Repair manual for

JSK 37 fifth-wheel coupling

Foreword Table of contents

Fifth wheel couplings are vehicle connecting parts 1 Safety instructions 4

that must comply with very high safety require- 2 Troubleshooting 5
ments and must also undergo design approval
tests. 3 Standard and special tools an
auxiliary materials 6
This repair manual is designed to act as a guide to 3.1 Standard tools 6
completing repair work on our fifth wheel couplings. 3.2 Special tools 6
It is essential that you use JOST spare parts. Modi- 3.3 Auxiliary materials 6
fications of any kind will render both the warranty 4 Repair work 7
and the type approval void. 4.1 To remove and install the version C
bearing 7
Instructions for the operation and installation of the
4.2 To remove and attach the version E
fifth wheel couplings and their permitted load data
pedestal 8
are provided in separate documents.
4.3 To remove and install the version E
bearing 8
4.4 Overview of the locking mechanism 9
4.5 To remove and install the locking
mechanism 9
4.6 To remove and install the safety latch 11
4.7 To remove and install the top plate
liners (W version only) 11
4.8 To remove and install the lock jaw/
on the vehicle 11
4.9 To check for wear/wearlimits 13
4.10 Function test 15
4.11 To set the locking mechanism 16
5 Spare parts for version JSK37C/CZ 17
6 Spare parts for version JSK37E 18
7 Spare parts for version JSK37CW/EW 19
8 Disposal instructions 20

ZDE 199 002 108 04/2012 3

1 Safety instructions

The relevant safety regulations in your country (for example Health & Safety at Work) apply for working
with fifth wheel couplings and vehicles.
The relevant safety instructions included in the vehicle and semi-trailer's operating instructions must also
be complied with.

4 ZDE 199 002 108 04/2012

 2 Troubleshooting

Fault Cause Remedy

Fifth wheel coupling 1. The king pin is too high.
will not close. 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.
The fifth wheel 1. Tractor unit not level or pulling.
coupling cannot be 2. Poor servicing, damage to the
opened. lock jaw or locking bar, or
incorrect locking mechanism
adjustment.
Fifth wheel coupling 1. Lock jaw deformed.
does not stay in the 2. Spring defective.
ready position.
3. Poor servicing
to 1. The skid plate should be at the same height or around 50 mm lower than the fifth wheel coupling.
to 2. Replace the skid plate. Permissible flatness deviation 2 mm.
to 3. Replace lock jaw SK 1489 or SK 1489Z.
to 4. Ease the mechanism and grease it.
to 5. Replace double spring SK 3105-20.
to 6. Replace/align lever SK 3105-18 and handle SK 3105-15 or SK 3105-113
to 1. Release the fifth wheel coupling locking mechanism.
to 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 3105-18, 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, e.g. SK 3105-05-97. 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 1489 or SK 1489Z.
to 2. Replace spring SK 847.
to 3. Clean and regrease the area of the locking mechanism.

Movement between 1. Bearing has excessive play. to 1. Version C replace E version On the EW version and
fifth wheel coupling the top rubber Replace the rubber E version from
and semi-trailer cushion SK1259, sleeve SK 2905-94 in the series 31, collar
(knocking). bottom rubber event of wear (see 4.3). SK 3105-95 must also be
cushion SK 2105-25 replaced in addition to
in the event of wear rubber sleeve
(see 4.1). SK 2905-94.
2. Locking mechanism has to 2. Check king pin, replace it if it is worn.
excessive play. If the king pin is in good condition but there is still play, adjust the locking mechanism (see
section 4.11). If this fails to resolve the problem, replace lock jaw SK 1489 or SK 1489Z, wearing
ring SK 2105-19 or wear part 3105-92.

ZDE 199 002 108 04/2012 5

 3 Standard and special tools and auxiliary materials

3.1 Standard tools

0

1/2´´ 1/2´´ 1/2´´ 1/2´´

SW17 SW19 SW24 SW30

SW 8 SW 11 SW17 SW 19

SW24 SW 30 SW 24

3.2 Special tools

0

J 919/2
JSK37C
JSK37E X
0

3.3 Auxiliary materials

High pressure grease (EP) with MoS2 or graphite additive, for example:
BP L21 M
BP HTEP 1
Esso multi-purpose grease M
Shell Retinax AM
Turmogear grease B2 from Lubcon (www.lubcon.com)

6 ZDE 199 002 108 04/2012

 4 Repair work

Worn, damaged and cracked parts must

0

always be replaced. Repair welds must not be 1

0

used. After completing the repair work, the entire 0

1/2´´
12
fifth wheel coupling locking mechanism must be
greased and its function tested. 0

1/2´´
a a

The item numbers in the illustrations refer to the

100 mm
0

1/2´´
spare parts lists in sections 5, 6, 7 and 8. 170 Nm
b
Nm

With the diagrams the work steps should be carried

0

1/2´´
a a
out in alphabetical order (e.g. a, b, c). Assembly is SW24
15
carried out correspondingly in reverse order.
0

1/2´´

Instructions for assembly are identified in the dia- SW10

16
gram number of the diagram itself with a diamond ◊.
0

JSK/02
The torque values shown in the illustrations are 0

required for the subsequent assembly process. The

2
0

prescribed tightening torques must be adhered to!

0

12

b 14

JSK/09
0

3
0

JSK/45
0

 Take the fifth wheel coupling off the tractor

1/2´´

unit, place it on workbench SK 2702-10 and

couple it up.

4.1 To remove and install the version C 13

bearing
In the case of version W fifth wheel couplings, the
top plate liners must be removed first
(see section 4.7). JSK/10
0

4
0

16
SW 24
0

1/2´´

Nm
0

1/2´´

SW10
14
15 13

170 Nm
16
JSK/55

ZDE 199 002 108 04/2012 7

 4 Repair work

4.2 To remove and install the version E

2
0

pedestal 0

In the case of EW version fifth wheel couplings and 1500 gr.

E version fifth wheel couplings from series 31, the

bearings and the collar SK 3105-95 must also be
replaced in the event of a repair.
0

12
1
0

a 16
1500 gr.
0

c JSK/11
0

6-10 mm b
3
0

1/2´´
15
b 0

Nm
0
1500 gr.
1/2´´

SW19
80 Nm 12 13 12
0

JSK/03
0

2
0

1/2´´

SW24 J 919/2
0

1/2´´
b
0
JSK/39

1500 gr.
a
4
0

1/2´´

14 b
0
Nm

1/2´´

12 SW19
0
JSK/04

12
1500 gr.
0
c
c 14
6-10 mm
80 Nm
4.3 To remove and install the version E 0

13
bearing
15 16
JSK/53

1
0

41

JSK/46

8 ZDE 199 002 108 04/2012

0
4

1
0

;
Repair work

4.4 Overview of the locking mechanism

6
5
8

4.5 To remove and install the locking mechanism

0 0
3 9

4
1

JSK/12

1 2
0 0

0 0

7 8
9 0
SW 24

SW 30
9 0

6
0

SW 24
0

SW 30 5
JSK/13 JSK/14

ZDE 199 002 108 04/2012 9

 4 Repair work

3 6
0 0

0 0

1/2´´

SW10
140 Nm
0

1/2´´

1/2´´

Nm

11
10
JSK/61 JSK/18

 During assembly, lubricate the articulated

0

6a
0

points, then tighten the castle nut (8) and then

loosen again one 1/2 turn. Secure the crown
0

1/2´´ 35 36
nut (8) with a splint. Only tighten the crown SW7

nut (5) until the splint can be inserted. Secure 0

1/2´´

the splint.
0

1/2´´
49 Nm
The installation and removal of the lock jaw Nm 38
and wearing ring must only be carried out with
the double spring released. Risk of injury!
0

4
0

0
JSK/40

7
0

2
10
24
24

JSK/16

5
0

0
JSK/19

5
7a
0

4 0

37
36

JSK/17

JSK/41

10 ZDE 199 002 108 04/2012

 4 Repair work

4.6 To remove and install the safety latch

0

8
0

1
0

M 14
0

1/2´´

3 Nm
29
0

SW 17

0 28
1/2··
27
1 SW17

30 Nm

JSK/20
a
a
0

JSK/51
9
0

4.7 To remove and install the top plate

liners (W version only)
0

1
0

0 39L
1/2´´ T45
1 3- 0 mm 40
T45 40
0

1/2´´

39 45 Nm 39R
0
a
JSK/21 1/2´´

0 Nm

10
0

0
JSK /24
25

26
4.8 To remove and install the lock jaw/on
the vehicle
1 The installation and removal of the lock jaw
and wearing ring must only be carried out with
the double spring (9) released. Risk of injury!
0

JSK/23a
1
0

 To remove the version Z locking mecha-

nism (1), the cable ties (26) must be removed 0
9
from the lubrication tube (25) and the lubrica-
0

tion tube screw loosened. During installation, 9

tighten the retaining screw by hand and then
tighten it by 1.5 further revolutions using the
wrench.

JSK/13

ZDE 199 002 108 04/2012 11

 4 Repair work
0 0

2 6
0 0

0 0

37
2 36

24
24

JSK/16 JSK/41

0 0

3 7
0 0

0 0

1/2´´ 0

140 Nm M 14
SW10
0

1/2´´
3
0

1/2´´

Nm

11 1

10
JSK/18 JSK/20

0 0

4 8
0 0

1/2´´ 35 36 0

SW7
0

1/2´´

1/2´´
49 Nm
Nm 38

JSK/40 JSK/21

5
0

0
10

JSK/19

12 ZDE 199 002 108 04/2012

 4 Repair work

4.9 To check for wear/wear limits

0

3
0

If the wear limit is reached, the component in 0

question must be replaced. 0

≥ 5 mm
0

1
0

10 1
150 mm
0

0
≥ 5 mm

17,5 -19 mm

JSK/27

30,5 -33,5 mm
 With version C, there must be a distance of at
0

JSK/47
least 5 mm in both the coupled-up and loaded
0

state.
0

1a
0

4
0

0
150 mm
0

0
17,5 -20,5 mm 0

36

< 5 mm

JSK/25

0
JSK/38

2
0

 The bearing of version E must exhibit a play of

0
no more than 5 mm. To check, lift the coupling
plate with a lifting lever.
150 mm
0

71-73 mm
84-82,5 mm

49-50,8 mm

JSK/26

ZDE 199 002 108 04/2012 13

 4 Repair work

0 0

5 6
0 0

0 0

150 mm
7 150 mm 7
0 0

0 0

0 mm

7 7

>10 mm

JSK/31 JSK/30

 Locking mechanism when new  Locking mechanism wear limit

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
10 mm. If the distance is less than 10 mm, the
handle (7) and the lever (6) must be checked
for warping.
0
The locking mechanism is worn if the distance
between the lever's bearing eyelet and the
abutment rib is 0 mm (top picture) or the outer
edge engages (bottom picture). The locking
mechanism cannot be adjusted any further at
this point.

7
0

150 mm
0

50 mm B
8 mm JSK/32

 The 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, in other
words up to approx. 3 mm lower than the
bottom of the lubricating groove, is permitted in
exterior part "B" over the bearings.
This does not apply to the W version.

14 ZDE 199 002 108 04/2012

 4 Repair work

4.10 Function test

0

8
0

39 40
1
0

150 mm
40 39 0
0

0
> 6 mm 7
150 mm
0

40
3- 0 mm
40
39
45 Nm 40
JSK/43

 In the case of fifth wheel couplings of

version W, the wear limit of the top plate
liners (39) is reached when they are worn up to
the top of the securing screws (40).
7

Service instructions for JOST sliders of

type JSK SL
0

9
0

6 B A
150 mm
0

0
12
10 mm

B
JSK/83

 If the fifth wheel coupling is worn on one slider,

0

this must be replaced once per slider if the wall A

thickness of the pedestal (12) is at least 10 mm
on each side before the coupling plate is re-
placed.
 The upper surfaces of the pedestals must be
greased before assembly with high-pressure
grease (EP).
4
JSK
 During the uncoupling process, the engaging
edge must be raised by at least 6 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 6 mm, the lever (6), the
handle (7) or the locking bar (4) must be
checked for signs of deformation and wear.

ZDE 199 002 108 04/2012 15

 4 Repair work

4.11 To adjust the locking mechanism

0

1
0

150 mm
1
0

B
0
SW 24 7 23 20

1500 gr.
A
0

SW 24
0

23
20

JSK/33

The locking mechanism must be adjusted using a Note:

semi-trailer without forced steering (or on a  If there is still excessive play, the wearing ring
SK 2702-10 workbench) as described below: and the lock jaw must be replaced as
described in the repair instructions.
 Uncouple the tractor unit on a flat, firm piece of 0

ground
 Undo the lock nut (23)
 Unscrew the adjusting screw (20) by approxi-
mately 15 turns
 Couple up the semi-trailer, introduce the king
pins into the fifth wheel coupling and close the
lock. If necessary, move the locking bar to its
terminal position by giving the handle (7) a few
gentle knocks in the locking direction A.
 Unlock the handle (7), swing it into position B
and hold it there (get a helper to hold it)
 Tighten the adjusting screw (20) again until the
handle (7) starts to move (have a helper check
this)
 To set 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 (23)
 Apply the semi-trailer brake
 Move off with the tractor and check the
maximum play in the locking mechanism.

16 ZDE 199 002 108 04/2012

 5 Spare parts for version JSK37C/CZ

20 23 22 16 10 11 21 19 25 26

35 36

18

27
28
29
13 9

14 32

30
16
15 33
12

24
2 1 3 4 5 6 8 7 34 31
JSK/35
0 0

Item No. Designation Order No. Item No. Designation Order No.
1 Lock jaw SK 1489 31 Handle SK 3521-02
1 Lock jaw JSK 37CZ SK 1489 Z 32 Cable, complete SK 2421-50
2 Spring SK 847 33 Hexagonal screw, complete SK 1974
3 Locating pin SK 2106-67 35 Splint
JSK 37C up to serial No. xx23 xxxxxx
4 Locking bar SK 3205-06 JSK 37CZ up to serial No. xx24 xxxxxx
5 Locking bolt, complete SK 3221-01 36 Spring hook SK 1436
6 Lever SK 3105-18 JSK 37C up to serial No. xx23 xxxxxx
JSK 37CZ up to serial No. xx24 xxxxxx
7 Handle (normal design) SK 3105-15 0

8 Hexagonal screw, complete SK 1513

9 Double spring SK 3105-20 Item No. Repair kits for Order No.
10 Wearing ring SK 2105-19 JSK 37C
11 Cylinder screw SK 2121-07 1,2,3,10,11 Repair kit for locking mechanism SK 3221-50
12 Pedestal 185 mm SK 2104-01 1,2,3 Repair kit for locking mechanism SK 3221-52
12 Pedestal 150 mm SK 2104-02 1,2,3,8,10,11,36 Repair kit for locking mechanism SK 3121-50
12 Pedestal 170 mm SK 2104-21 Up to serial No. xx23 xxxxxx
12 Pedestal 250 mm SK 2104-14 1,2,3,8,10,11 Repair kit for locking mechanism SK 3121-56
From serial No. 0428 xxxxxx
12 Pedestal 300 mm SK 2104-20
13,14,16 Repair kit for bearing SK 2121-69
13 Top rubber cushion SK 1259 0

14 Bottom rubber cushion SK 2105-25

15 Bridge SK 1372 Item No. Repair kits for Order No.
16 Countersunk screw, complete SK 2121-15 JSK 37CZ
18 Greasing nipple SK 3121-11 1,2,3,8,10,11,25 Repair kit for locking mechanism SK 3221-50 Z
19 Lubrication pipe SK 1989 1,2,3,25 Repair kit for locking mechanism SK 3221-52 Z
20 Adjusting screw SK 3105-05 1,2,3,8,10,11,25, Repair kit for locking mechanism SK 3121-50 Z
21 Screw connection SK 1976 36 Up to serial No. xx24 xxxxxx
22 Guide SK 3205-07 1,2,3,8,10,11,25 Repair kit for locking mechanism SK 3121-56 Z
From serial No. 0428 xxxxxx
23 Hexagonal nut SK 2121-78
13,14,16 Repair kit for bearing SK 2121-69
24 Eye bolt, complete SK 2122-04
25 Lubricating tube, complete + item 26 SK 3108-02 0

26 Cable tie SK 3121-13

27 Hexagonal screw, complete SK 3521-03 Item No. Retrofit kits Order No.
From serial No. 0428 xxxxxx
1,25 JSK 37C in JSK 37CZ SK 3108-05
28 Spring loop with spacer tube SK 3121-59
From serial No. 0428 xxxxxx 32,33,34 Handle extension, complete SK 3121-063
29 Latch, complete SK 3121-52
From serial No. 0428 xxxxxx SK 3105-115
30 Safety lever SK 3105-113

ZDE 199 002 108 04/2012 17

 6 Spare parts for version JSK37E

20 23 22 10 11 21 19 25

26

18

12
27
28
29
9

13

30
14 32

24 33

15
16
2 1 3 4 5 6 8 7 35 31
JSK/36
0 0

Item No. Designation Order No. Item No. Designation Order No.
1 Lock jaw JSK37AZ SK 1489 Z 31 Handle SK 3105-113
2 Spring SK 847 32 Cable, complete SK 3521-02
3 Locating pin SK 2106-67 33 Hexagonal screw, complete SK 2421-50
4 Locking bar SK 3205-06 41 Collar SK 3105-95
From serial No. xx31xxxxxx
5 Locking bolt, complete SK 3221-01 0

6 Lever SK 3105-18
7 Handle (normal design) SK 3105-15 Item No. Repair kits for Order No.
8 Hexagonal screw, complete SK 1513 JSK 37E
9 Double spring SK 3105-20 1,2,3,10,11,25 Repair kit for locking mechanism SK 3221-50 Z
10 Wearing ring SK 2105-19 1,2,3,25 Repair kit for locking mechanism SK 3221-52 Z
11 Cylinder screw SK 2121-07 1,2,3,8,10,11,25 Repair kit for locking mechanism SK 3121-56 Z
12 Pedestal 150 mm SK 2904-42 13,14,15 Repair kit for bearing SK 3121-58
12 Pedestal 172 mm SK 2904-41 Up to serial No. xx28xxx
12 Pedestal 185 mm SK 2904-40 13,14,15,41 Repair kit for bearing SK 3121-61
From serial No. xx31xxxxxx
13 Rubber sleeve, complete SK 2905-94 0

14 Locating pins + item 16 SK 3104-05

15 Hexagonal screw, complete SK 3121-28 Item No. Retrofit kits Order No.
16 Stoppers JS 1101-12 32,33,35 Handle extension, complete SK 3121-063
18 Greasing nipple SK 3121-11
19 Lubrication tube SK 1989
20 Adjusting screw SK 3105-05
Up to serial No. xx28xxx
20 Adjusting screw SK 3105-97
From serial No. xx31xxxxxx
21 Screw connection SK 1976
22 Guide SK 3205-07
23 Hexagonal nut SK 2121-78
24 Eye bolt, complete SK 2122-04
25 Lubricating tube, complete + item 26 SK 3108-02
26 Cable tie 3121
27 Hexagonal screw, complete SK 3521-03
28 Spring loop with spacer tube SK 3121-59
29 Latch, complete SK 3121-52
30 Safety lever SK 3105-115

18 ZDE 199 002 108 04/2012

 7 Spare parts for version JSK37CW/EW

36 37 38 39

42
40

41

JSK/37
0

Item No. Designation Order No.

36 Wearing part SK 3105-92
37 Securing ring SK 3105-93
38 Cylinder screw SK 3121-55
Top plate liner right SK 3105-129R
Top plate liner left SK 3105-129L
40 Countersunk screw SKE 001006000
41 Collar only for EW version SK 3105-95
0
42 Adjusting screw SK 3105-97

Item No. Repair kits for Order No.

JSK 37CW/EW
39, 40 Repair kit for liner SK 3106-003

ZDE 199 002 108 04/2012 19

8 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.

20 ZDE 199 002 108 04/2012

Siemensstraße 2, D-63263 Neu-Isenburg, Telefon +49 6102 295-0, Fax +49 6102 295-298, www.jost-world.com
ZDE 199 002 108 04/2012