jost KKS-U User manual

KKS-U
EN Installation and operating instructions

2MUB 007 004 M01 (REV--) 05-2023

Table of contents
1 Explanation of symbols................................................. 4
2 General information...................................................... 5
2.1 Identification............................................................. 5
2.1.1 Modul E-Drive................................................ 5
3 Safety instructions........................................................ 6
3.1 Liability...................................................................... 6
3.2 Safety instructions for installation............................ 6
3.3 Safety instructions for operation.............................. 7
3.4 Safety instructions for maintenance......................... 8
4 Intended use................................................................. 10
4.1 General information................................................. 10
4.2 System requirements and properties for operating
the JOST KKS............................................................. 11
4.3 Target group and existing knowledge...................... 13
4.4 Content and purpose of this documentation........... 13
4.5 Application limits...................................................... 14
4.6 Principle.................................................................... 15
5 List of components........................................................ 16
5.1 Semi-trailer system components.............................. 16
5.1.1 Modul E-Drive landing gears......................... 16
5.1.2 Swivel wedge with kingpin............................ 16
5.1.3 Cable store with cables................................. 17
5.1.4 Exploded view............................................... 18
6 Installation.................................................................... 19
6.1 Installing and electrically connecting the valve unit. 19
6.2 Installing the cable store.......................................... 24
6.3 Installing the swivel wedge...................................... 26
6.4 Connecting the Modul E-Drive landing gears........... 37
6.4.1 Procedure for semi-trailers without Modul
E-Drive landing gears..................................... 37
6.4.2 Procedure for semi-trailers with Modul E-
Drive landing gears........................................ 37
6.5 Warning stickers....................................................... 39
6.6 Before starting up..................................................... 40
6.6.1 Checking the KKS system on the semi-trailer 41
6.6.2 KKS complete system check.......................... 41
7 Operation, maintenance and troubleshooting............... 44
EN
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1 Explanation of symbols
WARNING!
Means that death, serious physical injury or significant
material damage can occur if the relevant safety instruc-
tions are not followed.
ATTENTION!
Means that minor physical injury or material damage
can occur if the relevant safety instructions are not fol-
lowed.
IMPORTANT!
Contains additional important information.
ADVICE!
Points out that reading the documentation is an obliga-
tion!
Failure to comply with these instructions can result in
mishandling by personnel.
4MUB 007 004 M01 (REV--) 05-2023

2 General information
With the JOST automatic coupling system, known for short as
“KKS”, you have a complete, state-of-the-art vehicle coupling sys-
tem with safety and convenience standards that satisfy ECE-R55,
R13 and ISO 13044-2 requirements.
Improper handling of the automatic coupling system during
installation, repair or operation can result in dangerous sit-
uations. Please pay attention to warnings and safety notices
in section 3 "Safety instructions" and the instructions in
section 4 "Intended use". Please also heed all warnings and safety
notices in this installation and operating manual. You will find an
explanation of hazard symbols in section 1 "Explanation of sym-
bols".
Modifications of any kind may have an impact on safety and are not
permitted. Furthermore, modifications will rule out all warranty
claims and invalidate the vehicle operating licence. Do not use the
product until you are certain that the tractor unit and semi-trailer
on which the JOST KKS is fitted comply with road traffic regulations
in your country.
Please refer to the installation and operating manuals of the fol-
lowing products:
JSK 42 fifth wheel coupling
Kingpin
Modul E-Drive
KKS
IMPORTANT!
Technical modifications reserved. You can find the latest
information at www.jost-world.com.
2.1 Identification
2.1.1 Modul E-Drive
ADVICE!
You can find information on identification in the JOST
Modul E-Drive landing gears installation and operating
manual at www.jost-world.com.
EN
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3 Safety instructions
3.1 Liability
This documentation describes the product’s characteristics, but
without guaranteeing them.
No liability will be accepted for damage attributable to:
Any use of the KKS system other than its intended use.
Failure to comply with the documentation.
Unapproved modifications to KKS system components.
Inexpert work on and with KKS system components.
Operating the KKS system if safety and protective equipment
is faulty, incorrectly installed or not functioning.
Inadequate monitoring of wearing components of the KKS
system.
Incorrectly performed repairs.
Unapproved, inexpert modification of operating parameters.
Disasters, the impact of foreign bodies, and force majeure.
The relevant safety regulations in your country (e.g. Health &
Safety at Work) apply to working with fifth wheel couplings, tractor
units, semi-trailers and the JOST KKS. The safety instructions in the
tractor unit and semi-trailer operating manuals continue to apply
and must be followed. Adhere to the safety instructions below
for the operation, maintenance and installation of the JOST KKS.
Safety instructions directly linked to each activity are also included
in the relevant section.
3.2 Safety instructions for installation
Install the JOST KKS on the semi-trailer as described in section
"Installation".
WARNING!
Have the JOST KKS installed by trained personnel at a
suitable workshop. The fitting guidelines of the vehicle
manufacturer, the installation instructions, the require-
ments of ECE R13 and, if applicable, road traffic licens-
ing regulations, such as sections 19, 20 and 21 of the
StVZO in Germany, must be adhered to.
ATTENTION!
Pay attention to the following points:
Make sure that warning signs are not covered or
removed when the JOST KKS is installed.
Only use the electric cables and pneumatic hoses
supplied in the installation kit.
Correctly insulate exposed cable ends, e.g. using
end seals or heat-shrink tubing → risk of short cir-
cuit!
IMPORTANT!
Incorrect installation will invalidate all warranty claims
against the manufacturer and supplier of the JOST KKS.
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3 Safety instructions
ATTENTION!
Please note the following when installing electric
cables and pneumatic hoses:
The electric cables and air hoses must be installed
at an adequate distance from moving parts of the
vehicle. If necessary, provide electric cables with
corrugated heat protection tubing or an anti-chafe
guard.
Lay electric cables and pneumatic hoses in such a
way that they do not kink or chafe.
The electric cables and air hoses must be secured
using cable ties (e.g. to the vehicle wiring harness).
Perform work on the compressed air system only
when it is not under pressure.
Comply with the fitting guidelines of the vehicle
manufacturer.
ATTENTION!
Please note the following before carrying out any
work on the electrical system:
Switch off the power supply to the vehicle.
Disconnect all electrical connections to the vehicle
or, if necessary, disconnect the vehicle battery.
3.3 Safety instructions for operation
Before commencing any journey and each time a trailer is coupled
up, check that the equipment is in good condition and the locking
mechanism is secure. Only drive the vehicle with the locking mech-
anism locked and secured.
WARNING!
If the fifth wheel coupling is not correctly closed and
secured, the semi-trailer may become detached. This
can cause an accident, injuring you and others. After
coupling, always check that the fifth wheel coupling is in
good condition and securely locked. Always carry out a
pre-departure inspection, even if “Fifth wheel coupling
closed” (green) is shown on the display. The JOST KKS is
only an assistance function that helps you with the cou-
pling and uncoupling of semi-trailers.
EN
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3 Safety instructions
WARNING!
Pay attention to the following points:
Do not operate the JOST KKS when the vehicle is
being driven.
Only authorised persons may use the JOST KKS.
The operator must also keep an eye on traffic while
operating the JOST KKS – particularly if he/she is
working outside of the tractor unit.
Use the JOST KKS only if it is in perfect technical
condition.
When coupling and uncoupling, make sure no one
is in the danger zone, e.g. under the semi-trailer,
between the semi-trailer and tractor unit or near
the landing gears.
Always comply with the relevant safety provisions,
e.g. Health & Safety at Work regulations.
Only couple semi-trailers on firm, even ground.
Do not raise or lower the semi-trailer using the
electric landing gear drive.
Before driving off, the driver must be absolutely
certain that the necessary clearances between the
tractor unit and semi-trailer will be maintained in
all expected driving situations.
ATTENTION!
Pay attention to the following point:
The stipulated pre-departure inspection must
continue to be performed in accordance with
road traffic regulations, such as the StVO in Ger-
many. This includes checking the condition of the
mechanical connection between the tractor unit
and semi-trailer, and the correct position of the
landing gears.
ADVICE!
Use of the system is described in the JOST KKS fifth
wheel coupling installation and operating manual.
You can find this installation and operating manual
at www.jost-world.com.
3.4 Safety instructions for maintenance
WARNING!
Pay attention to the following points:
Maintenance and repairs may only be performed
by trained personnel with knowledge of the prod-
uct.
Use only genuine JOST parts for repairs and
replacement.
Use only lubricants approved by JOST.
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3 Safety instructions
IMPORTANT!
Some components of the KKS system have their own
installation and operating manuals, because the sys-
tem is partially based on existing JOST products. It is
therefore essential to refer to maintenance and repair
instructions in other installation and operating manuals.
The following components have a separate installation
and operating manual:
JOST products:
KKS fifth wheel coupling
based on the JOST JSK 40/42 fifth wheel coupling
Modul E-Drive
Kingpin
LubeTronic 5Point
Lubetronic 1Point
SKS
You can find the relevant installation and operating
manuals at www.jost-world.com.
Third-party manufacturers:
Line filter (valve unit)
You can find the line filter manufac-
turer’s installation and operating manual at
http://inform.wabco-auto.com/intl/en_GB/.
EN
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4 Intended use
4.1 General information
The JOST KKS is designed to help the driver couple and uncouple
semi-trailers.
As with conventional connections between a semi-trailer and trac-
tor unit, the KKS also produces a mechanical connection via the
fifth wheel coupling of the tractor unit and the kingpin of the semi-
trailer.
However, it differs from the conventional method because as well
as the mechanical connection, the tractor unit and semi-trailer are
also connected electrically and pneumatically during the coupling
process. To achieve this, the system is operated via remote control
from the cab of the tractor unit in a predefined sequence.
The electric Modul E-Drive landing gears are also included in the
coupling process, and are operated via remote control during cou-
pling and uncoupling.
The driver must perform the following steps manually:
Remove and insert chocks.
Engage or release the parking brake.
Raise and lower the vehicle with the pneumatic suspension.
Operate the remote control of the KKS system.
WARNING!
Before driving off, the driver must perform a safety
inspection of the tractor unit and semi-trailer.
The KKS fifth wheel coupling, connection cable and remote control
are intended for installation in a tractor unit.
The kingpin with swivel wedge and cable store are intended for
installation in a semi-trailer.
IMPORTANT!
The JOST JSK 42 fifth wheel coupling used for this prod-
uct is produced in accordance with Regulation ECE R55
Class 50 and may only be used in combination with Class
H50 kingpins.
The JOST KKS complete system offers the driver maximum conve-
nience and safety during the coupling process. Moreover, the sys-
tem enhances road safety by continuously monitoring the condi-
tion of the fifth wheel coupling and giving the driver a visual or
acoustic warning if the connection is no longer in order.
During the development of the JOST KKS, a key priority was ensur-
ing that the mechanical properties and reliability of the compo-
nents used met the high standards expected from JOST. The system
was designed to enable a conventional semi-trailer to be towed
with the JOST KKS fifth wheel coupling, and a KKS semi-trailer to
be coupled with a selection of conventional fifth wheel couplings
(see section 4.5 "Application limits", page 14 for compatible
fifth wheel couplings).
Features such as remote control and sensors continue to be sup-
ported. The control and all mechanical functions of individual com-
ponents have been retained.
You can find details in the relevant JOST information brochures
(see www.jost-world.com).
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4 Intended use
4.2 System requirements and properties for operating the
JOST KKS
The following tractor units are suitable for use with the JOST
KKS:
The tractor unit must have pneumatic suspension at least on
the rear axle.
The system may only be installed in tractor units with a 24 V
electrical system and negative vehicle ground.
The generator (alternator) of the tractor unit must have an
integrated voltage regulator.
The JOST KKS can also be installed in ADR-approved tractor
units.
The tractor unit must supply an analogue parking brake sig-
nal. The parking brake signal must supply either ground or
+24 V when actuated.
Tractor units with a 4x2 axle configuration.
ADVICE!
Further axle configurations are possible on request. For
this, please get in touch with the JOST technical cus-
tomer support team.
Only semi-trailers that satisfy the following points are suitable
for use with the JOST KKS:
Figure 1: Installation space, KKS-U
1Crossmember (semi-trailer) L= 2,143 mm ± 5 mm
2Cable store base plate W= 420 mm
3Trailer plate b= 210 mm
4Kingpin bm= cable store may have a cen-
tral offset of up to 310 mm
H50 mm + 5 mm
ADVICE!
If your semi-trailer does not satisfy the installation
space requirements, get in touch with the JOST techni-
cal customer support team.
EN
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4 Intended use
ADVICE!
If H < 50 mm, the cable store has a gooseneck con-
tour in accordance with ISO 1726. Here, the tractor unit
and semi-trailer combination must be tested and har-
monised with one another.
ADVICE!
The cable store may also be mounted in the centre. The
dimension 110 mm will then change to approx. 210 mm.
The semi-trailer must provide the minimum required installa-
tion space, as shown in Figure 1.
The semi-trailer must also have the necessary installation
space for the attachment of the landing gears.
The semi-trailer must have cable ducts both to the front wall
and rear of the semi-trailer. If it does not, it must be possible
to bring existing cable ducts into the semi-trailer.
To enable the electric landing gears to be used to their full
extent, the semi-trailer must feature electrical connections
suitable for +24 V and 0 V ground.
The trailer plate with installed kingpin is located on the same
level (no difference in height) as the longitudinal members.
The semi-trailer chassis has a gooseneck geometry in accor-
dance with ISO 1726.
ADVICE!
If your chassis is different, please contact the JOST tech-
nical customer support team.
Figure 2: Trailer plate, view from below with KKS system
1Pivot range 0° ± 100° 2Retraction area of KKS fifth
wheel coupling connector
Make sure there are no projecting components or stiffen-
ers (e.g. longitudinal members or crossmembers) in the area
where the KKS coupling retracts or in the pivot range of the
swivel wedge.
Check beforehand that the semi-trailer is suitable for
installing the KKS system.
IMPORTANT!
If you are uncertain whether the semi-trailer is suitable
for the retrofit, please consult our technical customer
support team.
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4 Intended use
4.3 Target group and existing knowledge
This documentation is intended for the installation, operating and
maintenance personnel of the KKS system.
Installation, operating and maintenance personnel must be
appointed by the owner.
These persons are subject to the following requirements:
Basic technical knowledge
At least 18 years of age
Have read and understood this installation and operating
manual
The owner must take the following actions to ensure these
persons are in possession of the knowledge required to oper-
ate the KKS system:
– Product training
– Safety induction
WARNING!
Installation and repairs may be performed only by tech-
nical specialists with product-specific training.
4.4 Content and purpose of this documentation
This documentation contains the relevant information for installa-
tion, operation, maintenance and disposal of the KKS system. It is
intended to enable safe work on and with the KKS system.
Compliance with the instructions in this document helps to pre-
vent danger and damage to the KKS system.
EN
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4 Intended use
4.5 Application limits
A semi-trailer equipped with KKS is compatible with the follow-
ing JOST fifth wheel couplings with a minimum height of 162 mm
including mounting plate:
JSK 34 H
JSK 36 D
JSK 37 C
JSK 37 CX
JSK 37 E
JSK 40
JSK 42
ATTENTION!
As a rule, a KKS semi-trailer can be used with a tractor
unit that is not equipped with a KKS, provided that the
tractor unit does not have slider units, lead-on-ramps
or other special attachments, and provided that checks
have confirmed that the swivel wedge can move freely.
A standard semi-trailer may also be used with a KKS trac-
tor unit.
ATTENTION!
For operation with a KKS-U semi-trailer, wheel covers
may be used, depending on the height of the fifth wheel
coupling and the wheel/tyre combination.
IMPORTANT!
Please ask regarding the suitability of fifth wheel cou-
plings from other manufacturers.
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4 Intended use
4.6 Principle
The KKS system is a state-of-the-art product that conforms to the
applicable health and safety regulations.
WARNING!
Nevertheless, the following risks can arise if it is mis-
used or used incorrectly:
Serious or fatal injury to the user or third parties.
Damage to the KKS system and other material
assets of the owner.
Inefficient functioning of the KKS system.
EN
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5 List of components
5.1 Semi-trailer system components
5.1.1 Modul E-Drive landing gears
2
3
1
1
KKS/009
Figure 5: Modul E-Drive landing gears, components, CAD model
1Landing gear
2Electric landing gear drive
3Connection shaft
The electric landing gears are retracted and extended automati-
cally in the system routine by pressing the keys.
ADVICE!
You can find information on installation, operation,
maintenance and repair in the JOST Modul E-Drive land-
ing gears installation and operating manual or repair
manual at www.jost-world.com.
5.1.2 Swivel wedge with kingpin
Figure 6: Swivel wedge with kingpin, CAD model
1Kingpin 3Swivel wedge
2Swivel wedge bearing
The KKS trailer system consists of the kingpin (1), the swivel wedge
bearing (2) and the swivel wedge (3). The swivel wedge bearing
is a slide bearing that allows the swivel wedge to rotate around
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5 List of components
the central axis of the KKS kingpin when the vehicle corners. Dur-
ing coupling, the kingpin is held by the locking system of the fifth
wheel coupling and the swivel wedge slides into the coupling jaw
as it retracts. When retracted, the KKS coupling is situated on
the fifth wheel coupling opposite the KKS connector. Electric and
pneumatic contacts are also made automatically during the cou-
pling process.
5.1.3 Cable store with cables
Figure 7: Cable store with cables, CAD model
1Cable store 4Spring for the swivel wedge
return
2Crossmember (semi-trailer) 5Swivel bracket
3Wiring harness
(electric cables and pneu-
matic hoses)
6Swivel wedge
All electric cables and pneumatic hoses are bundled in a central
wiring harness in the cable store. The cable store allows sufficient
freedom of movement for the central wiring harness when corner-
ing. A spring between the swivel wedge and cable store returns the
swivel wedge to its straight-ahead position after uncoupling.
EN
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5 List of components
5.1.4 Exploded view
Figure 8: KKS system, semi-trailer, CAD model
1Locking ring 5Crossmember, semi-trailer
2Slip ring 6Cable store
3Kingpin 7Electric cables, pneumatic
hoses
4Trailer plate 8Swivel wedge
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6 Installation
WARNING!
Installation must be performed exclusively by
appropriately qualified personnel.
During installation, make sure that the swivel
wedge can move clockwise and anti-clockwise in
the direction of travel easily and without jamming.
Route electric cables and pneumatic hoses so they
cannot chafe and connect them at the intended
connection points.
Properly insulate exposed cable ends. Produce the
connection to the 7-pin socket using an ISO 7638-1
connector.
Produce the connection to the 15-pin socket using
an ISO 12098 connector. The manufacturer will not
accept any warranty claims if installation is carried
out incorrectly.
WARNING!
Support the semi-trailer with appropriate equip-
ment before commencing work underneath it. The
vehicle construction firm or workshop is responsi-
ble for safely supporting the semi-trailer.
ATTENTION!
Do not kink air hoses during installation!
IMPORTANT!
To enable the KKS system to be used to its full
extent, the vehicle must be equipped with JOST
Modul E-Drive landing gears. If the vehicle does not
have JOST Modul E-Drive landing gears, they must
be retrofitted. For installation, refer to the JOST
Modul E-Drive landing gears installation and oper-
ating manual at www.jost-world.com.
Make sure the following work is complete before you proceed with
the next steps:
The JOST Modul-E-Drive landing gears must be installed on
the semi-trailer as described in the installation and operating
manual.
6.1 Installing and electrically connecting the valve unit
The valve unit consists of the components shown in Figure 9. It is
needed to perform the following functions:
Connecting the KKS air hoses to the semi-trailer’s compressed
air system.
Enabling compressed air to be supplied to the semi-trailer via
the KKS system or via the conventional spiral hoses.
EN
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6 Installation
1
2
3
4
5
6
7
8
9
10
11
KKS/040
Figure 9: Overview of valve unit components
1Holder 7Screw-in connector
(2x)
2Screw M8 x 35 mm
(2x)
8Hex nut (4x)
3Shim (4x) 9Thrust collar (4x)
4Flange nut M8 (2x) 10 Washer (4x)
5Line filter (2x) 11 Connector, 8 or 10 mm (6x)
62-way valve (2x)
KKS/041
1
Figure 10: Valve unit holder,
marking the holder location
1
2
3
KKS/042
Figure 11: Valve unit holder,
screwed onto semi-trailer
Select a suitable location on the semi-trailer for fitting the
holder (1). It may be secured to any of the semi-trailer’s longi-
tudinal members.
IMPORTANT!
Install the holder (1) beyond the pivot range of the trac-
tor unit.
In your chosen location, mark the position of the holes for the
holder (1), as shown in Figure 10. Drill two holes with a diam-
eter of 8.5 mm.
Secure the holder (1) using the screws (2), shims (3) and
flange nuts (4), as shown in Figure 11.
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