repair manual for jsk 26 d fifth wheel coupling · repair manual for jsk 26 d fifth wheel coupling....
TRANSCRIPT
1ZDE 199 007 107 06/2013
Repair manual for
JSK 26 D fifth wheel coupling
2ZDE 199 007 107 06/2013
Foreword Table of contents
Fifth wheel couplings are vehicle-connecting parts that must comply with very high safety require-ments 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.
Installation of spare parts that are not genuine JOST spare parts, and modifications of any kind will render both the warranty and the design approval void and therefore also cancel the vehicle's insurance protection.
1 Safety instructions 3
2 Troubleshooting 4
3 Standard and special tools and auxiliary materials 5
3.1 Standard tools 5
3.2 Special tools 5
3.3 Auxiliary materials 5
4 Repair work 6
4.1 To remove and attach the pedestal 7
4.2 To remove and install the bearing 8
4.3 Overview of locking mechanism 9
4.4 To remove and install the locking mechanism 10
4.5 To remove and install the catch 12
4.6 Checking for wear / wear limits 13
4.7 Function test 15
4.8 To adjust the locking mechanism 16
5 Spare parts list 17
6 Disposal instructions 18
Page
3ZDE 199 007 107 06/2013
1 Safety instructions
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 information in the owner's handbook for the tractor unit and the semi-trailer are valid and must be followed.
The permitted load data and safety information must be complied with during operation and installation.
Safety information which is directly linked to the specific activity is listed in the following sections for servicing and repair work. It is essential that you follow this safety information.0
!Technical modifications reserved. You will find the latest information at: www.jost-world.com
JSK 26 D
4ZDE 199 007 107 06/2013
2 Troubleshooting
0
0
Fault Cause RemedyFifth wheel cou-pling 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. Lock jaw deformed.
4. Poor servicing.
5. Double spring defective.
6. Lever and/or handle buckled.
1. The skid plate should be at the same height or max. 50 mm lower than the fifth wheel coupling.
2. Replace the skid plate. Permissible flatness deviation max. 2 mm.
3. Replace lock jaw SK 2605-060.
4. Ease the mechanism and grease it.
5. Replace double spring SK 3105-152.
6. Renew/straighten lever SK 2605-59 and handle SKE004790000
The fifth wheel coupling can-not 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.
1. Relieve the pressure on the tractor unit’s locking mechanism.
2. The fifth wheel coupling can be opened by force as follows: Open the lock.Swivel the handle forwards and hold it extended as far as possible. With the aid of a second person, use a rod to hit the lever, e.g. SK 2605-59, in the area of the bent section on the opposite side of the fifth wheel coupling to release the bar. The clamp can also be released by screwing in the adjusting screw. Then rectify the poor servicing, check the locking mechanism parts for signs of damage and repair or reset the locking mechanism as necessary (see section 4.8)
Fifth wheel cou-pling does not stay in the ready position.
1. Lock jaw deformed.
2. Spring defective.
3. Poor servicing.
1. Replace lock jaw SK 2605-060.
2. Replace spring SK 847.
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.
1. Replace bearing bush SK 2604-04 if it is worn (see section 4.2).
2. Check king pin, replace it if it is worn. If the king pin is in good condition but there is still play, adjust the locking mechanism (see section 4.8). If this is unsuccessful, renew lock jaw SK 2605-060.
JSK 26 D
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3 Standard / special tools and auxiliary materials
3.1 Standard tools0
3.2 Special tools0
3.3 Auxiliary materials
JOST high-performance lubricant (art. no.: SKE 005 670 000)
SK2702-10 Ø 30 mm x 100 mm SKE00863000
1/2´´
SW16
1/2´´
SW17
1/2´´
SW18 SW10
SW16 SW17 SW18 SW30
1/2´´ 1/2´´
Nm 150 mm
1500 gr. 6-10 mm
SW 24
JSK 26 D
6ZDE 199 007 107 06/2013
4 Repair work
0Repair work must be carried out by trained personnel.
Repair work is to be carried out using suitable tools and processes.
The item numbers in the illustrations refer to the spare parts lists in section 5.
Instructions for assembly 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 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.
0
0
0
!The torque values shown in the illustrations must be used at all times. Worn, damaged and cracked parts must always be replaced.Repair welds must not be used.
0 Take the fifth wheel coupling off the tractor unit, place it on workbench SK 2702-10 and couple it up.
!The fifth wheel coupling may only be raised using suitable lifting gear.
JSK26/25
JSK 26 D
7ZDE 199 007 107 06/2013
4 Repair work
4.1 To remove and attach the pedestal0
0
0
0
0
0 Drive out the split pin.
0 Unscrew the castle nut.
◊ Tighten the castle nut until the bolt head, nut and washer are in contact without play, then turn the castle nut further until a split pin hole is free. Drive in and secure the split pin.
0 Unscrew the castle nut.
0
15 Pivot pin
16 Pedestal
Pull the pivot pin (15) out of the pedestal (16).
Remove the pedestal (16).
1500 gr. 6-10 mm
JSK26/02
SW 30
!
JSK26/01
JSK26/03
15
16
JSK26/04
JSK 26 D
8ZDE 199 007 107 06/2013
4 Repair work
4.2 To remove and install the bearing0
00
0 16 Pedestal
17 Bearing bush
Drive out the bearing bush (17) with a pin.
0 16 Pedestal
17 Bearing bush
◊ Grease the bearing bush (17) slightly and use a pin to drive it carefully into the pedestal (16).
1500 gr.
16
17
ø30
JSK26/05
16
17
JSK26/24
JSK 26 D
9ZDE 199 007 107 06/2013
4 Repair work
4.3 Overview of locking mechanism0
0
0
01 Double spring
02 Hexagon bolt
03 Handle
08 Locking bolt
09 Locking bar
10 Lever with bolts and nuts
11 Castle nut
13 Lock jaw
14 Spring
03 02 01
11
10
08
13
09
14
JSK26/06
JSK 26 D
10ZDE 199 007 107 06/2013
4 Repair work
4.4 To remove and install the locking mechanism0
0
00
0.
!Risk of injury!The installation and removal of the lock jaw (13) must only be carried out with the dou-ble spring (01) released.
0 01 Double spring
Unhook the double spring (01).
0 02 Hexagon bolt
03 Handle
08 Locking bolt
10 Lever with bolts and nuts
11 Castle nut
Drive out the split pin
Unscrew the castle nuts (11)
◊ First tighten the castle nuts (11) and then loosen again by one half turn. Secure the castle nuts (11) with a split pin.
0 02 Hexagon bolt
03 Handle
08 Locking bolt
10 Lever with bolts and nuts
11 Castle nut
SW 30
01
01
JSK26/07
0203
11
10
08JSK26/08
SW16 SW17 SW18
c
c
a
d
a
c
JSK26/09
JSK 26 D
11ZDE 199 007 107 06/2013
4 Repair work
0
0
0
0
0 12 Pin
14 Spring
20 Split pin
Unhook the spring (14) from the split pin (20).
Remove the split pin from the pin (12).
0 09 Locking bar
12 Pin
13 Lock jaw
Push the pin (12) upwards out of the lock jaw (13) (towards the contact surface).
Pull the locking bar (09) out of the interlock.
0 09 Locking bar
13 Lock jaw
14 Spring
Remove the lock jaw (13) with spring (14) from the coupling plate.
Hold the locking bar (09) in the open position.
0 08 Locking bolt
Push the locking bolt (08) upwards out of the locking bar.
14
20
20
12
JSK26/13
c
b
12
13
09
JSK26/10
13
09
d
14
JSK26/11
08
a
a
JSK26/12
JSK 26 D
12ZDE 199 007 107 06/2013
0
4.5 To remove and install the catch0
0 09 Locking bar
Remove the locking bar (09) from the coupling plate.
0 05 Hexagon bolt
06 Spring loop
07 Catch
Unscrew the nut from the hexagon bolt (05).
Pull the spring loop (06) and catch (07) off the hexagon bolt.
a
09
JSK26/14
05
07
06b
aa
30 Nm
JSK26/16
1/2´´
Nm SW17SW17SW17SW17
1/2´´
SW17
4 Repair work JSK 26 D
13ZDE 199 007 107 06/2013
4.6 Checking for wear / wear limits0
0
0
0 13 Lock jaw
14 Spring
Measure the wear limit at the narrowest point.
Replace the lock jaw (13) when the wear limit is reached.
0 Replace the king pin when the wear limit is reached.
0 The bearing should exhibit a play of no more than 2 mm. To check, lift the coupling plate with an assembly lever.
19 -
20,5
mm
13
14
JSK26/15
150 mm
JSK26/23
84-8
2,5
mm
71-73 mm
49-50,8 mm
150 mm
< 2 mm
JSK26/17
4 Repair work JSK 26 D
14ZDE 199 007 107 06/2013
0
0
0 03 Handle
10 Lever with bolts and nuts
Locking mechanism when new
If the fifth wheel coupling has been closed correctly, the distance of the locking edge to the inner edge of the plate must be at least 3 mm. If the distance is less than 3 mm, the handle (03) and the lever (10) must be checked for deformation.
0 03 Handle
10 Lever with bolts and nuts
Locking mechanism lever wear limitThe locking mechanism lever is worn when the dimension between the lever (10) and the abutment rib is 0 mm. The locking mechanism cannot be adjusted any further at this point.
> 3 mm
03
03
10
JSK26/18
0 mm
03 10
JSK26/20
150 mm
4 Repair work JSK 26 D
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4.7 Function test0
0
0 03 Handle
09 Locking bar
10 Lever with bolts and nuts
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) presses on the bar tip B and the handle is held in the direction indicated by the arrow.
If the gap is less than 4 mm, the lever (10), handle (03) and locking bar (09) must be checked for signs of deformation and wear.
NoteThe function test can be performed using the JOST setting king pin SKE 008 630 000.
> 4 mm 03
03 10
09
A B
JSK26/19
4 Repair work JSK 26 D
16ZDE 199 007 107 06/2013
4.8 To adjust the locking mechanism0
0 03 Handle
07 Catch
09 Locking bar
10 Lever
13 Lock jaw
The locking mechanism must be set as follows using a semi-trailer without forced steering with a new king pin or with the JOST setting king pin SKE 008 630 000.
Uncouple the tractor unit on a flat, firm piece of ground.
Undo the lock nut (I).
Unscrew the adjusting screw (II) approx. 5 turns until it is no longer in contact with the stop (III) of the coupling plate.
Hitch up the semi-trailer, if necessary lightly tapping the handle (03) in the closing direction A to bring the locking bar (09) into its limit position.
Unlock the handle (03) (raise the catch (07)), swing the handle (03) into position B and hold it there (get an assistant to hold it).
Tighten the adjusting screw (II) again until the handle (03) starts to move (have an assistant check this).
To set the recommended basic play of 0.3 mm, tighten the adjusting screw (II) by a further 2 turns and secure the adjusting screw (II) with the lock nut (I).
Apply the semi-trailer brake.
Move off with the tractor and check the maximum play in the locking mechanism.
NoteIf there is still excessive play, the lock jaw (13) must be replaced as described in the repair manual.
II
III
13 09
07 1003
I
AB
JSK26/21
150 mm SW17SW17SW17SW 17 SW17 1500 gr.
4 Repair work JSK 26 D
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0
0
Item Name Serial no./note Article number
01 Double spring SK 3105-15202 Hexagon screw SK 2621-5403 Handle SKE 00479000004 Clamping pin 000.003.02705 Hexagon screw SK 3521-0306 Spring loop SK 2921-3007 Catch SK 3121-5208 Locking bolt SK 2621-5309 Locking bar SK 2605-06110 Lever with bolts and nuts SK 2605-5911 Castle nut SK 2621-5612 Bolt SK 2621-5113 Lock jaw SK 2605-06014 Spring SK 84715 Pivot pin SK 2621-0216 Pedestal SKE 00550000017 Bearing bush SK 2604-0418 Cable, complete SK 3521-0219 Split pin SKE 35210060020 Split pin NTE 000001600
01
09
08
11
14
10
13 15
16
20
17
07
18
06
03
04
19
05
02
12
JSK26/22
5 Spare parts list JSK 26 D
18ZDE 199 007 107 06/2013
The mounted parts are valuable raw materials that can be recycled.
They can be split into plastics, rubber and metallic materials.
Plastic/rubber are labelled in accordance with VDA recommendation 260.
Before disposal, parts may need to be cleaned of any residual oil or grease.
6 Disposal instructions JSK 26 D