How to install a Jost KKS-U auto coupling on your trailer

According to a Jost brochure, their KKS Remote Trailer Coupling System is a cutting-edge solution designed to simplify and improve the trailer coupling process for commercial vehicles. The system leverages state-of-the-art technology to enhance safety, efficiency, and productivity in the transport industry. But best of all, the KKS-U model is easy to install onto your existing trailers.

“The KKS is an urgently needed step in the logistics sector; together with the kingpin, we connect the electrical and airlines simultaneously by splitting our system into three subsystems,” said Andreas Jakubin, Product Manager of Advanced Products at Jost-World.

“As a result, we immediately have air and electrics on the trailer when the kingpin is securely locked in the JOST fifth wheel. With this, we make the truck driver’s work easier, and maybe we can also motivate others to get a driver’s license.

“Of course, we are also doing something for safety with the KKS, as the number of accidents from falling is reduced because the driver no longer has to climb between the truck and the trailer. We also reduce the number of trailer losses because our fifth wheel is equipped with a large number of sensors.”

There are four key features of the Jost KKS Remote Trailer Coupling System. First, the system allows for remote control of the trailer coupling process. This means that drivers can couple and uncouple trailers without leaving the cabin of their truck.

Second, the system incorporates multiple safety measures, such as collision avoidance technology and real-time feedback to the driver. These features significantly decrease the chances of accidents and injuries during coupling and uncoupling operations.

Next, the system employs advanced sensors and algorithms to ensure precise coupling, reducing the likelihood of misalignment or errors during the process. This precision minimises wear and tear on equipment and reduces the need for maintenance.

Finally, the system has data collection and connectivity capabilities, allowing real-time monitoring and diagnostics. This enables transport companies to address maintenance issues and improve overall fleet efficiency proactively.

To estimate the potential cost savings for transport companies by converting their existing coupling systems to the Jost KKS Remote Trailer Coupling System, we can consider several factors:
Reduced Labor Costs: The Jost KKS system’s remote-control feature eliminates the need for additional personnel to assist with coupling and uncoupling. This can lead to substantial labour cost savings.

Increased Productivity: The increased number of daily deliveries, thanks to faster trailer coupling and uncoupling, directly contributes to higher revenue. This revenue boost is especially significant for long-haul transport companies.
Maintenance Savings: The precision of the Jost KKS system reduces maintenance costs, including expenses related to equipment repairs and replacement parts.
Safety: Improved safety measures and reduced accidents can lower operational expenses for transport companies, further contributing to cost savings.

Jost says that while the exact cost savings will vary depending on the size and scale of the transport operation, it is reasonable to estimate that adopting the Jost KKS Remote Trailer Coupling System could lead to cost reductions ranging from 10 to 20 per cent annually.

However, according to the Jost efficiency calculator, a distribution operation that requires multiple trailer couplings daily could increase deliveries by up to 21 per cent, with 13 per cent cost savings per journey leg and further savings of up to 17 per cent in hitching time. Basis for the calculation; 220 working days with nine-hour shifts for the truck and driver and two trailer changeovers per trip.

The investment required to retro-fit a KKS-U kit to an existing trailer, is estimated at $10k, but that is dependent on the condition of the skid-plate and ease of fitment for the cable box.

The trailer components of the KKS-U consist of the wedge with the KKS connector, which is already attached to a JOST kingpin, a spiral spring and the cable box. But first, you must check for enough mounting space under the trailer. It has to be at least as much as the measures shown in this article.

Start by uninstalling the existing king pin. In this case, Jost has the valve unit with the pipe filters already pre-installed on the mounting bracket and has prepared it for installation. The pre-assembled mounting bracket can then be installed on the chassis. It is mounted in such a way that the pipe filters are facing in the direction of travel. The pneumatic supply lines are divided and connected to ‘in’ 1.1 and ‘out’ 2.0 of the corresponding directional valves.

Handy Hint: To avoid confusing the lines, Jost recommends marking the control and supply lines with yellow and red tape, respectively, before dividing them.

Pre-assemble the cable box before mounting it on the trailer. First, construct a U-shaped structure with the side plates and cover plates. Then, fasten the side plates to the cover plate with three cable ties each. Now align the cover plate to the drilling holes and attach it. Before you tighten it firmly, remove the cable ties.

Now, you can install the wedge with the kingpin. Position it on an assembly jack under the trailer. Then, lift it up and put it into the mounting position using a suitable jacking device. Screw in the kingpin with the supplied screws. When tightening, be sure to observe the specified tightening torque.

Mount the swivel bracket. That is the connection to the cable box. Insert the swivel bracket with the cable harness into the cable box, align and fix it. Then position the screw connections and tighten them with a torque spanner and 10 Nm. Ensure the distance 480 +5 mm for the spiral spring pre-tensioning has been correctly observed.

Handy Hint: If the control dimension (measure) is incorrect, loosen the screws in the cable box and adjust the pretension via the slotted holes. Then, you can slide the base plate into the cable storage.

Make sure that it fits precisely and screw it in with the specified tightening torque. Then check the reset of the wedge. To do this, swivel it several times by approximately 20°. It must return by itself and should not rub against the sliding plate. To make any fine adjustment of the wedge, wind the adjusting nut until the wear piece rests against the kingpin.

Then, turn the adjusting nut 45 degrees further and secure it with the lock nut. Check that the swivel wedge can be moved freely by ±50 degrees in both directions, and then secure the adjusting nut with the lock nut.

An auxiliary marker is recommended to ensure a minimum of 45 degrees is set safely. The setting is perfect when the wedge can be moved freely by ±50 degrees.

Now, the pneumatic lines are connected. The previously marked supply and control lines are laid outwards from the wedge in the direction of the valve unit and connected to the corresponding pipe filter. Then, connect the electrical cables from the swivel wedge to the plug connections provided. The Modul E-Drive landing gear is simply connected to the cable harness with the plug provided.

Finally, the electrical supply lines are laid toward the trailer end wall. The ISO plugs are connected and connected to the sockets provided. After assembly, a system check with the KKS prime mover unit is required, and a test drive is made.

A KKS prime mover can couple to a non-KKS-equipped trailer; likewise, a KKS-equipped trailer can connect to the standard prime mover.

The Jost KKS Remote Trailer Coupling System represents a game-changing innovation in the transport industry. Its advanced features, including remote control, precise coupling, and enhanced safety measures, promise to revolutionise transport tasks, increasing safety and productivity.

The estimated cost savings for transport companies are significant, making adopting this system a strategic investment that can lead to long-term financial benefits.