INSTALLATION OUTLINE FOR JOHNNY JAWS 5.0 WITH CAN CUSHION TECHNOLOGY

 

PACKING LIST

 

CRATE  CONTENTS WILL BE THE SAME, PASSENGER AND DRIVERS SIDE BACK PLATES, WITH INDICATORS, KEEPER  AND AIR CYLINDER PRE BOLTED. 

OTHER PACKAGE(S) CONTENTS ARE:​

  1. 2 AIR SPRING COVERS W/ AIR SPRING  AND AIR FITTING ATTACHED

  2. 2 CYLINDER GAURDS W/BUMPERS ATTCHED (PASSENGER AND DRIVER’S SIDE)

  3. 2 PIVOT BOLTS

  4. 2 LINK ARMS

  5. 2 RETURN SPRINGS

  6. 1 CONTROL BOX W/ 2 -1/4” AND 2 -3/8” BARRELL CONNECTORS

  7. P.S.I. REGULATOR W/ 3/8” NPT X 3/8” QUICK CONNECT FITTINGS

  8. 2 SPACER PLATES  (BOLT-ON) OR 4 RADIUS MOUNTS  (WELD-ON TO BOLT-ON)

  9. 1 BOX W/FASTNERS, FITTINGS AND SWITCHES

HARDWARE LIST

  1. 8 – 5/8” X (3 ¼” and or 3 ½” BOLT-ON APP OR 2” WELD-ON APP) BOLTS

  2. 16 (BOLT) OR 8 (WELD) NOR-LOCK WASHERS MOUNTS

  3. 16 (BOLT) OR 8 - 5/8” (WELD) FLAT WASHERS MOUNTS

  4. 8 – 5/8” NUTS MOUNTS (BOLT-ON APP)

  5. 4 - HEX HEAD, 3/8" - 16 UNC X 2 " LG. REAR AIR SPRING

  6. 18 - HEX HEAD, 3/8" - 16 UNC X 3/4" LG. GUARD MOUNT

  7. 2 - HEX HEAD, 1/4"-20 UNC X 5/8" LG. PIVOT

  8. 18 - 3/8" LOCKWASHERS AND FLAT WASHERS

  9. 2 - 1/2" EXTENAL RETAINING RING. LINK ARMS

  10. 2 - 1/4" LOCK AND FLAT WASHER  

  11. 4- 1/2" FLAT WASHER SPRING

  12. 4 - 1/8" COTTER PIN X 1" LG. SPRING

  13. 2 - 1/2" SHIM WASHER LINK ARM

  14. 2 – 3/8” O. D. “T” CONNECTORS

  15. 2 – ¼” O. D. “T’ CONNECTORS

  16. 5 – HEX HEAD ¼” X 1½” SELF TAPPING SCREWS

  17. OPTIONAL 1 GUIDE PLATE FOR WELD-ON TO BOLT-ON APPLICATION

 

OPTIONAL

  1. 40’ OF COVERED TRI - AIR LINE

  2. 50 ZIP TIES

  3. 50’ OF RED AND WHITE WIRE

  4. 2 – BUTT CONNECTORS

  5. 4 – FEMALE ELECTRICAL CONNECTORS

  6. 2 – INTERRUPTOR SWITCHES

PLEASE READ THROUGH THE ENTIRE INSTRUCTIONS BEFORE STARTING THE INSTALL.  THE MAIN OBJECTIVE IS TO MOUNT THE JAWS AS LOW AND TOUCHING THE INNER FORKS.  PLEASE GRIND/CLEAN ALL EDGES OF THE FORKS.

 

  1. PARK AND SECURING TRUCK IN COMPLIANCE WITH ALL SAFTEY REGULATIONS.

  2. PLACE ARMS SO THAT THE FORKS ARE LEVEL AND OR AT PROPER HIEGHT FOR WORKING AROUND THE CONTAINER BUMPER AREA.

  3. UNBOLT CONTAINER BUMPERS OR IF WELDED FOLLOW a thru e

 

 

WELD-ON APPLICATION

   A. Cut off bumper assembly exposing the metal of the fork tube. See picture below.

   B. Secure Radius Mounts to guides using the 5/8” x 2” bolts

   C. Place guide against fork, arrow pointing to fork. SECURE, CENTERING THE MOUNTS ON THE FORK PIVOT TUBE

   D..Tack the mounts then unbolt guide and finish welding all 4 sides WITH A 1/2 INCH WELD.

  1. Repeat on other side

  2. Bolt Back Plate using Parts 1, 2, 3.

 

 

BOLT-ON APPLICATION

  1. TEMPORARILY PLACE THE 1 1/4" BLACK 4 HOLED SPACER CENTER  AT THE BOTTOM OF THE BUMPER WINDOW, CHECKING ALIGNMENT OF ALL FOUR HOLES, MARK IMPEDING MATERIAL, REMOVE SPACER THEN IMPEDING METAL

  2. PLACE JOHNNY JAWS REAR PLATE IN LINE WITH MARK HOLES, VERIFYING FIT

  3. ADJUST HOLES TO FIT 5/8” X 3 ½” (1) BOLTS PROVIDED

  4. ALIGN SPACER OVER NEW HOLES

  5. PLACE AND ALIGN J JAWS OVER TOP OF SPACER

  6. USING PARTS 1, 2, 3 ON THE FRONT AND 2, 3, 4 ON THE REAR BOLT J JAWS IN PLACE

 

REPEAT 1 THRU 8 ON OPPOSITE SIDE

 

ASSEMBLING YOUR JOHNNY JAWS

 

 

CAUTION THERE ARE DRIVER AND PASSENGER SIDE PARTS, THE DIFFERENCE CAN BE SUBTLE

 

  1. PLACE THE AIR BAG ASSEMBLY ROD AND REAR AIR FITTING INTO THE PROPER HOLES NOTE THERE IS A LEFT AND RIGHT

  1. INSERT PIVOT PIN AND SECURE WITH 7, 10.

  1. SECURE THE AIR SPRING THRU THE REAR OF THE JAWS USING 2 OF 5, 10​​

  1. INSTALL RETAINING SPRING ASSEMBLY AND SECURE USING 2 OF 6, 10  THEN INSTALL THE SPRINGS, BUSHINGS, WASHERS AND COTTER PINS 10, 12..

 

REPEAT 1 THRU 7 TO OPPOSITE SIDE

 

NEXT INSTALL THE GREY CONTROL BOX, PREFFERENCE IS NEAR THE ARM PIVOT TUBE UNDER THE BODY WITH LINES POINTING DOWN OR TOWARDS THE REAR.  GROUND BLACK WIRE TO MOUNTING SCREWS AND ATTACH THE REGULATOR TO THE COVER OR NEAR BY.

 

CONNECT THE "IN" SIDE OF THE REGULATOR TO THE 3/8 LINE THAT COMES OUT OF THE COVER.

 

RUN YOUR AIRLINES, SUPPLY THE AIR SPRINGS TO THE OUT-LINE OF THE REGULATOR WITH 3/8"

CONNECT THE BLUE 1/4" LINE FROM THE CONTROL BOX TO THE BLUE ELBOWS ON THE CYLINDERS

CONNECT THE BLACK 1/4" LINE FROM THE CONTROL BOX TO THE BLACK ELBOWS ON NTHE CYLINDERS 

RUN ONE LINE FOR EACH, TEEING OFF AT THE INITAL JAWS (PASSENGER OR DRIVERS SIDE DEOENDING ON WHICH SIDE YOU MOUNTED THE CONTROL BOX)

1) INSTALL THE CYLINDERS GAURDS

 

 

 

 

 

 

 

 

 

 

 

 

 

INSTALL TWO INTERUPTOR SWITCHES IN THE CAB PLACEMENT IS SUBJECTIVE.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ADD 12 VOLT POWER THE SWITCHES INCORPORATING A IN-LINE FUSE...

 

RUN TWO WIRES, RED for cylinder AND WHITE for air springs, FROM THE SWITCHES TO THE GREY BOX, CONNECTING THE SAME COLORS.

 

TAP AN AIR SUPPLY (PTO)LINE NEAR THE AIR TANK WITH 3/8 T PROVIDED

 

CONNECT T TO GREY BOX 3/8 BARRELL COUPLER MARKED PTO

 

GREASE FITTING ON PIVOT PIN AND LATCH AREA

 

TEST UNIT: CAB SWITCHES WHEN POSITIONED TOWARDS DRIVER CYLINDER ARE TO BE DOWN AND AIR SPRINGS COLLASPED.  

HERE ARE SEVERAL REFFERNCE PICTURE TO HELP GUIDE YOU THOUGH OUT YOUR  INSTALL