Montage- und Betriebsanleitung

KÖNIGSZAPFEN

GB Installation and operating instructions

for King Pins
F Instructions de montage et d’utilisation
pour pivot d’attelage
I Istruzioni per il montaggio e l’uso
del perno d’articolazione
E Instrucciones de montaje y funcionamiento
para el king pins
 Fore w ord Cont e nt s Pa ge
0

1 Safety instructions 14
Subject to technical changes. The latest information can be
! found at: www.jost-world.com
1.1
1.2
Safety information for installation
Safety information for servicing
14
14

2 Intended use 15
2.1 Application 15
2.2 Design 15

3 Installation 17

English
3.1 Installation suggestions 18
3.2 Weld seam thickness 19

4 Servicing and testing 20

4.1 Kingpin 50 (2“) 20
4.2 Kingpin 90 (3.5“) 20
4.3 Test instructions 20
4.4 Wear test 20

Kingpins ZDE 199 005 018 – 10/2010 13

 1 Sa fe t y inform a t ion

The relevant safety regulations in your country (for example Health & 1.2 Safety information for servicing
Safety at Work) apply for working with fifth wheel couplings, tractor Only use the specified lubricants for servicing work.
units, semi-trailers and the kingpins.
The servicing work should only be completed by trained
The appropriate safety information in the owner’s handbook for the personnel
tractor unit and the semi-trailer are valid and must be followed.
The applicable licensing regulations of the appropriate country are to
The following safety information apply to the installation, servicing and be observed.
mounting work. Safety information directly linked to the activity is listed Sections §§ 19, 20 and 21 of the German Road Traffic Act apply in
again individually.
Germany. In addition, the requirements of § 13 of the FZV Traffic Act
must be met with regard to the data in the vehicle documents in terms
0

Safety information in the following sections is shown of the maximum trailer load.
! with the warning triangle symbol. You must comply with
this safety information.

1.1 Safety information for installation

Only original JOST replacement parts may be used.

Damaged or repaired parts (e.g. repair by overlay welding) may
not be used.
Incorrect installation will invalidate all warranty claims against
the manufacturer and the supplier of the kingpin.
The kingpin may only be installed by authorised specialists.
Refer to the instructions issued by the vehicle manufacturer, for
example the type of fastening, fifth wheel position, fifth wheel
height, axle load, cavity etc.

14 ZDE 199 005 018 – 10/2010 Kingpins

2 I nt e nde d use

2.1 Use 2.2 Design

Kingpins provide the link between the tractor unit and the semi-trailer. The D-value is a criterion for the strength of kingpins. It can be
They are designed for mounting on the semi-trailer. calculated using the following formula:
Kingpins are connecting parts that must comply with very high safety
requirements and must also undergo design approval tests. D= Drawbar value [kN]
Modifications of any kind will invalidate both the warranty and the g= 9.81 m/s2
design approval and therefore also cancel the vehicle’s operating
R= Maximum gross weight of the semi-trailer [t]

English
licence.
T= Maximum gross weight of the tractor unit including U [t]
U= Maximum fifth wheel load [t]

Specimen calculation:

T= 17 t
R= 33 t
U= 10.5 t

Kingpins ZDE 199 005 018 – 10/2010 15

2 I nt e nde d use

The permissible D-values and the respective type Permissible load data
(Type series, e.g. KZ 10) can be obtained from the table opposite.
These specifications are likewise to be found on the respective JOST D value in
catalogue sheets and are imprinted on the end face of the kingpin. Test code type King pin kN

e1 00-0145 KZ 1008-1012 162

KZ 10
e1 00-0146 KZ 1108-1112 152
1 KZ 11
fen 0 2
lz ap 1 e1 00-0147 KZ 1410-1412 162
tte
a KZ 162 XX
g s D XX X
KZ 14
Zu p X X XX- XXX e1 00-0148 KZ 1516 170
Ty XXX XX
X
X XX
KZ 15
XX
XX XXX e1 00-0150 KZ1016 320
KZ 1016
e1 00-0151 KZ 1116 260
KZ 1116
e1 00-1572 KZ 1416 170
KGZ/020
KZ 1416
1 Type F 3458 KZ 1312 105
2 D value in kN KZ 1312
If kingpin is subject to additional dynamic forces, for example if used KZ 2816 152
on uneven road surfaces or on construction sites, do not use the full
imposed load and D value or use a stronger fifth wheel coupling or
consult JOST.

16 ZDE 199 005 018 – 10/2010 Kingpins

3 I nst a lla t ion

JOST kingpins comply with the applicable standards. When welding the mounting dish or mounting cones into place, the
! When fitted, the kingpin must protrude from the upper fifth following welding procedures are permissible with the specified
wheel plate by a length measurement subject to additional materials and welding materials:
tolerances.
Welding E II MAG C/MAG M MAG C/MAG M
Sharp edges and protruding weld seams can result in procedure
! serious injuries.
Additional Rod electrode Welding wire ––
material

English
Before installation, the evenness and the thickness of the fifth wheel
plate must be checked. The unevenness of the fifth wheel plate in the Welding –– –– Inert gas
material
load-bearing area must not exceed 2 mm. The fifth wheel plate must
cover the bearing surface of the fifth wheel in every position. Standard ISO 2560-A- ISO 14341-A-G 42 0 ISO 14175 - C1
The design designation of the kingpins is composed from the following designation E 35 0 (min) M(C) G3Si1 ISO 14175 - M21
elements: A5 ISO 14341-A-G 42 0 ISO 14175 - M24
M(C) G4Si1
e.g.:KZ10 12
12 - fifth wheel plate thickness, in this case 12 mm Other welding methods and additional materials approved by TÜV can
KZ10 - Type (series), in this case KZ10 also be used for the basic material used.

Permissible tolerances of the fifth wheel plate in mm, apart from

KZ1106 to KZ1112 and KZ1116:

+ 0,6 + 0,6 + 0,4 + 0,4 + 0,2 + 0,3

6 mm 7 mm 8 mm 10 mm 12 mm 16 mm
- 0,1 - 0,1 - 0,3 - 0,3 - 0,5 - 0,5

Permissible tolerances of the fifth wheel plate in mm for types KZ1106

to KZ1112 and KZ1116:

+0
6 mm to 16 mm
- 0.3

Kingpins ZDE 199 005 018 – 10/2010 17

3 I nst a lla t ion

The preparation of the welding seam is the responsibility of the user, 3.1 Suggested installations
subject to the regulations of the technology. The fifth wheel plate is to Depending on the type of fifth wheel plate, there are various options
be stiffened sufficiently corresponding to the load. The vehicle for fitting the kingpins (see Figures 1 - 6). The various options are
manufacturer decides on the type and dimension of the stiffeners. For shown in the following diagrams. (the flange hole template is shown
reasons of stability, we recommend for 2" kingpins a fifth wheel plate rotated by 22.5° in each case).
thickness of 12 mm and for 3.5" kingpins a fifth wheel plate thickness
of 16 mm (recommended material: EN 10025 S355J2G3). The 0

kingpins must be installed centrally and at right angles. Kingpins with

a taper are to be properly seated (by hammering) after cleaning the 1 Direction of travel
joining surfaces. The crown nut must be tightened to the specified A
torque and secured with a cotter pin. Suggested installations and
tightening torques are listed in the table below:

Type designation Bolt/nut Tightening

torque in Nm
Part no. Size
B
KZ1006 - KZ1012 KZE 1012-03 M14 x 35 190 ± 10 A A-A
KZ1410 - KZ1412
KGZ5006 - KGZ5012
KZ0906 - KZ0912 KZE0912-06 M14 x 1.5 190 ± 10 KZ 1012 (2")

KZ1712
a
KZ1416, KZ2816 KZE1416-03 M16 x 45 280 ± 15 a

B-B KGZ/01
KZ1016, KZ1516 KZE1016-06 M20 x 50 500 ± 30
+5
KZ1312 KZE1312-05 M14 120
-10

Once fitted, the kingpins must be protected against

! welding splatter. After welding in place, the fixing nuts or
bolts must be checked for the correct torque setting and
tightened if necessary. Before painting, the mating and
function surfaces must be covered.

18 ZDE 199 005 018 – 10/2010 Kingpins

3 I nst a lla t ion

3.2 Weld seam thickness

2 3
The required weld seam thickness
6 "a" for welding the mounting dish/
MA 1200 Nm
cone depends on the thickness of
a the fifth wheel plate.
KZ 1012 (2") KZ 1112 (2")

b
a a

English
a

KGZ/06

KGZ/02 KGZ/03

4 Type designation b (fifth wheel plate a (weld seam

KZ XX...... thickness) thickness)

MA 1500 Nm 06 6 mm 5 mm
07 7 mm 5 mm
KZ 1116 (3,5") a6
08 8 mm 6 mm
a 10 10 mm 7 mm
12 12 mm 8 mm
16 16 mm 8 mm

KGZ/04

8 x 45°

KZ 1312 (2")

X
- 2" : Ø 73.1 + 0.2
X

KGZ/05

Kingpins ZDE 199 005 018 – 10/2010 19

4 Se rvic ing a nd t e st ing

4.3 Inspection instructions

Before putting the trailer into service, the kingpin, the fifth wheel plate
and the fifth wheel coupling lock must be thoroughly lubricated with a Depending on the conditions of use, but at the latest every 50,000km
high-pressure grease (EP) with MoS2- or graphite additive (e.g. or every six months, check the function of the mounting plate, the
Turmogeargrease B2, from Lubcon (www.lubcon.com)). Generous kingpin and the fixing elements and also check for signs of wear,
lubrication of the kingpin and fifth wheel coupling is crucial for a long corrosion, damage or cracks and repair if necessary.
service life.
The respective fixings are to be checked to ensure that they are
4.1 Kingpin 50 (2") tightened to the correct torque.
0
0
0

7 0
0
4.4 Wear test
New Ø73
Fifth wheel couplings and king pins are subject to more or less wear
min. Ø71
depending on the conditions in which they are used, and this wear is

min. 82,5 mm
max. 84 mm
noticeable by play in the direction of travel.
New Ø50,8 Excessive play causes shocks and may lead to instability on the road
min. Ø49 and damage to the fifth wheel coupling, mounting plate, sliders and
vehicle chassis.
Wearing of the kingpin must not be compensated by
! adjusting the fifth wheel coupling.
KGZ/07
0

When the wear limit on the king pin has been reached, it must be
replaced.
4.2 Kingpin 90 (3.5")
0
After replacing the king pin, the locking mechanism on the fifth wheel
coupling must be readjusted.
0

8
New Ø114 Play caused by wear on the king pin should either be accepted if within
min. Ø112 the permitted wear limit for the king pin or should be eliminated by
max. 74 mm

fitting a new king pin.

min. 72 mm

New Ø89
min. Ø86

KGZ/08

20 ZDE 199 005 018 – 10/2010 Kingpins

Siemensstraße 2, D-63263 Neu-Isenburg, Telefon +49 6102 295-0, Fax +49 6102 295-298, www.jost-world.com
ZDE 199 005 018 10/2010