section 4.1.
4.6.1 To remove and install the locking mechanism, handle at the front
0
Release the double spring (7)0
0
Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).
0 7 Double spring
0 When installing the double spring (7) ensure that the installation is carried out as shown in the illustration.
0 4 Spring
5 Cable tie
19 Securing ring on the eye bolt
7
JSK40/63
45
19
JSK40/64
200 mm
JSK 40/42
23ZDE 199 002 111 GB 05/2004
4 Repair work
4.6.1 To remove and install the locking mechanism, handle at the front (continued)0
Undo the screw connector on the lubrication tube (5).
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
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
Undo the lever screw (12) from the underside through the hole (e). Remove the intermediate lever (10).
0 5 Lubrication tube
0 3 Securing bolt
10 Intermediate lever
11 Lever spring
0 10 Intermediate lever
12 Lever screw
5
JSK40/65
40 Nm
SW 10
1/2´´ 1/2´´
100 mm
3
10
11d e
110 Nm
JSK40/71
1/2´´ 1/2´´
SW14
10 110 Nm
12
JSK40/72
JSK 40/42
1/2´´
SW14
24ZDE 199 002 111 GB 05/2004
4 Repair work
4.6.1 To remove and install the locking mechanism, handle at the front (continued)0
Remove the locking bar (3).
0
0 Undo the lever screw (12).0
0 Undo the hexagonal nut (15).
0 3 Locking bar
0 12 Lever screw
0 15 Hexagonal nut
JSK40/73
3
1/2´´ 1/2´´
SW10
1245 Nm
JSK40/74
1/2´´ 1/2´´
SW18 SW 24
15
65 Nm
JSK40/75
JSK 40/42
25ZDE 199 002 111 GB 05/2004
4 Repair work
4.6.1 To remove and install the locking mechanism, handle at the front (continued)0
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
0 10 Lever
14 Pull lever
0 3 Locking bar and securing screw
4 Spring
6 Lock jaw
9 Handle
10 Intermediate lever and lever
11 Lever spring
12 Lever screws
14 Pull lever
15 Pull lever screw with hexagonal nut
19 Eye bolt, complete
! The screws (3) and (12) must always be replaced after being removed.
14
10JSK40/76
10
14
6
3
10
12
4
9
15
15
12
11
19
JSK40/77
3
JSK 40/42
26ZDE 199 002 111 GB 05/2004
4 Repair work
4.6.2 To remove and install the locking mechanism, handle at the rear
Note
On the „low maintenance“ version, the liner must be removed first as described in section 4.1.0
Lever out the securing clips with a screwdriver. Remove the gas pressure spring (13). Remove the ball head (17).
0
Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).0
Undo the screw connector on the lubrication tube (5).
0 13 Gas pressure spring
17 Ball head
0 4 Spring
5 Cable tie
19 Securing ring on the eye bolt
0 5 Lubrication tube
20 Nm
13
17
JSK40/78
SW 13
45
19
JSK40/64
200 mm
5
JSK40/65
40 Nm
SW 10
JSK 40/42
27ZDE 199 002 111 GB 05/2004
4 Repair work
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
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
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
Remove the pull lever (16).
0 3 Securing bolt
16 Pull lever
0 3 Locking bar
15 Hexagonal nut
16 Pull lever
0 16 Pull lever
1/2´´ 1/2´´
SW14
3110 Nm
f16
JSK40/79
1/2´´ 1/2´´
SW14
3
1516 65 Nm
f
JSK40/80
16
JSK40/81
SW 24
JSK 40/42
28ZDE 199 002 111 GB 05/2004
4 Repair work
4.6.2 To remove and install the locking mechanism, handle at the rear (continued)0
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
0 10 Lever
12 Lever screw
0 3 Locking bar and securing screw
4 Spring
6 Lock jaw
9 Handle
10 Lever
12 Lever screw
13 Gas pressure spring
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.
12
10
45 Nm
JSK40/82
1/2´´ 1/2´´
100 mm
1/2´´
SW10
13
6
34
169
12
10
15
15
3
17
19
JSK40/83
JSK 40/42
29ZDE 199 002 111 GB 05/2004
4 Repair work
4.7 To adjust the locking mechanism
0
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 jaw0
Replace the lock jaw (6) when the wear limit is reached.
0 3 Locking bar
6 Lock jaw
9 Handle
20 Adjusting screw
g Lock nut
0 6 Lock jaw
1/2´´ 1/2´´
SW24 SW 24
9
20g
3
6
JSK40/96
150 mm
JSK40/86
6
17.5 - 19.0 mm
JSK 40/42
30ZDE 199 002 111 GB 05/2004
4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)
Wearing part0
Replace the wearing part (1) when the wear limit is reached.
Collar0
Replace the collars (22) when the wear limit is reached.
King pin0
Replace the king pin when the wear limit is reached.
0 1 Wearing part
0 22 Collar
0
150 mm
JSK40/87
1
17.5 - 20.5 mm
150 mm
3.0 - 8.0 mm
JSK40/97
22
150 mm
JSK40/88
49-50.8 mm
84-8
2.5
mm
71.0 - 73.0 mm
JSK 40/42
31ZDE 199 002 111 GB 05/2004
4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)
Coupling plate0
0The fifth wheel coupling must be replaced if:
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 liner0
Replace the liner (24) when it has worn down to the surface of the securing screws (h).
0 A Lubricating groove depth
B Exterior
0 24 Liner
h Securing screws
100 mm
110
mm
70 mm
B
100 mm
110
mmB
AA
JSK40/98
JSK 40 JSK 42
150 mm
150 mm
JSK40/103
0 -3 mm
hh
hh 24
h
2445 Nm
JSK 40/42
32ZDE 199 002 111 GB 05/2004
4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)
Locking mechanism (handle at the front)0
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
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.
0 10 Intermediate lever and lever
0 16 Pull lever
0 mm
0 mm
0 mm 0 mm
10
JSK40/99
150 mm150 mm
0 mm
0 mm
JSK40/100
16
150 mm
JSK 40/42
33ZDE 199 002 111 GB 05/2004
4 Repair work
4.9 Function test
Locking mechanism (handle at the front)0
Locking mechanism (handle at the rear)0
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.
0 3 Locking bar
9 Handle
10 Lever
A King pin
B Locking bar tip
0 3 Locking bar
9 Handle
10 Lever
A King pin
B Locking bar tip
A
B
9
10
3
min 4 mm
JSK40/101
150 mm
min 4 mm
JSK40/102
A
B
9
10
3
150 mm
JSK 40/42
34ZDE 199 002 111 GB 05/2004
5 Spare parts for JSK 40/40 W – Mounting plate installation
0
0
Item Description Serial No./Note Article numberQuantityper JSK
1 Wearing part with securing screws SKE 001740020 1 2 Securing ring, with item 1 SK 3105-94 1 3 Locking bar with securing screw SKE 001009720 1 4 Spring SK 847 1 5 Lubrication tube, complete with cable tie SK 3108-02 1 6 Lock jaw, with items 4 and 5 SK 3221-52Z 1 7 Double spring SK 3105-20 1 8 Securing spring SKE 001440000 1
9 Handle, short, complete with item 8Handle, long, complete with item 8
L = 220 mmL = 390 mm
SKE 001390020SKE 001390120
11
10 Lever set, with items 11 and 12 for front handle SKE 001380020 111 Lever spring SKE 001009800 112 Lever screw SKE 001750020 113 Gas pressure spring for rear handle SKE 001560000 114 Pull lever, complete with item 15 for front handle SKE001620020 115 Pull lever screw SKE 001650020 116 Pull lever, complete with items 15 and 17 for rear handle SKE 001630020 117 Ball head for rear handle SKE 001007800 218 Lever set with item 12 for rear handle SKE 001006820 119 Eye bolt, complete SK 2122-04 120 Adjusting screw with guide SKE 500740420 121 Bridge screw SKE 001011400 422 Collar with item 21 SKE 001370020 223 Bridge with intermediate piece and item 21 SKE 001530020 224 Liner with screws SKE 001007020 1
24(8x)
18
09
13
1214 10
11
1516
17
L
08
07
03
04
06
19
05
020120
22
21
25
23
JSK40/91
35ZDE 199 002 111 GB 05/2004
5 Spare parts for JSK 40/40 W – Mounting plate installation
0
00
25Pedestal height 150 with item 21Pedestal height 185 with item 21Pedestal height 225 with item 21Pedestal height 250 with item 21
SKE 001005620SKE 001005720SKE 001005820SKE 001005920
2222
Item Repair and retrofit kits Article number
1, 2, 3, 4, 5, 6, 19
Locking mechanism, complete SKE 001640020
Item Description Serial No./Note Article numberQuantityper JSK
36ZDE 199 002 111 GB 05/2004
6 Spare parts for JSK 40/40 W – with traverse
0
0
Item Description Serial No./Note Article numberQuantityper JSK
1 Wearing part with securing screws SKE 001740020 1 2 Securing ring, with item 1 SK 3105-94 1 3 Locking bar with securing screw SKE 001009720 1 4 Spring SK 847 1 5 Lubrication tube, complete with cable tie SK 3108-02 1 6 Lock jaw, with items 4 and 5 SK 3221-52Z 1 7 Double spring SK 3105-20 1 8 Securing spring SKE 001440000 1
9 Handle, short, complete with item 8Handle, long, complete with item 8
L = 220 mmL = 390 mm
SKE 001390020SKE 001390120
11
10 Lever set, with items 11 and 12 for front handle SKE 001380020 111 Lever spring SKE 001009800 112 Lever screw SKE 001750020 113 Gas pressure spring for rear handle SKE 001560000 114 Pull lever, complete with item 15 for front handle SKE001620020 115 Pull lever screw SKE 001650020 116 Pull lever, complete with items 15 and 17 for rear handle SKE 001630020 117 Ball head for rear handle SKE 001007800 218 Lever set with item 12 for rear handle SKE 001006820 119 Eye bolt, complete SK 2122-04 120 Adjusting screw with guide SKE 500740420 121 Bridge screw SKE 001011400 422 Collar with item 21 SKE 001370020 223 Bridge with intermediate piece and item 21 SKE 001530020 224 Liner with screws SKE 001007020 1
24(8x)
18
09
13 1214
10
11
1516
17
L
08
07
03
04
06
19
05
020120
22
21
23
25
2726
JSK40/92
37ZDE 199 002 111 GB 05/2004
6 Spare parts for JSK 40/40 W – with traverse
0000
25
Pedestal height 150 LB K1/K2 with item 21Pedestal height 150 LB K3 with item 21Pedestal height 150 LB K4/K5 with item 21Pedestal height 150 LB K6 with item 21Pedestal height 190 LB K1/K2 with item 21Pedestal height 190 LB K3 with item 21Pedestal height 190 LB K4/K5 with item 21Pedestal height 190 LB K6 with item 21Pedestal height 225 LB K1/K2 with item 21Pedestal height 225 LB K3 with item 21Pedestal height 225 LB K4/K5 with item 21Pedestal height 225 LB K6 with item 21
SKE 001500020SKE 001500120SKE 001500220SKE 001500320SKE 001510020SKE 001510120SKE 001510220SKE 001510320SKE 001520020SKE 001520120SKE 001520220SKE 001520320
222222222222
26 Traverse screws set SKE 002770020 1
27
Traverses LB K1/K5 with item 26Traverses LB K2/K5 height 150 with item 26Traverses LB K2/K5 height 190/225 with item 26Traverses LB K3/K6 with item 26
SKE 001010020SKE 001570020
SKE 001590020SKE 001010120
11
11
Item Repair and retrofit kits Article number
1, 2, 3, 4, 5, 6, 19
Locking mechanism, complete SKE 001640020
Item Description Serial No./Note Article numberQuantityper JSK
38ZDE 199 002 111 GB 05/2004
7 Spare parts for JSK 42/42 W – Mounting plate installation
0
0
Item Description Serial No./Note Article numberQuantityper JSK
1 Wearing part with securing screws SKE 001740020 1 2 Securing ring, with item 1 SK 3105-94 1 3 Locking bar with securing screw SKE 001009720 1 4 Spring SK 847 1 5 Lubrication tube, complete with cable tie SK 3108-02 1 6 Lock jaw, with items 4 and 5 SK 3221-52Z 1 7 Double spring SK 3105-20 1 8 Securing spring SKE 001440000 1
9 Handle, short, complete with item 8Handle, long, complete with item 8
L = 220 mmL = 390 mm
SKE 001390020SKE 001390120
11
10 Lever set, with items 11 and 12 SKE 001380020 111 Lever spring SKE 001009800 112 Lever screw SKE 001750020 114 Pull lever, complete with item 15 SKE001620020 115 Pull lever screw SKE 001650020 119 Eye bolt, complete SK 2122-04 120 Adjusting screw with guide SKE 500740420 121 Bridge screw SKE 001011400 422 Collar with item 21 SKE 001370020 223 Bridge with item 21 SKE 001530220 224 Liner with screws SKE 001007020 1
25Pedestal height 150 with item 21Pedestal height 185 with item 21Pedestal height 225 with item 21Pedestal height 250 with item 21
SKE 001005620SKE 001005720SKE 001005820SKE 001005920
2222
24(8x)
09
1214
10
11
15
L
08
07
03
04
06
19
05
020120
22
21
25
23
JSK40/93
39ZDE 199 002 111 GB 05/2004
7 Spare parts for JSK 42/42 W – Mounting plate installation
00
Item Repair and retrofit kits Article number
1, 2, 3, 4, 5, 6, 19
Locking mechanism, complete SKE 001640020
40ZDE 199 002 111 GB 05/2004
8 Spare parts for JSK 42/42 W – with traverse
0
0
Item DescriptionSerial No./Note Article number
Quantityper JSK
1 Wearing part with securing screws SKE 001740020 1 2 Securing ring, with item 1 SK 3105-94 1 3 Locking bar with securing screw SKE 001009720 1 4 Spring SK 847 1 5 Lubrication tube, complete with cable tie SK 3108-02 1 6 Lock jaw, with items 4 and 5 SK 3221-52Z 1 7 Double spring SK 3105-20 1 8 Securing spring SKE 001440000 1
9 Handle, short, complete with item 8 Handle, long, complete with item 8
L = 220 mmL = 390 mm
SKE 001390020SKE 001390120
11
10 Lever set, with items 11 and 12 SKE 001380020 111 Lever spring SKE 001009800 112 Lever screw SKE 001750020 114 Pull lever, complete with item 15 for front handle SKE001620020 115 Pull lever screw SKE 001650020 119 Eye bolt, complete SK 2122-04 120 Adjusting screw with guide SKE 500740420 121 Bridge screw SKE 001011400 422 Collar with item 21 SKE 001370020 223 Bridge with item 21 SKE 001530220 224 Liner with screws SKE 001007020 1
24(8x)
09
1214
10
1115
L
08
07
03
04
06
19
05
020120
22
21
23
25
27
JSK40/94
26
41ZDE 199 002 111 GB 05/2004
8 Spare parts for JSK 42/42 W – with traverse
00
25
Pedestal height 150 LB K2 with item 21Pedestal height 150 LB K3 with item 21Pedestal height 150 LB K4 with item 21Pedestal height 150 LB K6 with item 21Pedestal height 190 LB K2 with item 21Pedestal height 190 LB K3 with item 21Pedestal height 190 LB K4 with item 21Pedestal height 190 LB K6 with item 21Pedestal height 225 LB K2 with item 21Pedestal height 225 LB K3 with item 21Pedestal height 225 LB K4 with item 21Pedestal height 225 LB K6 with item 21
SKE 001500020SKE 001500120SKE 001500220SKE 001500320SKE 001510020SKE 001510120SKE 001510220SKE 001510320SKE 001520020SKE 001520120SKE 001520220SKE 001520320
222222222222
26 Traverse screw set SKE 002770020 1
27Traverses LB K2/K5 height 150 with item 26Traverses LB K2/K5 height 190/225 with item 26Traverses LB K3/K6 with item 26
SKE 001570020
SKE 001590020SKE 001010120
1
11
Item Repair and retrofit kits Article number
1, 2, 3, 4, 5, 6, 19
Locking mechanism, complete SKE 001640020
Item DescriptionSerial No./Note Article number
Quantityper JSK
42ZDE 199 002 111 GB 05/2004
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.