Operators Manual

Automatic trailer coupling for industrial trucks type KU 25

5. determination of the characteristic values

1. technical data and designations:

Area of application:
For use on tractors and towing industrial trucks such as lorries, forklift trucks etc. and their trailers. Series 25 couplings largely comply with DIN 15170, form E.

Type approval and characteristic values:

General type approval:
Perm. D-value: 45 kN

Approval mark:

Fig. 1 – Versions KU 25-3 / KU 25-3DP

Note:

If additional official approvals are required for the use of these characteristic values in accordance with the applicable national approval regulations of the respective country of use, these must be applied for

Designations (= order designation): (see Fig. 1)

Table 1
Designation	Flange size	Hole pattern dimension A x B (mm)	Tightening torque screw M14 – 8.8 / M14 – 10.9 *)	Actuation type
KU 25-2	2	130×30	145 / 215	Manual operation
KU 25-3	3	120×55	145 / 215	Manual operation
KU 25-3M	3	120×55	145 / 215	Manual operation, manual release possible
KU 25-3L	3	120×55	145 / 215	Foot actuation on one side by lever
KU 25-3DP	3	120×55	145 / 215	Foot actuation on both sides via straight pedal
KU 25-3DP2	3	120×55	145 / 215	Foot actuation on both sides via cranked pedal
KU 25-3DP3	3	120×55	145 / 215	Foot actuation on both sides via cranked pedal
KU 25-3DP3M	3	120×55	145 / 215	Foot actuation on both sides via cranked pedal, manual release possible

Figure 2 – Dimensions

The couplings can also be mounted offset by 180° so that the coupling head points downwards. The clutches with the letters “L”, “DP”, “DP2” and “DP3” are designed for foot operation and 180° mounting.
All clutches can be fitted with a manually operated release. In this case, the letter “M” is added to the design designation.

Drawbar eyes:
Only suitable for connection with drawbar eyes in accordance with DIN 8454.
Exception: In non-public road traffic, drawbar eyes in accordance with DIN 74054 or ISO 8755 and ISO 5692-3 Form X can also be used. The required swivel angle in accordance with DIN 15170 is not fully achieved with these drawbar eyes; they may therefore only be used in conjunction with the KU 25 on level road surfaces.

Important:

To avoid injury, protective gloves, safety glasses and safety shoes must be worn during all dismantling/ assembly actions described in this chapter.

Environment:

Lubricants can enter the environment. Environmental pollution: Collect, store and correctly dispose of lubricants in suitable containers.

2nd assembly:

Note:

The pertinent regulations (e.g. Accident Prevention Regulations for Vehicles) and the attachment guidelines of the vehicle manufacturers must be observed when installing the coupling! The coupling must be attached to the vehicle in accordance with the requirements in Appendix VII of Directive 94/20 / EC (see Appendix I, Section 5.10).

Note:

Attention is drawn to the obligations of § 13 FZV (in registration area D) with regard to the data in the registration certificate concerning the permissible trailer load and the permissible drawbar load.

The coupling is attached directly to the crossbar or other vehicle parts suitable for mounting using 4 hexagon bolts M14x45 – DIN EN 24017 and 4 self-locking hexagon nuts of the same quality. The bolt heads must face the coupling head side, and the bolt and nut surfaces must be flat, clean and free of grease and dirt. A torque wrench must be used to achieve the correct tightening torque. As a rule, the fastening screws are not included in the scope of delivery of the clutch, so the vehicle manufacturer’s specifications for fastening must be observed. If no information is available, please refer to the values in Table 1.

For other screw types or qualities, please contact us or your specialist dealer.
*) Values apply for a total coefficient of friction of μ= 0.14 (corresponds to unlubricated or lightly oiled and phosphated surface condition).

Warning:

The regulations of the employers’ liability insurance association must be observed when coupling and uncoupling.
No one may stand between the vehicles. The coupling may only be operated in locked condition. When coupling and uncoupling, the drawbar must be as horizontal as possible relative to the coupling.

The user is obliged to always operate the Connecting device in perfect condition and to forbid its use by unauthorised persons. The loads indicated on the type plate may not be exceeded. Unauthorised conversion or modification of the coupling head is not permitted.

3. operation: (see Fig. 3)

Figure 3 – Trailer coupling KU 25-3

3.1 Uncoupling and opening the trailer coupling:

Press the hand lever (5) upwards until it engages (lever or pedal downwards for “L”, “DP” and “DP3” versions). This releases the locking position, pushes the coupling bolt (2) upwards (“L”, “DP” and “DP3” downwards) and locks it in place. The existing clutch connection is released and the clutch is opened.

The coupling readiness is restored by moving the towing eye completely out of the jaw.

Warning:

Never uncouple when the trailer is pulling or pushing. Use of force on the hand lever can destroy the mechanism.

3.2 Automatic coupling:

If a drawbar eye is inserted into the coupling in the open state, it presses against the release button (3) and the automatic coupling process is triggered, i.e. the coupling pin (2) is abruptly pressed downwards through the drawbar eye (“L”, “DP” and “DP3” upwards) into the seat in the coupling housing (1). The lifting fork (4) lies over the coupling pin (2) and secures it.

3.3 Manual coupling: (see also Fig. 4)

Clutches with a manually operated release can be locked by hand. This may be necessary for certain internal uses. To do this, pull the release lever (8) against the direction of travel until the coupling process is triggered.

Bild 4 – Ausführungen KU 25-3M und KU 25-3DP3M

Figure 4 – Versions KU 25-3M and KU 25-3DP3M

4. maintenance:

Important:

The care instructions must be followed to prevent damage to the clutch.

4.1 Care:

The clutch must always be cleaned of dirt and corrosion to ensure proper functioning. All moving parts of the clutch must be lubricated regularly (depending on the period of use) and checked for ease of movement.
Before commissioning and after prolonged use, lubricate the coupling bolt (2) and the towing eye with tough, water-resistant grease.
The clutch head is filled with a grease reservoir at the factory, so constant re-greasing is not necessary. Too much grease in the clutch head can impair the clutch function, especially in cold ambient temperatures.
Avoid cleaning with high-pressure cleaners if possible. If this does occur, the clutch must be regreased.
The clutch should always be replaced completely. However, if repairs are required in individual cases (e.g. changing the coupling bolt), the old grease must be removed and the coupling head lubricated with fresh grease. A water-resistant multi-purpose grease (grease type: lithium saponified, consistency class: NL-GI2) must be used for lubrication

Important:

The checks must be carried out at the appropriate intervals in order to prevent damage to the clutch.

4.2 Examination:

Screw connection:
The fastening screws must be checked for correct fit using a torque wrench once a year, or more often if used frequently. If necessary, retighten, see section 2.
Coupling pin (2):
Measure the diameter of the coupling pin at its thinnest point when cleaned. Wear limit: 23 mm. If the dimension falls below the limit, the coupling or coupling pin must be replaced. The rotating coupling pin prevents excessive wear and contributes significantly to the long service life of the clutch.
Height play:
If the height play on the coupling bolt is more than 3 mm when closed, the coupling must be replaced.
Housing (1):
The mounting hole for the coupling bolt (7) must not exceed a dimension of 26 mm, otherwise the coupling must be replaced. Make sure that the hole is always clear so that any dirt can pass through and the coupling bolt can always drop to the lower stop.

Important:

Use only original Walterscheid spares when replacing parts. If the vehicle owner does not have the appropriate specialists and the necessary technical equipment, the replacement must be carried out by a specialist workshop.

Warning / safety instructions:

- - - The user is obliged to operate the clutch only when it is in perfect condition and to prohibit its use by unauthorized persons.
    - The loads indicated on the type plate may not be exceeded.
    - Unauthorized conversions and modifications to the clutch are not permitted

5. determination of the characteristic values for correct operation of the trailer coupling:

The theoretical comparative force for the drawbar force between the towing vehicle and trailer is defined as the D value. The D value is calculated from the two permissible gross weights (towing vehicle and multi-axle trailer) as follows:

D-value calculation

T: Total mass of the vehicle in t
R: Total mass of the trailer in t
g: Acceleration due to gravity: 9.81 m/s2

Warning:

Like all couplings for industrial trucks, the KU 25 coupling is not suitable for transferring drawbar loads and is therefore not suitable for operation with rigid drawbar trailers!

Calculation example D-value:

D-value example calculation

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Automatic trailer coupling for industrial trucks type KU 25

1. technical data and designations:

Type approval and characteristic values:

Note:

Designations (= order designation): (see Fig. 1)

Important:

Environment:

2nd assembly:

Note:

Note:

Warning:

3. operation: (see Fig. 3)

Warning:

4. maintenance:

Important:

Important:

Important:

Warning / safety instructions:

5. determination of the characteristic values for correct operation of the trailer coupling:

Warning:

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