Repair manual for

JSK 40, JSK 42 fifth wheel couplings

ZDE 199 002 111 GB 05/2004

Foreword
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.

Table of contents
1 Safety information 2 Troubleshooting 3 Standard and special tools, auxiliary material 3.1 3.2 3.3 Standard tools Special tools Auxiliary material 3 4

5 5 5 5 18

4 Repair work 4.1 4.2

4.3

4.4 4.5 4.6

4.7 4.8 4.9

To remove and install the liner 6 To remove and install the bearing on the workbench 7 4.2.1 To remove and install the bearing for mounting plate installation 7 4.2.2 To remove and install the bearing with the traverse 10 To remove and install the bearing on the vehicle 13 4.3.1 To remove and install the bearing for mounting plate installation 13 4.3.2 To remove and install the bearing with the traverse 16 To remove and install the wearing part 18 To remove and install the lock jaw 19 To remove and install the locking mechanism 22 4.6.1 To remove and install the locking mechanism, handle at the front 22 4.6.2 To remove and install the locking mechanism, handle at the rear 26 To adjust the locking mechanism 29 Wear limits, adjustment and control dimensions 29 Function test 33

5 Spare parts for JSK 40/40 W Plate installation 6 Spare parts for JSK 40/40 W with traverse 7 Spare parts for JSK 42/42 W Plate installation 8 Spare parts for JSK 42/42 W with traverse 9 Disposal instructions
ZDE 199 002 111 GB 05/2004

34

36

38

40 42 2

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 owners 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.

ZDE 199 002 111 GB 05/2004

2 Troubleshooting
0

JSK 40/42
Remedy to 1. The skid plate should be at the same height or max. 50 mm lower than the fifth wheel coupling.

Fault

Cause

Fifth wheel coupling will 1. The king pin is too high. not close.

2. The skid plate is uneven, thus to 2. Replace the skid plate. Maximum flatness causing the king pin to be in deviation 2 mm. the wrong position. 3. The king pin is not the correct to 3. Replace the king pin. size or is damaged. 4. Lock jaw deformed. 5. Poor servicing. 6. Double spring defective. 7 Lever and/or handle bent. . 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 1. Tractor unit not level or pulling. to 1. Relieve the pressure on the tractor units locking mechanism. cannot be opened. 2. Poor servicing, damage to the lock jaw or locking bar, or incorrect locking mechanism adjustment. 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. 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. 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.

Fifth wheel coupling does not stay in the ready position.

1. Lock jaw deformed. 2. Spring defective. 3. Poor servicing.

Movement between 1. Bearing has excessive play. fifth wheel coupling and semi-trailer (knocking). 2. Locking mechanism has excessive play.

ZDE 199 002 111 GB 05/2004

3
3.1
0

Standard and special tools, auxiliary material JSK 40/42

Standard tools
0

3/4

3/4

1/2

1/2

3/4

1/2

1/2

Nm 1/2 1/2 1/2 1/2

Nm

100 mm 1/2

100 mm T45 1/2 3/4

SW18

SW24

SW7

SW8

SW10

SW14

SW14

150 mm

SW 10

SW 11

SW 13

SW 17

SW 22

SW 24

4 - 12

300 gr.

200 mm

JSK40/95

3.2
0

Special tools
0

SK 2702-10

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)

ZDE 199 002 111 GB 05/2004

4 Repair work

JSK 40/42

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

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.

Version with handle at the front

0

Version with handle at the rear

0

9 Handle

JSK40/115

Note The position of handle must be noted for some of the work shown in the following sections.

4.1
0

To remove and install the liner

0

1/2

1/2

1/2

24 Liner

T45

SW8

45 Nm

24
JSK40/56

Undo the Allen bolts or inner round hex bolt. Remove the liner (24).

ZDE 199 002 111 GB 05/2004

4 Repair work
4.2 To remove and install the bearing on the workbench

JSK 40/42

Note On the low maintenance version, the liner must be removed first as described in section 4.1.
0 0

JSK40/50
0

The fifth wheel coupling may only be raised using suitable lifting gear. 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

3/4

3/4

21 Bridge screw

SW14

450 Nm

21 21
JSK40/51
0

The bridge screws (21) must always be replaced after being removed. Undo the bridge screws (21).

ZDE 199 002 111 GB 05/2004

4 Repair work

JSK 40/42

4.2.1 To remove and install the bearing for mounting plate installation (continued)
0 0

23 Bridge

23

JSK40/52

Remove the bridge (23).

0 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

22 b 25
JSK40/53

Remove the rubber bearing (22).

0 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

25

Remove the pedestal (25).

0 0

When installing the pedestal (25) ensure that the JOST logo faces the outside.
ZDE 199 002 111 GB 05/2004

TS
JSK40/54

4 Repair work

JSK 40/42

4.2.1 To remove and install the bearing for mounting plate installation (continued)
Version JSK 40 only
0 0

22 Collar c Intermediate piece

22

JSK40/117

Remove the collar (22) and intermediate piece (c).

Version JSK 42 only

0 0

22 Collar

22

JSK40/55

Remove the collar (22).

ZDE 199 002 111 GB 05/2004

4 Repair work
4.2.2 To remove and install the bearing with traverse
0 0

JSK 40/42

1/2

1/2

1/2

26 Traverse screw 27 Traverse

100 mm

SW14

SW 24

280 Nm

26

27
JSK40/57

Undo the traverse screws (26) on both sides. Remove the traverse (27).
0 0

3/4

3/4

21 Bridge screw

SW14

450 Nm

21

21
JSK40/58

!
0

The bridge screws (21) must always be replaced after being removed. Undo the bridge screws (21).
0

23 Bridge

23

JSK40/59

Remove the bridge (23).

0 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.

ZDE 199 002 111 GB 05/2004

10

4 Repair work
4.2.2 To remove and install the bearing with traverse (continued)
0 0

JSK 40/42

22 Rubber bearing 25 Pedestal b Cam

25

22

b
JSK40/60

Remove the rubber bearing (22).

0 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

25

JSK40/61

Remove the pedestal (25).

0 0

When installing the pedestal (25) ensure that the JOST logo faces the outside.

ZDE 199 002 111 GB 05/2004

11

4 Repair work
4.2.2 To remove and install the bearing with traverse (continued)
Version JSK 40 only
0 0

JSK 40/42

22 Collar c Intermediate piece

JSK 40 K1, K5

JSK 40 K2, K3, K4, K6

22

22

JSK40/116

Remove the collar (22) and intermediate piece (c).

Version JSK 42 only

0 0

22 Collar

22

JSK40/55

Remove the collar (22).

ZDE 199 002 111 GB 05/2004

12

4 Repair work
4.3 To remove and install the bearing on the vehicle

JSK 40/42

Note On the low maintenance version, the liner must be removed first as described in section 4.1.
0 0

JSK40/104

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

3/4

3/4

21 Bridge screw

SW14

21

450 Nm

JSK40/105
0

The bridge screws (21) must always be replaced after being removed. Undo the bridge screws (21).

ZDE 199 002 111 GB 05/2004

13

4 Repair work

JSK 40/42

4.3.1 To remove and install the bearing for mounting plate installation (continued)
0 0

22 Rubber bearing 23 Bridge

22 23

JSK40/106

Remove the bridge (23) and rubber bearing (22). Raise the fifth wheel coupling with lifting gear.

Version JSK 40 only

0 0

22 Collar c Intermediate piece

c 22

JSK40/118

Remove the collar (22) and intermediate piece (c).

Version JSK 42 only

0 0

22 Collar

22

JSK40/107

Remove the collar (22).

ZDE 199 002 111 GB 05/2004

14

4 Repair work

JSK 40/42

4.3.1 To remove and install the bearing for mounting plate installation (continued)
0 0

22 Rubber bearing 23 Bridge

150 mm

106.5 mm 62.5 mm 52.5 mm

22

23

JSK40/109

Secure the rubber bearing (22) to the bridge (23) as shown with Sellotape / insulating tape for later installation.
0 0

22 Rubber bearing 23 Bridge b Cam

23 22

JSK40/110

Slide in the bridge (23) on both sides as shown. Lower the fifth wheel coupling with lifting gear.
0 0

3/4

3/4

21 Bridge screw 23 Bridge i Gap

Nm

SW14

21 i

450 Nm

23
JSK40/111
0 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. Insert the bridge screws (21).

ZDE 199 002 111 GB 05/2004

15

4 Repair work
4.3.2 To remove and install the bearing with traverse
0 0

JSK 40/42

3/4

3/4

21 Bridge screw 23 Bridge

SW14

21 23

450 Nm

JSK40/112
0

The bridge screws (21) must always be replaced after being removed. Undo the bridge screws (21). Remove the bridge (23). Raise the fifth wheel coupling with lifting gear.

Version JSK 40 only

0 0

22 Collar c Intermediate piece

22 c

JSK40/108

Remove the collar (22) and intermediate piece (c).

ZDE 199 002 111 GB 05/2004

16

4 Repair work
4.3.2 To remove and install the bearing with traverse (continued)
Version JSK 42 only
0 0

JSK 40/42

22 Collar

22

JSK40/107

Remove the collar (22).

0 0

22 Rubber bearing 23 Bridge 25 Pedestal b Cam

b 22

23

25

JSK40/113
0 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). Slide in the rubber bearing (22) and bridge (23). Lower the fifth wheel coupling with lifting gear.

3/4

3/4

21 Bridge screw 23 Bridge

Nm

SW14

21

23

450 Nm

JSK40/114

Insert the bridge screws (21).

ZDE 199 002 111 GB 05/2004

17

4 Repair work
4.4
0

JSK 40/42

To remove and install the wearing part

0

1/2

1/2

Allen bolt

SW7

49 Nm 49 Nm

JSK40/66

Undo the Allen bolts (1).

0 0

Securing ring

JSK40/67

Lever out the securing ring (2) with a screwdriver.

0 0

1 2

Wearing part Securing ring

JSK40/85

Remove the wearing part (1).

ZDE 199 002 111 GB 05/2004

18

4 Repair work
4.5 To remove and install the lock jaw

JSK 40/42

Version with the handle at the front only

0 0

Double spring

JSK40/63

Release the double spring (7).

0 0

When installing the double spring (7) ensure that the installation is carried out as shown in the illustration.

Version with the handle at the rear only

0 0

13 Gas pressure spring 17 Ball head

SW 13

13

20 Nm

17
JSK40/78

Lever out the securing clips with a screwdriver. Remove the gas pressure spring (13). Remove the ball head (17).

ZDE 199 002 111 GB 05/2004

19

4 Repair work
4.5 To remove and install the lock jaw (continued)

JSK 40/42

All versions
0 0

4 Spring 5 Cable tie 19 Securing ring on the eye bolt

200 mm

19 4 5

JSK40/64

Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).
0 0

Lubrication tube

SW 10

40 Nm
JSK40/65

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 0

6 a

Bolt M14 screw (removal tool)

a 6

JSK40/68

Screw in the screw (a) and pull out the bolt (6).

ZDE 199 002 111 GB 05/2004

20

4 Repair work
4.5 To remove and install the lock jaw (continued)

JSK 40/42

Version with the handle at the front only

0 0

Handle

JSK40/69

Pull the handle (9) to the outside.

Version with the handle at the rear only

0 0

Handle

JSK40/89

Pull the handle (9) to the outside.

All versions
0 0

5 6

Lubrication tube Lock jaw

SW 10

SW 11

3 Nm

5
JSK40/90

Turn the lock jaw (6) as shown and remove it. Unscrew the lubrication tube (5) from the lock jaw (6).
ZDE 199 002 111 GB 05/2004

21

4 Repair work
4.6 To remove and install the locking mechanism

JSK 40/42

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 0

Double spring

JSK40/63

Release the double spring (7)

0 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

200 mm

19 4 5

JSK40/64

Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).

ZDE 199 002 111 GB 05/2004

22

4 Repair work

JSK 40/42

4.6.1 To remove and install the locking mechanism, handle at the front (continued)
0 0

Lubrication tube

SW 10

40 Nm
JSK40/65

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 0

1/2

1/2

1/2

3 Securing bolt 10 Intermediate lever 11 Lever spring

100 mm

SW14

d 11 10

110 Nm

3
JSK40/71

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 0

1/2

1/2

10 Intermediate lever 12 Lever screw

SW14

12 10
110 Nm

JSK40/72

Undo the lever screw (12) from the underside through the hole (e). Remove the intermediate lever (10).
ZDE 199 002 111 GB 05/2004

23

4 Repair work

JSK 40/42

4.6.1 To remove and install the locking mechanism, handle at the front (continued)
0 0

Locking bar

JSK40/73

Remove the locking bar (3).

0

1/2

1/2

12 Lever screw

SW10

45 Nm

12

JSK40/74
0

Undo the lever screw (12).

0

1/2

1/2

15 Hexagonal nut

SW18

SW 24

15

65 Nm

JSK40/75
0

Undo the hexagonal nut (15).

ZDE 199 002 111 GB 05/2004

24

4 Repair work

JSK 40/42

4.6.1 To remove and install the locking mechanism, handle at the front (continued)
0 0

10 Lever 14 Pull lever

14

10
JSK40/76
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

3 Locking bar and securing screw 4 Spring 6 Lock jaw 9 Handle

14 11 3 10 12

15

10 Intermediate lever and lever 11 Lever spring 12 Lever screws 14 Pull lever

15 6 4 19 12 3
JSK40/77

15 Pull lever screw with hexagonal nut 19 Eye bolt, complete

10

The screws (3) and (12) must always be replaced after being removed.

ZDE 199 002 111 GB 05/2004

25

4 Repair work

JSK 40/42

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 0

13 Gas pressure spring 17 Ball head

SW 13

13

20 Nm

17
JSK40/78

Lever out the securing clips with a screwdriver. Remove the gas pressure spring (13). Remove the ball head (17).
0 0

4 Spring 5 Cable tie 19 Securing ring on the eye bolt

200 mm

19 4 5

JSK40/64

Remove the securing ring (19) and release the spring (4). Remove the cable tie (5).
0 0

Lubrication tube

SW 10

40 Nm
JSK40/65

Undo the screw connector on the lubrication tube (5).

ZDE 199 002 111 GB 05/2004

26

4 Repair work

JSK 40/42

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 0

1/2

1/2

3 Securing bolt 16 Pull lever

SW14

110 Nm

3 16 f

JSK40/79

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 0

1/2

1/2

3 Locking bar 15 Hexagonal nut 16 Pull lever

SW14

SW 24

16

65 Nm

15 f
JSK40/80

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 0

16 Pull lever

16

JSK40/81

Remove the pull lever (16).

ZDE 199 002 111 GB 05/2004

27

4 Repair work

JSK 40/42

4.6.2 To remove and install the locking mechanism, handle at the rear (continued)
0 0

1/2

1/2

1/2

10 Lever 12 Lever screw

100 mm

SW10

12 10

45 Nm

JSK40/82

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

12

3 Locking bar and securing screw 4 Spring 6 Lock jaw 9 Handle

10

10 Lever 12 Lever screw 13 Gas pressure spring

13 17 15 3 4 15 9 16 3 19
JSK40/83
0

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.

ZDE 199 002 111 GB 05/2004

28

4 Repair work
4.7
0

JSK 40/42

To adjust the locking mechanism

0

1/2

1/2

3 Locking bar 6 Lock jaw 9 Handle 20 Adjusting screw g Lock nut

SW24

SW 24

6 9

20 g
JSK40/96

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 jaw
0 0

Lock jaw

150 mm

17.5 - 19.0 mm

JSK40/86

Replace the lock jaw (6) when the wear limit is reached.
ZDE 199 002 111 GB 05/2004

29

4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)

JSK 40/42

Wearing part
0 0

Wearing part

150 mm

17.5 - 20.5 mm 1

JSK40/87

Replace the wearing part (1) when the wear limit is reached.

Collar
0 0

22 Collar

150 mm

22

3.0 - 8.0 mm

JSK40/97

Replace the collars (22) when the wear limit is reached.

King pin
0 0

150 mm

71.0 - 73.0 mm
84-82.5 mm
JSK40/88

49-50.8 mm

Replace the king pin when the wear limit is reached.

ZDE 199 002 111 GB 05/2004

30

4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)

JSK 40/42

Coupling plate
0 0

A B

150 mm

Lubricating groove depth Exterior

100 mm

JSK 40

JSK 42

100 mm

A
110 mm

A B
110 mm
JSK40/98

70 mm

The fifth wheel coupling must be replaced if:

0

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 liner

0 0

24 Liner h Securing screws

150 mm

24

h h

0 -3 mm

45 Nm

24
JSK40/103

h
Replace the liner (24) when it has worn down to the surface of the securing screws (h).

ZDE 199 002 111 GB 05/2004

31

4 Repair work
4.8 Wear limits, adjustment and control dimensions (continued)

JSK 40/42

Locking mechanism (handle at the front)

0 0

150 mm

10 Intermediate lever and lever

0 mm

0 mm

10

0 mm

0 mm

JSK40/99

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 0

16 Pull lever

150 mm

0m

16
0m m
JSK40/100

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.

ZDE 199 002 111 GB 05/2004

32

4 Repair work
4.9 Function test

JSK 40/42

Locking mechanism (handle at the front)

0 0

3 Locking bar 9 Handle 10 Lever A King pin B Locking bar tip

150 mm

min 4

mm

10 B 3

A
Locking mechanism (handle at the rear)
0

JSK40/101

3 Locking bar 9 Handle 10 Lever

150 mm

mm min 4

10 B

A King pin B Locking bar tip

3 A 9
JSK40/102

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.

ZDE 199 002 111 GB 05/2004

33

5 Spare parts for JSK 40/40 W Mounting plate installation

0

21

24 20 (8x) 01 02 03

22 04 05 19 06 07

08 L 25 13 23 16 17 15 14 12 11
JSK40/91
0

09

18 10

Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Gas pressure spring Pull lever, complete with item 15 Pull lever screw Pull lever, complete with items 15 and 17 Ball head Lever set with item 12 Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with intermediate piece and item 21 Liner with screws

Quantity Serial No./Note Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE 001560000 SKE001620020 SKE 001650020 SKE 001630020 SKE 001007800 SKE 001006820 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530020 SKE 001007020 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 2 2 1

L = 220 mm L = 390 mm for front handle

for rear handle for front handle for rear handle for rear handle for rear handle

ZDE 199 002 111 GB 05/2004

34

5 Spare parts for JSK 40/40 W Mounting plate installation

Item Description 25 Pedestal height 150 with item 21 Pedestal height 185 with item 21 Pedestal height 225 with item 21 Pedestal height 250 with item 21 Quantity Serial No./Note Article number per JSK SKE 001005620 SKE 001005720 SKE 001005820 SKE 001005920 2 2 2 2

Item Repair and retrofit kits 1, 2, 3, 4, 5, 6, 19

0

Article number SKE 001640020

Locking mechanism, complete

ZDE 199 002 111 GB 05/2004

35

6 Spare parts for JSK 40/40 W with traverse

0

21 20 22

24 (8x) 01 02 03

04 05

19 06

07

27 26

08 L 09

25

18 23 17 16 15 14 13 12 11
JSK40/92
0

10

Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Gas pressure spring Pull lever, complete with item 15 Pull lever screw Pull lever, complete with items 15 and 17 Ball head Lever set with item 12 Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with intermediate piece and item 21 Liner with screws

Quantity Serial No./Note Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE 001560000 SKE001620020 SKE 001650020 SKE 001630020 SKE 001007800 SKE 001006820 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530020 SKE 001007020 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 2 2 1

L = 220 mm L = 390 mm for front handle

for rear handle for front handle for rear handle for rear handle for rear handle

ZDE 199 002 111 GB 05/2004

36

6 Spare parts for JSK 40/40 W with traverse

Quantity Serial No./Note Article number per JSK SKE 001500020 SKE 001500120 SKE 001500220 SKE 001500320 SKE 001510020 SKE 001510120 SKE 001510220 SKE 001510320 SKE 001520020 SKE 001520120 SKE 001520220 SKE 001520320 SKE 002770020 SKE 001010020 SKE 001570020 SKE 001590020 SKE 001010120 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1

Item Description Pedestal height 150 LB K1/K2 with item 21 Pedestal height 150 LB K3 with item 21 Pedestal height 150 LB K4/K5 with item 21 Pedestal height 150 LB K6 with item 21 Pedestal height 190 LB K1/K2 with item 21 Pedestal height 190 LB K3 with item 21 Pedestal height 190 LB K4/K5 with item 21 Pedestal height 190 LB K6 with item 21 Pedestal height 225 LB K1/K2 with item 21 Pedestal height 225 LB K3 with item 21 Pedestal height 225 LB K4/K5 with item 21 Pedestal height 225 LB K6 with item 21 Traverse screws set Traverses LB K1/K5 with item 26 Traverses LB K2/K5 height 150 with item 26 Traverses LB K2/K5 height 190/225 with item 26 Traverses LB K3/K6 with item 26

25

26 27

Item Repair and retrofit kits 1, 2, 3, 4, 5, 6, 19 Locking mechanism, complete

Article number SKE 001640020

ZDE 199 002 111 GB 05/2004

37

7 Spare parts for JSK 42/42 W Mounting plate installation

0

21

24 20 (8x) 01 02 03

22 04 05 19 06 07

08 L 25 09

23

15 14 12 11
JSK40/93

10

Item Description 1 2 3 4 5 6 7 8 9 10 11 12 14 15 19 20 21 22 23 24 25 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Pull lever, complete with item 15 Pull lever screw Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with item 21 Liner with screws Pedestal height 150 with item 21 Pedestal height 185 with item 21 Pedestal height 225 with item 21 Pedestal height 250 with item 21

Quantity Serial No./Note Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE001620020 SKE 001650020 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530220 SKE 001007020 SKE 001005620 SKE 001005720 SKE 001005820 SKE 001005920 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 2 1 2 2 2 2

L = 220 mm L = 390 mm

ZDE 199 002 111 GB 05/2004

38

7 Spare parts for JSK 42/42 W Mounting plate installation

0

Item Repair and retrofit kits 1, 2, 3, 4, 5, 6, 19 Locking mechanism, complete

Article number SKE 001640020

ZDE 199 002 111 GB 05/2004

39

8 Spare parts for JSK 42/42 W with traverse

0

21 20 22

24 (8x) 01 02 03

04 05 27
26

19 06

07

08 L 09

25

23 15

14

12 11

10

JSK40/94
0

Item Description 1 2 3 4 5 6 7 8 9 10 11 12 14 15 19 20 21 22 23 24 Wearing part with securing screws Securing ring, with item 1 Locking bar with securing screw Spring Lubrication tube, complete with cable tie Lock jaw, with items 4 and 5 Double spring Securing spring Handle, short, complete with item 8 Handle, long, complete with item 8 Lever set, with items 11 and 12 Lever spring Lever screw Pull lever, complete with item 15 Pull lever screw Eye bolt, complete Adjusting screw with guide Bridge screw Collar with item 21 Bridge with item 21 Liner with screws

Serial No./Note

Quantity Article number per JSK SKE 001740020 SK 3105-94 SKE 001009720 SK 847 SK 3108-02 SK 3221-52Z SK 3105-20 SKE 001440000 SKE 001390020 SKE 001390120 SKE 001380020 SKE 001009800 SKE 001750020 SKE001620020 SKE 001650020 SK 2122-04 SKE 500740420 SKE 001011400 SKE 001370020 SKE 001530220 SKE 001007020 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 2 1

L = 220 mm L = 390 mm

for front handle

ZDE 199 002 111 GB 05/2004

40

8 Spare parts for JSK 42/42 W with traverse

Serial No./Note Quantity Article number per JSK SKE 001500020 SKE 001500120 SKE 001500220 SKE 001500320 SKE 001510020 SKE 001510120 SKE 001510220 SKE 001510320 SKE 001520020 SKE 001520120 SKE 001520220 SKE 001520320 SKE 002770020 SKE 001570020 SKE 001590020 SKE 001010120 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1

Item Description Pedestal height 150 LB K2 with item 21 Pedestal height 150 LB K3 with item 21 Pedestal height 150 LB K4 with item 21 Pedestal height 150 LB K6 with item 21 Pedestal height 190 LB K2 with item 21 Pedestal height 190 LB K3 with item 21 Pedestal height 190 LB K4 with item 21 Pedestal height 190 LB K6 with item 21 Pedestal height 225 LB K2 with item 21 Pedestal height 225 LB K3 with item 21 Pedestal height 225 LB K4 with item 21 Pedestal height 225 LB K6 with item 21 Traverse screw set Traverses LB K2/K5 height 150 with item 26 Traverses LB K2/K5 height 190/225 with item 26 Traverses LB K3/K6 with item 26

25

26 27

Item Repair and retrofit kits 1, 2, 3, 4, 5, 6, 19 Locking mechanism, complete

Article number SKE 001640020

ZDE 199 002 111 GB 05/2004

41

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.

ZDE 199 002 111 GB 05/2004

42