Repair manual for

Exchanging locking mechanism

sensor JSK37C

JSK_12_048

ZDE 199 007 102 07/2013 1

Foreword Table of contents Page

Sensor-enabled fifth wheel couplings are parts that 1 Safety instructions 3

must comply with very high safety requirements.
This repair manual is designed to act as a guide to 2 Standard / special tools 4
completing repair work on our sensor set.
2.1 Standard tools 4
It is essential that you use JOST spare parts. 2.2 Special tools 4
Modifications of any kind will render both the
warranty and the type approval void.
3 Repair work 5
Operation and installation are described separately
3.1 Preparing the fifth wheel coupling 5
in dedicated publications.
3.2 Removing cable ties 5
3.3 Removing the locking mechanism sensor 6
3.4 Creating a repair drill hole 6
3.5 Installing the locking mechanism sensor 7
3.6 Installing the guard plate 7
3.7 Removing the connection plug 8
3.8 Renewing the locking mechanism sensor 8
3.9 Assembly 10

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 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.

Technical modifications reserved. The latest information can be found at:

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www.jost-world.com.

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 2 Standard / special tools

2.1 Standard tools

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1/2´´

SW 17 D4.2

1/2´´

D5.5 SW5 M5

2.2 Special tools

• Ejector tool for Tyco HDSCS flat connector 2.8
• Ejector tool for Tyco HDSCS flat connector 1.6

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 3 Repair work


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Conversion work must be carried out by trained personnel in suitable workshops.

 Repair work is to be carried out using suitable tools and state of the art methods.
 Clean all parts thoroughly before assembly. Ensure that electrical plug connectors or compressed air
connectors do not become soiled.
 Once the conversion work is complete, the function must be verified in accordance with the
installation and operating instructions.
 Do not touch contacts on electronic components (e.g. plugs) with bare fingers.
 Do not allow the wiring harness to drop!
 Only use the new screws and nuts provided with the repair kit.
 Before carrying out any work on the electrical system, disconnect the battery.
 With the diagrams the work steps should be carried out in alphabetical order (e.g. a, b, c).
 Assembly is carried out correspondingly in reverse order.
 Instructions for assembly are identified in the diagram number or in the diagram itself with a diamond ◊.
 The torque values shown in the illustrations are required for the subsequent assembly process.
The torque values shown in the illustrations must be used at all times.
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Worn, damaged and cracked parts must always be replaced.
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3.1 Preparing the fifth wheel coupling

 Disconnect the electrical connection to the tractor.
 Take the fifth wheel coupling off the tractor unit and place it on a suitable base.

3.2 Removing cable ties

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Ensure that the cable sleeve is not dam-

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!
aged during the following step.

 Cut cable ties open at the indicated points.

 Cable tie (A) is secured with a washer.

A
JSK37C_11

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 3 Repair work

3.3 Removing the locking mechanism sensor

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 Position of locking mechanism sensor (1).

1

JSK37C_12

 Remove the head from blind rivet (23) using 5.5

mm drill bit and undo the screw (24).
D5.5 SW 17
 Remove the trap (25) and the sensor with holder (22).

25
24
23

22

JSK_12_025

3.4 Creating a repair drill hole

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 Drive the rivet (23) using a pin punch of diameter 3 mm

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into the drill hole.

D4.2 M5
 Open up the drill hole using a 4.2 mm drill bit.
23
 Deburr the hole.
 Cut the M5 thread.

JSK_12_026

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 3 Repair work

3.5 Installing the locking mechanism sensor

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Only use a new securing nut (28) for

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24 22 25 !
installation.
Also note the "Repair instructions for
the JSK 37 fifth wheel coupling".

 Fit the exchange locking sensor with a sensor

holder (22) and trap (25) as shown adjacent.
28  Tighten the securing nut (28) to hand tightness.

JSK_12_029
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 To secure the retaining plate, insert the

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M5 x 10 screw (29) included with the repair kit and

tighten it to the specified torque.
 Tighten the hexagonal screw (24) to the specified
torque.
49Nm
29 24

3Nm

JSK_12_030

3.6 Installing the guard plate

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 Unscrew the mounting dome (1) by turning it anti-

clockwise out of the threaded hole.

JSK37C_02
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 Route the cable of the exchange locking mechanism

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sensor through under the handle (arrow).

 Attach the cable to the second mounting dome (30)
using a cable tie.
30

JSK37C_14

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 3 Repair work

Make sure the cable ends up in the

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1/2´´ 1/2´´
!
SW5
radius range (1) of the plate intended for
it!

 Insert the cable under the guard plate (2).


1 3
2 
2 4
8 Nm
Fit the guard plate (2) with the screw (3) and
washers (4) as shown.
Push the guard plate (2) onto the rib (arrow) and
tighten the screw (3) to the torque specified.

JSK37C_13

3.7 Removing the connection plug

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 Slide the safety slide (10) in the direction of the

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arrow (C) away from the plug.

 Pull the plug (11) towards the centre of the
coupling plate (D) out of the retaining plate.
10 ◊ Installation is carried out correspondingly in the
D reverse order.
11

C
JSK_12_011

3.8 Renewing the locking mechanism sensor

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1/2´´ Ensure that the cable is not damaged during the fol-
lowing step!
 Cut open the cable tie (31) at the connector cap (32).
31 33  Open the locking clips (33) of the connector cap
(32) with a flat screwdriver and remove the
connector cap.

32 JSK37C_05

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 3 Repair work

 Unlock the second contact lock of the connector.

 Insert a flat screwdriver into the hole provided in
order to unlock the second contact lock. Light
pressure moves the contact lock into the pre-
detent position.

JSK37C_06

Never pull the line before unlocking the

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!
contact. Light pressure opposite to the
cable lead-out direction facilitates
unlocking.

 Push out contacts

Pin 3 = black (ejector tool for Tyco flat connector 2.8)
Pin 4 = red (ejector tool for Tyco flat connector 1.6)
Pin 5 = brown (ejector tool for Tyco flat connector 1.6)
 To press out the contacts, push the blades of the
unlocking or press-out tool into the two slots in the
corresponding contact chamber up to the stop.
JSK37C_07
 Once the press-out tool has been inserted and the
contact unlocked, it is possible to remove the
contact on the line.
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 Nip off the pushed-out contacts directly behind the

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seal using a cable cutter (A).

A  Then pull the cable of the locking mechanism
sensor out of the shrink-fit hose (B).

JSK37C_08

When inserting the contacts, make sure

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!
03 they are aligned correctly. The contacts
04
must be heard engaging in the connec-
tor.

 Insert the contacts of the new locking mechanism

sensor
05 JSK37C_09 Pin 3 = black
Pin 4 = red
Pin 5 = brown
 Close the contact lock on the connector.

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 3 Repair work

Shrink-fit hose, cable sleeve and insula-

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0

35 31 !
tion of the strands can be damaged by
the heat of the hot air blower.

 Shrink the shrink-fit hose around the remaining two

lines using a hot air blower.
34 32  Then secure the jacket cable of the new locking
JSK37C_10
mechanism 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).

3.9 Assembly
◊ Cable routing, cable securing and connector installation are performed in the corresponding manner,
but in reverse order.

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