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Kingpin KGZ 31DE Montage- und BetriebsanleitungEN Installation and operating instructionFR Instructions de montage et d'utilisationIT Istruzioni per il montaggio e l’usoES Instrucciones de montaje y funcionamiento
Kingpin KGZ 31DE Montage- und BetriebsanleitungEN Installation and operating instructionFR Instructions de montage et d'utilisationIT Istruzioni per il montaggio e l’usoES Instrucciones de montaje y funcionamiento
Kingpin KGZ 31 MUB 005 002 M01 (REV-A) 11-2016 3
Montage- und Betriebsanleitung 5
DE
Installation and operating instruction 14
EN
Instructions de montage et d'utilisati-on
23
FR
Istruzioni per il montaggio e l’uso 32
IT
Instrucciones de montaje y funciona-miento
41
ES
Table of contents
EN
14 MUB 005 002 M01 (REV-A) 11-2016 Kingpin KGZ 31
1 Explanation of symbols......................................... 15
2 Safety information.................................................. 162.1 Safety information for installation.............................. 162.2 Safety information for servicing................................. 16
3 Proper usage........................................................... 173.1 Application................................................................. 173.2 Design........................................................................ 17
4 Installation............................................................... 184.1 Suggested installations.............................................. 204.2 Weld seam thickness................................................ 21
5 Servicing and testing............................................. 225.1 Kingpin 50 (2")........................................................... 225.2 Test instructions......................................................... 225.3 To check for wear...................................................... 22
1 Explanation of symbols
EN
Kingpin KGZ 31 MUB 005 002 M01 (REV-A) 11-2016 15
WARNING!Means that death, serious phys-ical injury or significant materi-al damage can occur if the rel-evant safety instructions are notfollowed.
ATTENTION!Means that slight physical injuryor material damage can occurif the relevant safety instructionsare not followed.
ADVICE!Contains additional important in-formation.
2 Safety information
16 MUB 005 002 M01 (REV-A) 11-2016 Kingpin KGZ 31
The relevant safety regulations in your coun-try (for example Health & Safety at Work)apply for working with fifth wheel couplings,tractor units, semi-trailers and the kingpin.
The relevant safety information in the own-er's handbook for the tractor unit and thesemi-trailer remains valid and must be fol-lowed.
The following safety information applies tothe operating, servicing and assembly work.Safety information directly linked to the ac-tivity is listed again individually.
ADVICE!Technical modifications re-served. The latest informationcan be found atwww.jost-world.com
2.1 Safety information for installa-tion
– Only original JOST spare parts must beused.
– Damaged and repaired (e.g. repair bydeposition welding) individual partsmust not be used.
– If the kingpin is not installed correctly,all warranty claims against the manu-facturer and the supplier of the kingpinwill be rendered void.
– The kingpin must only be installed byauthorised specialist workshops.
– Refer to the instructions issued by thevehicle manufacturer, for exampleregarding the type of fastening, fifthwheel position, fifth wheel height, axleload, clearance, etc.
2.2 Safety information for servic-ing
– Only use the specified lubricants forservicing work.
– The servicing work should only be com-pleted by trained personnel.
The licensing regulations of the appropriatecountry must also be complied with.
3 Proper usage
EN
Kingpin KGZ 31 MUB 005 002 M01 (REV-A) 11-2016 17
3.1 ApplicationKingpins provide the link between the tractorunit and the semi-trailer. They are designedfor mounting on the semi-trailer.
Kingpins are vehicle-connecting parts thatmust comply with very high safety require-ments and must also undergo design ap-proval tests.
Modifications of any kind will render both thewarranty and the design approval void andtherefore also cancel the vehicle's operatinglicence.
3.2 DesignThe D value is a criterion for the load capac-ity of kingpins. It is calculated using the fol-lowing formula:
D = Draw bar value [kN]g = 9.81 m/s2
R = Max. total weightSemi-trailer [t]
p = Max. total weightWeight of the towing vehicle, in-cluding U [t]
U = Permitted fifth wheel load [t]
D = g x [kN]0.6 x T x RT + R - U
Sample calculation:
R = 33 tp = 17 tU = 10.5 t
D = 9,81 x = 83,6 kN0,6 x 17 x 3317 + 33 - 10,5
The permitted D value can be found in thetable below. This information can also befound on the relevant pages of the JOST cat-alogue and is embossed on the front of thekingpin.
H 50-XD16
2E155R - 0
1XXXXKingpin
Type KGZ311
2KGZ/039
1 Type2 D value in KN
If they are subject to additional dynamicforces, for example if they are used on un-even road surfaces or on construction sites,do not use the complete fifth wheel load andD value, or alternatively, consult JOST.
Permitted load data
Type Test mark Design designation D value [kN]
KGZ 31 E1 55R - 01 2719 KGZ 3106 - KGZ 3112 162
4 Installation
18 MUB 005 002 M01 (REV-A) 11-2016 Kingpin KGZ 31
ADVICE!When installed, the kingpinsmust extend by a tolerated lon-gitudinal distance from the se-mi-trailer plate.
WARNING!Sharp edges and protrudingwelding seams can cause seri-ous injuries.
Before installation, the semi-trailer platemust be checked to ensure it is even, andthe semi-trailer plate thickness must also bechecked. The unevenness of the semi-trail-er plate must be no more than 2 mm inthe load-bearing section of the fifth wheelcoupling. The semi-trailer plate must coverthe fifth wheel coupling's set-down surfacein every position. The design designation ofthe kingpins is made up as follows:
For example:KGZ31 12
12 mm semi-trailer plate thickness in mm KGZ31 - type (type series)
Permissible tolerances of the semi-trailerplate in mm:
+ 0.6 + 0.6 + 0.4 + 0.4 + 0.2
6 mm 7 mm 8 mm 10 mm 12 mm
- 0.1 - 0.1 - 0.3 - 0.3 - 0.5
4 Installation
EN
Kingpin KGZ 31 MUB 005 002 M01 (REV-A) 11-2016 19
When the mounting flanges or mounting cones are being welded, the following welding methods are permitted with the specified additionalmaterials and welding materials:
Welding method according toISO 4063
111 135 135
Welding additive(approved by one of the followingorganisations: BV, DB, DNV, GL,LR, TÜV)
Rod electrode Welding wire Inert gas
Standard nameWelding additive/Welding consumables
ISO 2560-A- E 35 3 B
ISO 2560-A- E 38 3 B
ISO 2560-A- E 42 3 B
ISO 14341-A-G 38 3 C1 2Si
ISO 14341-A-G 42 3 M21 2Si
ISO 14341-A-G 42 3 C1 3Si1
ISO 14341-A-G 42 4 M21 3Si1
ISO 14341-A-G 46 3 C1 4Si1
ISO 14341-A-G 46 4 M21 4Si1
ISO 14175 - C1
ISO 14175 - M21
ATTENTION!The quality of the welding must satisfy the requirements of evaluation group B in accordance with EN ISO 5817.The choice of welding material must be made in accordance with the stability of the substrate material used.
4 Installation
20 MUB 005 002 M01 (REV-A) 11-2016 Kingpin KGZ 31
Welding seam preparation is the responsi-bility of the user, in accordance with tech-nological regulations. The semi-trailer platemust be adequately reinforced according tothe load. The vehicle constructor will decideon the type and dimensions of the reinforce-ment. For stability reasons we recommenda semi-trailer plate thickness of 12 mm for 2"kingpins (recommended material: EN 10025S355J2G3). The kingpins must be installedcentred and at right angles. Suggested in-stallations and tightening torques can befound in the following table:
Screw/nutType des-ignation Art. No. Size
Tight-eningtorquein Nm
KGZ 3106-KGZ 3112 KZE1012-03 M14 x 35 190 ± 10
ATTENTION!The installed kingpins must beprotected from weld spatter. Af-ter welding, the fastening nutsand screws must be checked toensure they are at the correcttightening torque and tightenedas necessary. After installation,check the tolerated length dimen-sion by which the kingpin projectsout of the semi-trailer plate. Theadjustment and functional sur-faces must be masked beforepainting.
4.1 Suggested installationsDepending on the type of semi-trailer plate,there are different options for fitting the king-pins. The various options are described ingraphic form below. (The flange hole patternis shown rotated around 22.5°).
The residual collar protects the mountedparts during the coupling process and mustbe installed in the direction of travel (see De-tails 3).
B-B aa
A-ABB
Direction of travelA
A
KGZ/40
1
KGZ/41
2 3 Direction of travel
aa
Residual collar
4 Installation
EN
Kingpin KGZ 31 MUB 005 002 M01 (REV-A) 11-2016 21
4.2 Weld seam thickness
a2
1
b
a
6
KGZ/06
The required weld thickness "a" for weldingthe mounting flange depends on the thick-ness of the semi-trailer plate.
a (weldseam thick-
ness)
Type des-ignationKZ 31YY
b (se-mi-trail-er plate
thickness)1 2
YY = 06 6 mm 4 mm 6 mm
YY = 07 7 mm 5 mm 6 mm
YY = 08 8 mm 5 mm 7 mm
YY = 10 10 mm 7 mm 7 mm
YY = 12 12 mm 8 mm 8 mm
5 Servicing and testing
22 MUB 005 002 M01 (REV-A) 11-2016 Kingpin KGZ 31
Before commissioning the semi-trailer, thekingpin, the semi-trailer plate and the fifthwheel coupling lock must be greased thor-oughly. We recommend the use of JOSThigh-performance lubricant (Art. No. SKE005 670 000). Generous lubrication of thekingpin and fifth wheel coupling is essentialfor a long service life.
5.1 Kingpin 50 (2")
New diameter 73min . diameter 71
New diameter 50.8min . diameter 49
max
. 8
4 m
mm
in.
82.
5 m
m
KGZ/43
5.2 Test instructionsDepending on the conditions of use, butafter no more than 50,000 km or everysix months, the mounting plate, the king-pins and the fastening elements must bechecked to ensure they are functioningproperly and are free from wear, damage orcracks and repaired as necessary. The fas-tening elements must be checked to ensurethat they are tightened to the correct torque.
5.3 To check for wearFifth wheel couplings and kingpins are sub-ject to more or less wear depending onthe conditions in which they are used, andthis wear is noticeable by play towards thefront of the vehicle. Excessive play causesshocks and may lead to instability on theroad and damage to the fifth wheel coupling,mounting plate and vehicle chassis.
ATTENTION!The wear on the kingpin must notbe compensated by adjusting thefifth wheel coupling.
When the wear limit on the kingpin has beenreached, it must be replaced. After the king-pin has been replaced, the locking mech-anism on the fifth wheel coupling must bereset. Play caused by wear on the kingpinshould either be accepted within the permit-ted wear limit for the kingpin or should berectified by fitting a new kingpin.
JOST, Germany, Tel. +49 6102 295-0, [email protected], www.jost-world.com
MUB 005 002 M01 (REV-A) 11-2016 • 3.3