JSK_36_37_02_titel.qxd 02.02.

2004 9:15 Uhr Seite 1

-Montage- und Betriebsanleitung

JOST
SATTELKUPPLUNG JSK 36 D & JSK 37

Installation and operating instructions for

FIFTH WHEEL COUPLING JSK 36 D & JSK 37
Instructions de montage et de d’utilisation pour
SELLETTE D‘ATTELAGE JSK 36 D & JSK 37
Istruzioni per il montaggio e l’uso del
RALLA A PERNO JSK 36 D & JSK 37
Instrucciones de montaje y functionamiento para el
QUINTA RUEDA JSK 36 D & JSK 37
Contents Page

1 Safety information 3
1.1 Safety information for operation 3
1.2 Safety information for servicing 3
1.3 Safety information for installation 3

2 Proper usage 4
2.1 Application 4
2.2 Design 4

English
3 Operation 5
3.1 Fifth wheel coupling closed and locked 5
3.2 Fifth wheel coupling ready for engagement 5
3.3 To open the fifth wheel coupling 6
3.4 To connect a semi-trailer 6
3.5 To check the locking mechanism 6
3.6 To disconnect a semi-trailer 7

4 Servicing and testing 7

4.1 Servicing instructions 7
4.1.1 Fifth wheel coupling with manual lubrication 7
4.1.2 Fifth wheel coupling with central lubrication connection 8
4.1.3 Low maintenance fifth wheel coupling with top plate liners 8
4.2 Test instructions 9
4.3 Wear test 9
4.4 To adjust the locking mechanism 10
4.5 Wear limit – top plate liners 11

5 Installation 12
5.1 General installation instructions 12
5.2 To install the fifth wheel coupling 12
5.3 Fastening material and tightening torque values 13

2
1 Safety information JSK 36 / 37

The safety information is compiled in one section. Where the 1.2 Safety information for servicing
! user of the fifth wheel coupling is in danger, the safety
! Only use the specific lubricants for the servicing work
information is repeated in the various sections and marked
with the danger symbol shown here on the left.
! The servicing work should only be completed by trained personnel

The relevant safety regulations in your country (for example Health & Safety 1.3 Safety information for installation
at Work) apply for working with fifth wheel couplings, tractor units and
semi-trailers. The appropriate safety information in the owner’s handbook ! Do not change the installation area defined by the manufacturer of
for the tractor unit and the semi-trailer are valid and must be followed. the tractor unit
The following safety information applies to operation, servicing and ! The installation work may only be completed by authorised
installation. Safety information that is directly linked to the activity is listed specialists
again individually. ! Refer to the instructions issued by the vehicle manufacturer, for
example the type of fastening, fifth wheel position, fifth wheel
1.1 Safety information for operation height, axle load, cavity, mounting plate, slider, etc.
! Follow the installation instructions supplied by the mounting plate
! The fifth wheel coupling may only be used by authorised persons. and slider manufacturers
! Only use the fifth wheel coupling and skid plate on the semi-trailer if
they are in perfect technical condition The fifth wheel coupling must be mounted on the vehicle in compliance
! The skid plate must be larger than the support area of the fifth wheel with the requirements of Appendix VII of Directive 94/20/EC (see Appendix
coupling No. I, No. 5.10 of this Directive). It may also be necessary to comply with
! The front of the skid plate must not be sharp, otherwise it may the licensing regulations of the appropriate country.
damage the fifth wheel coupling or the top plate liner §§ 19, 20 and 21 of the Road Traffic Act apply in Germany. In addition, your
! Comply with the relevant safety regulations when connecting a attention is drawn to the requirements of § 27 of the Road Traffic Act
semi-trailer, for example the Health and Safety at Work Regulations. relating to the data in the vehicle documents in terms of the maximum
Only connect a semi-trailer on firm, flat ground trailer load.
! The skid plate must ideally be at the same height as or no more than
50 mm lower than the coupling plate on the fifth wheel coupling.
Pressure losses in the air suspension may change the height of the
semi-trailer
! Check the locking mechanism before starting your journey to ensure
that it is properly locked. Only drive the vehicle with the locking
mechanism locked and secured, even when driving without a
semitrailer (solo mode).

3
2 Proper usage JSK 36 / 37

2.1 Application Specimen calculation:

Fifth wheel couplings provide the link between the tractor unit and the T = 17 t
semi-trailer. They are designed for mounting on a tractor unit.
R = 33 t
The fifth wheel coupling and mounting plate are connecting parts that must U = 10.5 t
comply with very high safety requirements and must also undergo design
approval tests. . . . . . .
Modifications of any kind will render both the warranty and the design .
approval void and therefore also cancel the vehicle’s operating licence.

English
The maximum load data for JOST fifth wheel couplings are set out on the
type plate and the appropriate JOST catalogue sheets. They are applicable
JOST fifth wheel couplings, e.g. type JSK 37, are specified to comply with for proper usage pursuant to Directive 94/20/EC. If they are subject to
Directive 94/20/EC Class G50 and are to be used together with king pins of additional dynamic forces, for example if they are used on uneven road
class H50 and class J mounting plates or with comparable licensed surfaces or on construction sites, do not use the complete imposed load
equipment. and D value or use a stronger fifth wheel coupling or consult JOST.

2.2 Design 1 2 3
The fifth wheel coupling is specified with the vehicle by the vehicle
manufacturer (the design must comply with Directive 94/20/EC, Appendix e1 xxxx G50-X D XX U XX
VII).
In addition to the fifth wheel coupling the D value is a criterion for the load
capacity of fifth wheel couplings and mounting plates. xx xxx xx xxxx
xx xx xx xxxx x
JSK 37
It can be calculated using the following formula:

D = Drawbar value [kN]

4 5 G50/16
1 EC licence number
g = 9.81 m/s2 2 Maximum D value in kN
R = Maximum gross weight of the semi-trailer [t] 3 Maximum imposed load U in t
4 Article no. and type
T = Maximum gross weight of the tractor unit including U [t] 5 Serial no.
U = Maximum imposed load [t]
Each fifth wheel coupling has a serial number, which is embossed on the
. . .. factory plate and also on the edge of the plate. This is designed to give the
coupling a unique identity.

4
3 Operation JSK 36 / 37

3.1 Fifth wheel coupling closed and locked 3.2 Fifth wheel coupling ready for engagement

4
1
1

4
2 3 G50/19 2 3 G50/18
1 Handle 1 Handle
2 Locking bar 2 Locking bar
3 Lock jaw 3 Lock jaw
4 King pin 4 King pin

5
3 Operation JSK 36 / 37

3.3 To open the fifth wheel coupling ! Conduct an initial driving test in a low gear
! Check the locking mechanism (see section 3.5)
! Lift the catch (1). ! Connect the supply lines
! Retract the landing gear as described in the operating manual
! Release the parking brake and remove the chocks
Check the locking mechanism status before starting any
! journey (see section 3.5).
1

English
G50/20
3.5 To check the locking mechanism
! Swing the handle (2) towards the
front into position A to release the
lock
! The catch (1) must be down as
shown
! Pull out the handle (2) as far as
possible into position B

A
B 2 G50/21 1
! With the handle (2) pulled out, G50/23
swing it forwards into position C The skid plate must rest on
and engage it on the edge of the ! the fifth wheel coupling
!
plate
2 without a gap.

C G50/22

JSK40/15
3.4 To connect a semi-trailer Note
To prevent the fifth wheel coupling
! Secure the semi-trailer to prevent its rolling away.
being opened without authorisation, a
! The fifth wheel coupling must be ready to engage (see section 3.2).
security device (for example a padlock)
Otherwise open the fifth wheel coupling (see section 3.3)
can be inserted into the hole in the
! Check the height of the semi-trailer. The skid plate must ideally be
handle as shown.
at the same height as or no more than 50 mm lower than the
coupling plate on the fifth wheel coupling
! Drive the tractor unit under the semi-trailer G50/31
! The locking mechanism will close automatically

6
3 Operation 4 Servicing and testing

3.6 To disconnect a semi-trailer 4.1 Servicing instructions

! Park the vehicle on flat, firm ground The skid plate on the semi-trailer that engages with the fifth wheel coupling
! Secure the semi-trailer to prevent its rolling away must meet the following conditions to provide a long service life and
! Extend the landing gear as described in the operating manual until trouble-free function:
the fifth wheel coupling has almost no strain on it ! Max. 2 mm unevenness
! Disconnect the supply lines ! Adequate reinforcement must be assured
! Open the fifth wheel coupling (see section 3.3) ! Smooth and groove-free surface if possible, without weld bumps
! Drive the tractor unit out from under the semi-trailer (smooth existing groove burr)
! The fifth wheel coupling is automatically ready for engagement ! Rounded or chamfered front and side edges
again ! Complete coverage of the fifth wheel coupling support area
Effective lubrication of the top of the fifth wheel plate (apart
! from on the W version), the locking mechanism, the pivot
bearing (only the A and D versions) and the king pin (before
using for the first time and after cleaning) is essential to en-
sure their long service life. In the W version, we recommend
applying a thin coat of grease to the skid plate.
Note
When you clean the fifth wheel coupling you may produce waste products
that contains pollutant substances. We would like to point out that you
must comply with the various national waste regulations for the disposal of
these waste products.

4.1.1 Fifth wheel coupling with manual lubrication

At short intervals, at the latest every 5,000 km:
! Disconnect the semi-trailer
! Clean the fifth wheel coupling and the skid plate
! Grease the fifth wheel plate, locking parts and king pin
! Grease specification: Extreme pressure grease (EP) with MoS2 or
graphite additive (e.g. Collgranit A3 paste)
! Grease the pivot bearing on the A version at the grease nipple (see
figure G50/24) or on the D version at the holes on the top of the plate
(see figure G/27)

7
4 Servicing and testing JSK 36 / 37

Note 4.1.3 Low maintenance fifth wheel coupling with top plate liners
The pivot bearings on the C and E versions require no servicing. (W version)
The grease nipples on the edge of the fifth wheel coupling plate are only
designed for additional greasing of the locking mechanism between service At the latest every 50,000 km or every six months, in harsh conditions
intervals. every 25,000 km:
! Disconnect the semi-trailer
! Clean the skid plate and the king pin
! Grease the king pin and lock jaw
! Check the top plate liners for signs of wear and damage (see
section 4.5)

English
! Grease specification: Extreme pressure grease (EP) with MoS2 or
graphite additive (e.g. Collgranit A3 paste) or Turmogeargrease B2
supplied by Lubcon, www.lubcon.com

Note
G50/24 G50/27
The pivot bearings on the C and E versions require no servicing.
! Grease the pivot bearing on both sides

1 ! In addition, every 10,000 km

4.1.2 Fifth wheel coupling with central lubrication connection grease the locking mechanism –
(Z version) with a trailer attached – using the
grease nipple (1) on the edge of the
Depending on the conditions in which it is used, the grease specification fifth wheel coupling plate
and metering used, at the latest every 50,000 km or every six months:
! Disconnect the semi-trailer
! Clean the fifth wheel coupling and the skid plate G50/26
! Check the function of the central lubrication system as described in
the manufacturer’s instructions You can also install automatic lubricant dispensers. To prevent corrosion on
! Grease the fifth wheel plate, the locking mechanism parts and the the skid plate, we recommend that the skid plate is greased lightly during
king pin using a grease recommended in section 4.1.1 the above service intervals.
! Grease the pivot bearing on the D version (see figure G50/27)
! Grease specification: According to the instructions issued by the
manufacturer of the central lubrication system

Note
The pivot bearings on the C and E versions require no servicing.

8
4 Servicing and testing JSK 36 / 37

4.2 Test instructions

Depending on the conditions in which it is used, but at the latest every
50,000 km or every six months, the fifth wheel coupling, the mounting
plate or slider, the king pin and their securing elements are to be checked
to ensure that they are in good working condition, not suffering from wear, 71-73 mm
corrosion, damage or cracks and to be repaired if necessary (see appro-

84-82,5 mm
priate JOST repair manual for fifth wheel couplings JSK37 on www.jost-
world.com).
The securing elements are to be checked to ensure that they are tightened 49-50,8 mm
to the correct torque.

4.3 Wear test

Fifth wheel couplings and king pins are subject to more or less wear JSK40/05
depending on the conditions in which they are used, and this wear is
noticeable by play towards the front of the vehicle.
Excessive play causes shocks and may lead to instability on the road and When the wear limit on the king pin has been reached, it must be replaced.
damage to the fifth wheel coupling, mounting plate, sliders and vehicle After replacing the king pin, the locking mechanism must be adjusted again.
chassis. Play caused by wear on the king pin should either be accepted if within the
JOST fifth wheel couplings have a manual infinite adjustment facility for the permitted wear limit for the king pin (see figure JSK 40/05) or should be
locking mechanism to extend their service lives. rectified by fitting a new king pin.
The wear on the king pin must not be compensated by the
! adjustment facility.

9
4 Servicing and testing JSK 36 / 37

4.4 To adjust the locking mechanism ! To adjust the recommended basic play of 0.3 mm, tighten the
adjusting screw (3) by a further 11/2 turns and secure it with the lock
A nut (4)
3 ! Apply the semi-trailer brake
1 4 ! Move off with the tractor and check the maximum play in the locking
B mechanism

Note
5 If the play is still excessive, replace the wearing ring and the lock jaw as

English
described in the repair manual.
6
2

7
3 1 G50/8
1 Handle 5 Lock jaw
2 Locking mechanism 6 Locking bar
3 Adjusting screw 7 Lever
4 Lock nut

The locking mechanism must be adjusted using a semi-trailer without

forced steering with an unworn king pin as described below:
! Park the vehicle on flat, firm ground and uncouple the trailer
! Undo the lock nut (4)
! Unscrew the adjusting screw (3) by approx. 15 turns
! Connect the semi-trailer, if necessary lightly tapping the handle (1) in
the closing direction A to bring the locking bar into its limit position
! Unlock the handle, swing it into position B and hold it there (get an
assistant to hold it)
! Tighten the adjusting screw (3) again until the handle (1) starts to
move (have your assistant check this)

10
4 Servicing and testing JSK 36 / 37

4.5 Wear limit – top plate liners

45 Nm
1

ISO10664 - 45

3 - 0 mm 2
1

G50/32

1 Top plate liner 2 Securing bolt 3 Coupling plate

The top plate liners (1) must be checked for signs of wear and damage at regular intervals that depend on usage, but at least every 50,000 km or every six
months.
The top plate liners (1) must be replaced when they have worn to the top of the securing bolts (2).

11
5 Installation JSK 36 / 37

5.1 General installation instructions 5.2 To install the fifth wheel coupling
To secure the JOST fifth wheel coupling (pursuant to Directive 94/20/EC
and ISO 3842 / DIN 74081) on the mounting plate or on the flitch, at least
eight M16 bolts, ideally M16 x 1.5 of strength class 8.8 must be used.
These must be positioned in a symmetrical pattern to the longitudinal and
lateral axes of the fifth wheel coupling. 1 7
If the coupling is used in harsh conditions (for example on construction
sites), with trailers with forced steering or with trailers that use the full D 11
value and/or imposed load, we recommend that you use all 12 bolts. 8

English
Fifth wheel couplings with a design height of over 250 mm and a D value 3 12
of over 133 kN must be secured with 12 bolts. 2
We recommend that you use JOST mounting kits (see JOST catalogue for 4
order numbers). 5
We recommend securing the pedestals in the longitudinal and lateral
directions and the mounting plates in the longitudinal direction by pre- 6 9
welded thrust plates. Use the welding methods set out by the 10
manufacturers of the vehicle and mounting plate for this purpose.
There is no need to use thrust plates, however, if it can be ensured that the 9
correct tightening torque for the bolts and therefore the perfect friction
contact can be generated and maintained at all times. The bolt connections
10 G50/09
are therefore to be designed so that the prescribed tightening torque values
or prestressing forces can be applied permanently. The general rule is that 1 Fifth wheel coupling
the coating thickness of the paintwork around the securing area of the bolts 2 Mounting plate
must be no more than 170 µm per component. The bolt connections are to 3 Thrust plate to secure the pedestals
be secured using state of the art methods to prevent them coming loose. 4 Thrust plate to secure the mounting plate
Appropriate reinforcement must be made in accordance with the 5 Vehicle chassis
application. 6 Flitch
7 Hexagonal bolt DIN EN 28765/28676 (DIN 960/961) M16 x 1.5-8.8
The fifth wheel coupling must be able to move freely and must not be in 8 Washer 17 DIN 7349 6 thick (min. HB150)
contact with either the mounting plate or parts of the chassis or flitch when
9 Optional washer (min. HB150) or disc spring
the vehicle is being driven.
10 Hexagonal nut DIN 980 M16 x 1.5-8.8 or M20 x 1.5-8.8
If you use a different installation method (for example chassis installed),
11 Hexagonal bolt DIN EN 28765/28676 (DIN 960/961) M16 x 1.5-8.8 or
follow the instructions supplied by the vehicle manufacturer.
M20 x 1.5-8.8
12 Optional washer/disc spring

Tightening torque, see section 5.3

12
5 Installation JSK 36 / 37

5.3 Fastening material and tightening torque values

Fastening material Strength class 8.8 Strength class 10.9

Hexagonal bolt DIN EN 24014/24017 (DIN 931/933) standard thread M16 210 Nm 260 Nm
M20 410 Nm 500 Nm

Hexagonal bolt DIN EN 28765/28676 (DIN 960/961) fine thread M16 x 1.5 225 Nm 280 Nm
M20 x 1.5 460 Nm 500 Nm

Countersunk bolt DIN 7991 M16 or M16 x 1.5 170 Nm 250 Nm

M20 or M20 x 1.5 330 Nm 400 Nm

Washer DIN 7349 min. 150 Nm min. 250 Nm

Note
The values shown above are guide values for a coefficient of friction µ tot. = 0.14. Further information is available in VDI 2230.

13
Siemensstraße 2, D-63263 Neu Isenburg, Telefon +49 (0) 61 02-2 95-0 Fax +49 (0) 61 02-2 95-98, www.jost-world.com

ZDE 199 002 052, 08/2006