AS 4968.3-2011 Heavy Road Vehicles - Mechanical Coupling Between Articulated Vehicle Combinations - Kingp - PDF (Personal Use)

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equipment
combinations
Part 3: Kingpins and associated

Heavy road vehicles—Mechanical
Australian/New Zealand Standard™
coupling between articulated vehicle

AS/NZS 4968.3:2011
AS/NZS 4968.3:2011
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee ME-053, Heavy Road Vehicles. It was approved on behalf of the
Council of Standards Australia on 3 March 2011 and on behalf of the Council of
Standards New Zealand on 5 April 2011.
This Standard was published on 21 April 2011.
The following are represented on Committee ME-053:
Austroads
Australian Road Transport Suppliers Association
Australian Trucking Association
Commonwealth Department of Transport and Regional Services
Get permission to copy from or network this publication www.saiglobal.com/licensing
Department of Transport,WA
New Zealand Heavy Haulage Association
New Zealand Transport Agency
New Zealand Truck and Trailers Manufacturers Federation
Road Transport Forum, New Zealand
The Institute of Road Transport Engineers of New Zealand
Truck Industry Council
Additonal Interests:
Mechanical coupling manufacturers
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This Standard was issued in draft form for comment as DR 07401.

AS/NZS 4968.3:2011
Australian/New Zealand Standard™

Heavy road vehicles—Mechanical

coupling between articulated vehicle
combinations
Part 3: Kingpins and associated

equipment
Originated as part of AS D14—1968, AS D15—1968, AS 1771—1975, AS 1772—1975,

AS 1773—1975, AS 2175 Supplement 1—2002 and AS 4235—1994.
Previous editions AS 1771—1996, AS 1773—1996, AS 2175—1995,
AS 2175 Supplement 1—2002 and AS 4235—1994.
AS 1771—1996, AS 1773—1996, AS 2175—1995, AS 2175 Supplement 1—2002
and AS 4235—1994 jointly revised, amalgamated and redesignated in part
as AS/NZS 4968.3:2003.
Second edition 2011.
COPYRIGHT
© Standards Australia Limited/Standards New Zealand
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any means, electronic or mechanical, including photocopying, without the written
permission of the publisher, unless otherwise permitted under the Copyright Act 1968
(Australia) or the Copyright Act 1994 (New Zealand).
Jointly published by SAI Global Limited under licence from Standards Australia Limited,
GPO Box 476, Sydney, NSW 2001 and by Standards New Zealand, Private Bag 2439,
Wellington 6140
ISBN 978 0 7337 9834 4

AS/NZS 4968.3:2011 2
PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee ME-053, Heavy Road Vehicles, to supersede AS/NZS 4968.3:2003. This
revision has been prepared in order to broaden the application of this Standard from semi-
trailers to include lighter installations such as inverted installations where the kingpin is
used on the tow vehicle.
The objectives of this Standard are to provide performance requirements and
recommendations for the installation of kingpins and associated equipment, to assist in the
development of standard practice in this field, to provide the transport industry with a
standardized kingpin to ensure full interchangeability when coupling vehicle combinations,
and provide a procedure for rating and selecting a kingpin for safe usage for specific
vehicle combinations.
This Standard is Part 3 of AS/NZS 4968, Heavy road vehicles—Mechanical coupling

between articulated vehicle combinations, which is published in three parts as follows:
Part 1: Design criteria and selection requirements for fifth wheel, kingpin and associated
equipment
Part 2: Testing and installation of fifth wheel and associated equipment
Part 3: Kingpins and associated equipment (this Standard)
The Standard correlates with the dimensional requirements in International Standards for
50 mm kingpins (ISO 337:1981, Road vehicles—50 semi-trailer fifth wheel coupling pin—
Basic and mounting/interchangeability dimensions), 90 mm kingpins (ISO 4086:2001, Road
vehicles—90 semi-trailer fifth wheel kingpin—Interchangeability), and the rating and
selecting of kingpins is based on the ‘D-value’ method used in the United Nations ECE
Regulation 55.
In this Standard, 75 mm kingpins have been included due to their widespread use in certain
parts of Australia and recent developments in standardizing their dimensions. These
kingpins are not contained in ISO Standards or ECE Regulations.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
3 AS/NZS 4968.3:2011
CONTENTS
Page
1 SCOPE........................................................................................................................ 4
2 REFERENCED DOCUMENTS.................................................................................. 4
3 DEFINITIONS............................................................................................................ 5
4 SKID PLATE.............................................................................................................. 6
5 KINGPIN ATTACHMENT ...................................................................................... 10
6 RATING ................................................................................................................... 10
7 SELECTION............................................................................................................. 11
8 MATERIALS............................................................................................................ 12
9 RECOMMENDED WEAR LIMITS ......................................................................... 12

10 DIMENSIONS .......................................................................................................... 13
APPENDICES
A DYNAMIC TEST METHOD FOR D-RATED KINGPINS....................................... 20
B DETERMINATION OF THE DYNAMIC STRENGTH OF D-RATED
KINGPINS USING FINITE ELEMENT ANALYSIS ............................................... 22
C GUIDELINES FOR THE ATTACHMENT OF KINGPIN TO SKID PLATE........... 26
AS/NZS 4968.3:2011 4
STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
Australian/New Zealand Standard

Heavy road vehicles—Mechanical coupling between articulated vehicle

combinations
Part 3: Kingpins and associated equipment
1 SCOPE
This Standard specifies requirements for 50 mm, 75 mm and 90 mm kingpins for use in
articulated vehicles, B-doubles and road trains, in normal use on both sealed and unsealed
roads.
Requirements covering mechanical properties, dimensional standards for interchangeability

and dynamic testing are provided in Appendix A.
The determination of dynamic strength using finite element analysis is given in
Appendix B.
NOTES:
1 Recommendations and requirements for fifth wheel assemblies on prime movers are given in
AS/NZS 4968.2.
2 Guidelines for the attachment of kingpin to skid plate are given in Appendix C.
3 The method of calculation of D-values is given in AS/NZS 4968.1.
2 REFERENCED DOCUMENTS
The following documents are referred to in this Standard:
AS
1110 ISO metric hexagon bolts and screws—Product grades A and B
1110.1 Part 1: Bolts
1391 Metallic materials—Tensile testing at ambient temperature
1815 Metallic materials—Rockwell hardness test (series)
2174 Heavy road vehicles—Mechanical coupling between prime movers and semi-
trailers—Interchangeability requirements
2174.1 Part 1: Non-dedicated vehicle combinations
AS/NZS
1594 Hot-rolled steel flat products
4968 Heavy road vehicles—Mechanical coupling between articulated vehicle
combinations
4968.1 Part 1: Design criteria and selection requirements for fifth wheel, kingpin and
associated equipment
4968.2 Part 2: Testing and installation of fifth wheel and associated equipment
ISO
4287 Geometrical Product Specifications (GPS)—Surface texture: Profile method—
Terms, definitions and surface texture parameters
SAE
J700 Upper Coupler Kingpin—Commercial Trailers and Semi-trailers
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5 AS/NZS 4968.3:2011
3 DEFINITIONS
For the purpose of this Standard, the definitions in AS/NZS 4968.1 and those below apply.
3.1 Boundary conditions
Appropriate constraints assigned to the kingpin, simulating its attachment to a skid plate via
intermediate components (e.g. retention plate).

3.2 Design case
A combination of load case and boundary condition.
3.3 Endurance limit (also known as ‘fatigue limit’)
The maximum stress to which a material can be subjected without fatigue failure, regardless
of the number of load cycles.
3.4 Finite element analysis (FEA)
A numerical method for the evaluation and analysis of the structural behaviour at any point
within a body for a design case.
3.5 Kingpin
A pin (including retention plate and bolts, where applicable) attached to the skid plate, and
used for connecting the towed vehicle to the towing vehicle (see Figure 4.3).
3.6 Load case
An applied load representing a critical vehicle movement.
3.7 Material test
Tensile testing of a specimen removed from a sample of the subject kingpin to determine
the UTS.
3.8 Node
A fixed point on a body.
3.9 Kingpin retention plate
A component of a bolt-in kingpin assembly that is attached directly to the skid plate and
which provides for the simple exchange of the kingpin should it become worn or damaged.
The kingpin retention plate may be either of the following:
(a) ‘Dome’ type used for flange bolt-in kingpins.
(b) ‘Cone’ type used for taper bolt-in kingpins.
NOTE: See Figures 10.2 and 10.3.
3.10 Shall
Indicates that a statement is mandatory.
3.11 Should
Indicates a recommendation.
3.12 Skid plate
The plate structure which houses the kingpin and which mounts on the coupler plate to form
the connection between the towing vehicle and the semi-trailer (see Figure 4.3).
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AS/NZS 4968.3:2011 6
3.13 Skid plate locking key

A steel block attached to the skid plate. It is located rearward of the king pin to key into the
throat of the coupler plate of a turntable base fifth wheel, in order to prevent relative
rotation of these two components (see Figure 4.3).
NOTE: This means that the fifth wheel transverse pivot mounting is fixed constantly at 90
degrees relative to the longitudinal centre-line of the towed or towing vehicle. Rotation is
effected at the turntable.
3.14 Ultimate tensile strength (UTS)
The maximum stress encountered during a tensile test.
3.15 von Mises stress
A combination of all the stress components at a point within a body, yielding a single value.
4 SKID PLATE
4.1 Design
The skid plate and its attachment shall be designed to cover each of the loading conditions
for its given application as stated in Clause 5 of AS/NZS 4968.1 (see Figure 4.1).
NOTE: Although the figures in this Standard reflect conventional upright installations, they do
not preclude the use of inverted installations where the kingpin is fitted to the tow vehicle,
provided that the installation will still function correctly in this configuration.
4.2 Material
The skid plate working surface shall be manufactured from steel plate having a minimum
thickness of 8 mm and complying with AS/NZS 1594.
NOTE: Other materials equivalent in strength, fatigue resistance and wear resistance may be
used.
4.3 Installation
When the skid plate is installed and subjected to the applicable forces given in Clause 5 of
AS/NZS 4968.1, any deflection shall be no greater than the limits of flatness shown in
Figure 4.2.
4.4 Flatness
The load-bearing surface of the installed skid plate shall not exceed the limits of flatness
prescribed in Figure 4.2 (see Note). Alternatively, the upper coupler plate surface shall not
bow downward (convex) more than the designed effective diameter of the fifth wheel
divided by 150 mm. The upper coupler plate surface shall not bow upward (concave) more
than the designed effective diameter divided by 300 mm.
NOTE: These flatness limits are based on the requirements of SAE J700.
4.5 Attachment
The skid plate may be attached by bolting or welding. Irrespective of the method, the
attachment shall be designed and manufactured—
(a) to withstand the loadings specified in Clause 5 of AS/NZS 4968.1; and
(b) to be horizontal when the forward end of the trailer is at the correct operating height
and standing on a horizontal surface.
NOTE: The skid plate height should be in accordance with AS 2174.1.
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7 AS/NZS 4968.3:2011
4.6 Attachment of skid plate locking key

Where a skid plate locking key is provided the following apply:
(a) The key shall be inserted into the fifth wheel kingpin entry slot to provide the rotation
stop means.
(b) The skid plate locking key should preferably be bolted by two M20 bolts Class 8.8, as
specified in AS 1110.1, or alternatively be welded in accordance with Figure 4.3.
FIGURE 4.1 SKID PLATE DESIGN LOADS
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AS/NZS 4968.3:2011
8
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DIMENSIONS IN MILLIMETRES
FIGURE 4.2 SKID PLATE FLATNESS LIMITS

9 AS/NZS 4968.3:2011
Kingpin size Dimensions, mm

Key type Notes
mm A B (Ref) C
50 100 63 75
8 mm fillet weld
Welded key 75 90 40 100
all around key
90 90 33 114
50 100 63 75
Use at least two
Bolted key 75 90 40 100 M20 × 8.8 bolts
with lock washers
90 90 33 114
NOTE: Special types of keys or alternative dimensions may be required in some cases.
FIGURE 4.3 TYPICAL SKID PLATE LOCKING KEY
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AS/NZS 4968.3:2011 10
5 KINGPIN ATTACHMENT
5.1 Strength of attachment
When installed, the assembly shall satisfy the loadings as specified in Clause 5 of
AS/NZS 4968.1. Particular attention should be paid to the mounting of the kingpin to
ensure the centre-line of the kingpin is at 90 ±1° to the skid plate surface.
NOTE: Guidelines for the attachment of kingpin to skid plate are given in Appendix C.
5.2 Kingpin protrusion
Kingpin attachment shall be designed such that the kingpin, when secured to the skid plate,
protrudes dimensionally in accordance with Clause 10. For a skid plate intended for use
with intermediate-wear liner material between the coupler plate and skid plate, appropriate
kingpin protrusion shall be provided in accordance with Clause 10.
6 RATING
6.1 General
Kingpins shall be rated in accordance with one of the following:
(a) D-value based on dynamic test results in accordance with Clause 6.2 (D-rated
kingpins).
(b) D-value based on finite element analysis in accordance with Appendix B (D-rated
kingpins).
(c) Compliance with material specifications in accordance with Clause 6.3 (M-rated
kingpins).
NOTE: Kingpin performance is determined by the mechanical properties of the kingpin material
and the kingpin dimensions. Compliance with the material requirements specified in Clause 6.3
and the dimensional requirements of Section 4 will ensure sufficient strength and adequate
dynamic performance of M-rated kingpins in normal applications.
6.2 D-rated kingpins—Dynamic test
When a D-rated kingpin is tested in accordance with Appendix A, there shall be no residual
deformation, breaks, cracks or separation of components that would interfere or degrade the
function of the kingpin, nor shall there be any wear in excess of the limits specified in
Table 6.1, when measured in any direction (see Figure 9.1).
NOTES:
1 Wear limits are also recommended for in-service operations (see Clause 9).
2 Where both a fifth wheel and a kingpin are rated for a D-value and are connected in a vehicle
combination, the component with the lower rating will determine the overall rating for that
towing connection.
TABLE 6.1
D-RATED KINGPINS—MAXIMUM WEAR LIMITS
Size F G
mm mm mm
50 49 71
75 73 100
90 86 112
NOTE: Dimensions F and G are illustrated in Figure 9.1.
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11 AS/NZS 4968.3:2011
6.3 M-rated kingpins

6.3.1 Material strength
When tested in accordance with AS 1391, a test piece of a practicable size which has been
cut from a finished M-rated kingpin at the mid-radius position as shown in Figure 6.1 shall
have the following mechanical properties:

(a) Tensile strength* (minimum) ...................................................................... 850 MPa.
(b) Proof stress* (minimum)............................................................................. 665 MPa.
(c) Elongation (minimum).......................................................................................13%.
6.3.2 Hardness
When tested in accordance with the relevant part of AS 1815, the surface of a finished
M-rated kingpin shall have a Rockwell hardness value between 29 HRC and 39 HRC.
NOTE: A suitable area for testing is the centre of the journal (see Figure 6.1).
FIGURE 6.1 TENSILE TEST PIECE
7 SELECTION
Selection of kingpins shall be based on the D-value determined in accordance with Clause 6
of AS/NZS 4968.1. When a combination of vehicles requires a D-value greater than
102 kN, a D-rated kingpin in accordance with Clause 6.2 or Appendix B shall be used.
The greatest M-rated kingpins shall not be used in applications requiring a D-value of
greater than 102 kN. The highest D-value required by the combination shall be used for all
trailers.
NOTE: During the installation of bolt-in kingpins, care should be taken with the preparation and
welding of the taper block or cap (as applicable) to maintain the dimensional requirements of
Clauses 10.1 and 10.2.
* AS 1391 allocates the symbols R m and Rp0.2 to the quantities of tensile strength and proof stress (non-
proportional elongation) respectively.
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AS/NZS 4968.3:2011 12
8 MATERIALS
8.1 General
Kingpins that are to be welded shall be made of either steel having a carbon equivalent
(CE) of less than 0.87 when calculated in accordance with Clause 8.2, or other materials if
it can be demonstrated by the kingpin manufacturer that the material is weldable without
degrading the mechanical properties of the finished kingpin (refer to Clause 6 for
mechanical properties of M-rated kingpins).
NOTES:
1 A steel grade having a carbon equivalent (CE) of less than 0.87 (based on published nominal
chemical analysis) has been specified based upon Grade AS 1444, which is a steel commonly
used in Australia for the manufacture of kingpins.
2 Welding should comply with Appendix C, Paragraph C3.
8.2 Calculation of carbon equivalent
An equation for calculating the carbon equivalent is—

Mn Cr + Mo + V Cu + Ni
CE = C + + +
6 5 15
where
CE = carbon equivalent
C = percentage carbon content
Mn = percentage manganese content
Cr = percentage chromium content
Mo = percentage molybdenum content
V = percentage vanadium content
Cu = percentage copper content
Ni = percentage nickel content
9 RECOMMENDED WEAR LIMITS

The recommended wear limits of kingpins for in-service operations are given in Table 9.1
and the dimensions are shown in Figure 9.1.
Where these wear limits are exceeded during the service life of the kingpin, the kingpin
should be replaced.
NOTE: Re-machining of kingpins or ‘building up’ kingpins by welding to achieve or restore
required dimensions is not an acceptable practice.
TABLE 9.1
RECOMMENDED WEAR LIMITS
Dimension
Kingpin
mm
mm F G H
50 49 71 73
75 73 100 73.3
90 86 112 62
NOTE: Dimensions F, G and H are illustrated in Figure 9.1.
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13 AS/NZS 4968.3:2011
FIGURE 9.1 TYPICAL KINGPIN
10 DIMENSIONS
10.1 General
New kingpins shall comply with the dimensions shown in Figure 10.1 and with the
additional dimensional requirements given in Clause 10.2 and Clause 10.3, as applicable.
Where a wear liner is attached to the skid plate, the dimensions in Figures 10.1, 10.2 and
10.3 (which control kingpin protrusion) shall be adjusted accordingly.
The surface texture for all surfaces of the kingpin below the skid plate shall not be rougher
than 3.2 µm RA when measured in accordance with ISO 4287.
Any internal radius resulting from a section change shall be not less than 3 mm.
10.2 Bolt-in kingpins
Flange bolt-in kingpins shall conform to the dimensions given in Figure 10.2. In addition,
M-rated bolt-in kingpins shall have a minimum flange thickness of 14 mm.
Taper bolt-in kingpins shall conform to the dimensions given in Figure 10.3.
NOTE: Figure 10.2 shows standard flanges and pin dimensions for 50 mm and 90 mm kingpins
and standard pin dimensions for 50 mm, 75 mm and 90 mm kingpins. For reasons of flexibility, it
is permissible to manufacture kingpins with any combination of the standard flange and the
standard kingpin. In such cases the marking relates to the kingpin size.
10.3 Weld-in kingpins
Weld-in kingpins shall be designed so that for their installation no welding is to be
performed within the non-welding zone shown in Figure 10.5.
Flange weld-in kingpins shall conform to the dimensions given in Figure 10.4. In addition,
M-rated in kingpins shall have a minimum flange thickness of 14 mm.
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AS/NZS 4968.3:2011
14
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(b) 75 mm KINGPIN
(a) 50 mm KINGPIN
FIGURE 10.1 (in part) BASIC DIMENSIONS OF KINGPINS

15
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(c) 90 mm KINGPIN
(a) 50 mm KINGPIN
FIGURE 10.2 (in part) FLANGE BOLT-IN KINGPIN

FIGURE 10.1 (in part) BASIC DIMENSIONS OF KINGPINS
AS/NZS 4968.3:2011
AS/NZS 4968.3:2011 16
(b) 75 mm KINGPIN
(c) 90 mm KINGPIN
LEGEND:
a Corresponds to the pivot dimension.
b To be checked before mounting a new part.
c Control dimension for built-in new kingpin (to be checked after mounting).
FIGURE 10.2 (in part) FLANGE BOLT-IN KINGPIN
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(a) 50 mm KINGPIN
(b) 75 mm KINGPIN
FIGURE 10.3 (in part) TAPER BOLT-IN KINGPIN

AS/NZS 4968.3:2011
AS/NZS 4968.3:2011 18
LEGEND:
a Corresponds to the pivot dimension.
b To be checked before mounting a new part.
c Control dimension for built-in new kingpin (to be checked after mounting).
(c) 90 mm KINGPIN
FIGURE 10.3 (in part) TAPER BOLT-IN KINGPIN
50 mm 75 mm 90 mm
Dimension
kingpin, mm kingpin, mm kingpin, mm
J 84.0−10.5 84.0−02.0 74.0−02.0
FIGURE 10.4 FLANGE WELD-IN KINGPIN
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K
Dimension
110
50 mm
kingpin, mm
19
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130
75 mm
kingpin, mm
FIGURE 10.5 NON-WELDING ZONE

150
90 mm
kingpin, mm
AS/NZS 4968.3:2011
AS/NZS 4968.3:2011 20
APPENDIX A
DYNAMIC TEST METHOD FOR D-RATED KINGPINS
(Normative)
A1 INTRODUCTION
This Appendix sets out a method for dynamic testing of D-rated kingpins.
A2 PRINCIPLE
A horizontal alternating test load is applied for a specified number of cycles.
A3 APPARATUS
The test rig shall incorporate a test bed simulating the trailer skid plate to mount the
kingpin. An alternating horizontal loading shall be applied at the centre of the kingpin
journal by a device simulating fifth wheel jaws, as shown in Figure A1.
NOTE: Guidance on the attachment of the kingpin to the simulated trailer skid plate is given in
Appendix C.
A4 PROCEDURE
A4.1 Inspection before testing
Measurements of dimensions F and G (refer to Clause 6.2 and Figure 9.1) and other
appropriate measurements shall be recorded to allow the determination of wear and
permanent deformation after the dynamic test (refer to Paragraph A4.4).
A4.2 Installation of kingpin
The kingpin shall be mounted on the test bed in a position geometrically identical with the
position in which it will be mounted on the skid plate, and with the same mechanical
attachments as nominated by the kingpin manufacturer.
A4.3 Dynamic test load
The test load (D T) shall alternate in a sinusoidal manner between +0.6D and −0.6D,
where D is the relevant D-value rating (in kilonewtons). The number of cycles shall be not
less than 2 ×10 6 .
The selected frequency shall not exceed 30 Hz, and shall be chosen not to coincide with the
natural frequency of the system.
A4.4 Inspection after testing
At the completion of the loading cycles, the kingpin shall be inspected for any residual
deformation, breaks, cracks, separation of components, or wear that would interfere or
degrade the function of the kingpin. The measurement and inspection techniques shall be
the same as for the inspection before testing (refer to Paragraph A4.1) and the results shall
be recorded.
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A5 REPORT
The test report shall include the following information:
(a) Kingpin identification (e.g. serial number) and nominal size of kingpin (i.e. 50 mm,
75 mm or 90 mm).
(b) D-rating of the kingpin, in kN.

(c) Test loading, cycle rate, and number of cycles.
(d) Description of test apparatus.
(e) A statement as to whether there was any residual deformation, breaks, cracks,
separation of components, or wear that would interfere or degrade the function of the
kingpin.
(f) A statement indicating the inspection procedures before and after testing and an
illustration of the measurements taken for the determination of wear and residual
deformation (Refer to Paragraphs A4.1 and A4.4), including the values for
dimensions F, G, and H (refer to Clause 6.2 and Figure 9.1) before and after testing.
(g) A reference to this test method, i.e. AS/NZS 4968.3, Appendix A.
FIGURE A1 APPLICATION OF DYNAMIC LOADING
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AS/NZS 4968.3:2011 22
APPENDIX B
DETERMINATION OF THE DYNAMIC STRENGTH OF D-RATED
KINGPINS USING FINITE ELEMENT ANALYSIS
(Normative)
B1 INTRODUCTION
This Appendix sets out requirements for the assessment of the dynamic strength of D-rated
kingpins using Finite Element Analysis (FEA) method, which may be used as an alternative
to the dynamic test method set out in Appendix A.
B2 FEA MODEL REQUIREMENTS

B2.1 FEA model description
The FEA model includes information on the following:

(a) Symmetry geometry and load symmetry/non-symmetry, i.e. is a whole model required
or a sector model.
(b) Model co-ordinate system(s) which shall be the same as vehicle co-ordinate systems.
(c) Units of measure used in the model.
(d) Material and geometry, linearity/non-linearity.
(e) The type of solution process, i.e. static and dynamic.
(f) Use of special purpose elements to represent mechanisms, e.g. rigid elements, gap
elements, friction elements.
(g) Difference between model mass and physical mass.
B2.2 Material
The material shall be either steel or alloy steel with the following properties:
(a) The value of ultimate tensile strength (UTS) lies between 800 MPa and 1200 MPa.
(b) Percentage of elongation shall be at least 10%.
If these properties are unknown, a test piece shall be taken from the area shown in
Figure B1 and tested to determine the properties.
B2.3 Limits
One of the following limits shall apply:
(a) FEA steady state test load The maximum tensile stress shall not exceed 40% of the
UTS.
(b) FEA dynamic test load The maximum tensile stress shall not exceed the endurance
limit after 2 × 106 cycles.
In addition, the D-rating shall not in any case exceed the following values:
(i) 210 kN for 50 mm flange bolt-in kingpins.
(ii) 500 kN for 50 mm weld-in or taper bolt-in kingpins.
(iii) 210 kN for 75 mm flange bolt-in kingpins with 150 PCD.
(iv) 500 kN for 75 mm weld-in or taper bolt-in kingpins.
(v) 500 kN for 90 mm kingpins.
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23 AS/NZS 4968.3:2011
B2.4 Codes
Half of the kingpin, through the symmetrical axis, shall be modelled with the following
codes:
(a) For H-element
(i) The aspect ratio shall be between 0.5 and 1.5 (i.e. sides of similar length).
(ii) Acute angles and distorted elements shall be avoided.
(iii) If eight-noded hexahedral elements are used, they shall be maximized.
(iv) If four-noded, tetrahedral or six-noded pentahedral elements are used, they shall
be minimized and avoided in critical stress regions.
(v) The thin section, such as flanges, shall consist of at least three elements through
the thickness.
(vi) A minimum of eight elements shall be used for small fillet radius and more than
eight elements shall be used for large fillet radius.

(vii) Careful attention shall be placed on boundary conditions particularly the
constraint methodology.
NOTE: At non-critical stress region, the fillet radius can be modelled as sharp edges.
(b) For P-element
(i) All fillet radii shall be modelled.
(ii) Careful attention shall be placed on boundary conditions particularly the
constraint methodology.
(iii) The solution shall be considered to have converged when the strain energy in
successive passes is within 5% of the previous pass.
(c) Test loads
The test load (D T) shall be applied as a distributed load to the centre of the kingpin
journal as shown in Figure B2. The result of the pressure distribution shall be not less
than one of the following test loads:
(i) FEA static test load of +0.6D.
(ii) FEA dynamic test load alternating between +0.6D and 0 .6D for a minimum of
2 × 106 cycles.
FIGURE B1 TENSILE TEST PIECE
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AS/NZS 4968.3:2011 24
FIGURE B2 APPLICATION OF STEADY STATE LOADING
B3 VALIDATION
For each type of kingpin model validated (i.e. flange or taper), at least one physical kingpin
shall be subjected to strain and deflection validation and a minimum of two physical
kingpins shall be subjected to endurance limit validation. FEA testing of kingpins shall be
conducted in accordance with this Appendix. Dynamic testing of kingpins shall be
conducted in accordance with Appendix A.
Measurement of strains and deflections shall be carried out in a static test with application
of loading as shown in Figure A1, strain gauge(s) shall be attached at critical stress
location(s) (e.g. at all radii in the flange to shaft radius).
The validation shall be carried out for the following:
(a) FEA steady state load test Comparison of maximum stress to the material’s
endurance limit.
(b) FEA dynamic load test Review of fatigue stress after 2 × 1 06 cycles.
(c) Strain and deflection FEA results for deflection in the direction of applied load and
measurements of strain at strain gauge location(s) shall be within 5% of dynamic test
results.
(d) Endurance limit Each kingpin analysed (for model validation purposes) shall pass
both dynamic testing in accordance with Appendix A and FEA testing in accordance
with this Appendix.
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25 AS/NZS 4968.3:2011
B4 STRESS ANALYSIS AND ENDURANCE LIMIT

B4.1 Stress analysis
A finite element stress analysis on the kingpin shall be carried out to determine one of the
following:
(a) FEA steady state test The magnitude and location of the maximum von Mises
surface stress in a tensile region.
(b) FEA dynamic test The fatigue life assessment of the kingpin.
B4.2 Steady state test endurance limit
The endurance limit shall be determined, based on the material properties (40% of UTS)
and compared to the maximum von Mises surface stress in a tensile region with the
endurance limit.
B5 REPORT
The test report shall include the following information:

(a) Kingpin identification (e.g. serial number) and nominal size of kingpin (i.e. 50 mm,
75 mm or 90 mm).
(b) Methodology including a description of the finite element modelling software, model
constraints (location and application), applied load (magnitude, location and
application), fatigue material data and number of test cycles (where applicable).
(c) A statement regarding the material properties (including the material endurance limit
where applicable) and the D-rating.
(d) A reference to the validation of the FEA modelling technique for the type of kingpin
(i.e. flange bolt-in, taper bolt-in or flange weld-in).
(e) Results of stress analysis and endurance limit.
(f) A reference to this test method, i.e. AS/NZS 4968.3, Appendix B.
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AS/NZS 4968.3:2011 26
APPENDIX C
GUIDELINES FOR THE ATTACHMENT OF KINGPIN TO SKID PLATE
(Informative)
C1 SCOPE
This Appendix sets out recommendations for the attachment of kingpins to the semi-trailer
skid plate.
NOTE: Although the recommendations on methods of attachments are not mandatory in this
Standard, they may be specified as statutory requirements by regulatory authorities if considered
appropriate.
C2 STRENGTH OF ATTACHMENT
Requirements for the strength of attachment of a kingpin to a skid plate are set out in
Clauses 4 and 5.
C3 METHODS OF ATTACHMENT
The kingpin should preferably be attached to the skid plate by bolting to a housing which
has been welded to the skid plate.
NOTE: Bolt-in kingpins are preferred as they are easier to replace once worn, and are not prone
to localized heat effects from welding.
For flange bolt-in kingpins, the bolts used should be of Class 8.8 in accordance with
AS 1110.1 or equivalent and as shown in Figure 10.2. The bolt should be tightened to a
torque of 120 Nm to 140 Nm for M14 bolts or 330 Nm to 370 Nm for M20 bolts. Adequate
provision for locking should be made, e.g. wire locking. Spring washers are not
recommended.
If the kingpin is to be welded to the skid plate, a suitable design should be used which
allows the welding to be applied sufficiently far from the critical areas of the pin to prevent
adverse heat effects. Welding is not recommended in the zone bounded by the broken line
in Figure 10.5 (see Clause 10.3). All welding should be subject to process control, in
particular preheating of the immediate weld zone to not less than 200°C and not more than
300°C, use of low-hydrogen techniques, and where necessary post-weld heat treatment.
NOTE: A preheating temperature of 300°C should not be exceeded under any circumstances.
When fixed in position, the kingpin axis should be at an angle of 90 ±1° to the skid plate in
all directions.
When a wear liner is to be used between the coupler plate and the skid plate, the kingpin
protrusion dimension H, as shown in Figure 10.1, should be adjusted accordingly.
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27
NOTES
AS/NZS 4968.3:2011
AS/NZS 4968.3:2011
28
NOTES
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LICENCE

Licensee: Mr Allan Wells

Date: Friday, July 12, 2013 8:07 AM

1. Definitions and Interpretations

Licence means the right to access and use the Product.

Licensee means the purchaser and user of the Product.

3.2. The Licensee isLearn

Part 3: Kingpins and associated

coupling between articulated vehicle

The following are represented on Committee ME-053:

Mechanical coupling manufacturers

Keeping Standards up-to-date

This Standard was issued in draft form for comment as DR 07401.

Australian/New Zealand Standard™

Heavy road vehicles—Mechanical

Part 3: Kingpins and associated

Originated as part of AS D14—1968, AS D15—1968, AS 1771—1975, AS 1772—1975,

ISBN 978 0 7337 9834 4

This Standard is Part 3 of AS/NZS 4968, Heavy road vehicles—Mechanical coupling

9 RECOMMENDED WEAR LIMITS ......................................................................... 12

STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND

Australian/New Zealand Standard

Heavy road vehicles—Mechanical coupling between articulated vehicle

Part 3: Kingpins and associated equipment

Requirements covering mechanical properties, dimensional standards for interchangeability

intermediate components (e.g. retention plate).

3.13 Skid plate locking key

4.6 Attachment of skid plate locking key

FIGURE 4.1 SKID PLATE DESIGN LOADS

FIGURE 4.2 SKID PLATE FLATNESS LIMITS

Kingpin size Dimensions, mm

FIGURE 4.3 TYPICAL SKID PLATE LOCKING KEY

6.3 M-rated kingpins

have the following mechanical properties:

FIGURE 6.1 TENSILE TEST PIECE

An equation for calculating the carbon equivalent is—

9 RECOMMENDED WEAR LIMITS

FIGURE 9.1 TYPICAL KINGPIN

FIGURE 10.1 (in part) BASIC DIMENSIONS OF KINGPINS

FIGURE 10.2 (in part) FLANGE BOLT-IN KINGPIN

FIGURE 10.2 (in part) FLANGE BOLT-IN KINGPIN

FIGURE 10.3 (in part) TAPER BOLT-IN KINGPIN

FIGURE 10.3 (in part) TAPER BOLT-IN KINGPIN

J 84.0−10.5 84.0−02.0 74.0−02.0

FIGURE 10.4 FLANGE WELD-IN KINGPIN

FIGURE 10.5 NON-WELDING ZONE

(b) D-rating of the kingpin, in kN.

FIGURE A1 APPLICATION OF DYNAMIC LOADING

B2 FEA MODEL REQUIREMENTS

The FEA model includes information on the following:

eight elements shall be used for large fillet radius.

FIGURE B1 TENSILE TEST PIECE

FIGURE B2 APPLICATION OF STEADY STATE LOADING

B4 STRESS ANALYSIS AND ENDURANCE LIMIT

The test report shall include the following information:

Standards New Zealand

Australian/New Zealand Standards

Visit our web sites

ISBN 978 0 7337 9834 4 Printed in Australia

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