standard durable drum brake axle prime dca family – durable disc brake … · 2016-06-05 · •...

www.jost-world.com

Standard

Prime

Durable Drum Brake Axle

DCA Family – Durable Disc Brake Axle

JOST Axle Systems

Standard

Prime

JOST Trailer Axles

Innovation meets experience

JOST is a corporate group that has been a global leader in the production of systems, modules and components

since its foundation in 1952. On the african market it has been present for more than 50 years.

In 2015 JOST expanded its portfolio with Axle Systems, formerly Mercedes-BenzTrailerAxleSystems. With this

Prime-Series, JOST offers weight-saving trailer axles for a wide range of uses. Innovative products from the axle

series DCA and the use of disc brakes revolutionised the trailer market in a long-lasting way.

JOST and the experts from MercedesBenz have now developed an addition to the existing axle programme,

especially for Africas toughest environment: The Standard-Series, a robust and high performance running gear. The

new drum brake axle is a very durable and delivers optimum performance under cost-effective aspects. Furthermore

it is especially easy to maintenance and hte spare parts are widely available through JOST’s worldwide network.

The beam

• One piece beam design with high grade seamless

tube material to minimize weight at matching rated

capacity.

• Non-welded, uniformity & consistency beam wall

thickness to optimize durability & performance.

• Water-jet peening process inducing compressive

residual stresses on surface and improving the

beam’s fatigue life.

• Beam straightening process to eliminate

unexpected tire wear.

• Surface cleaning and dual layers coating for better

rust resistance.

The spindle

• Thicker wall section of straight spindle & induction

hardened on spindle journal to optimize durability &

product lifespan.

• High precision machined bearing journal ensured

best fitment of taper bearings and improved wear

resistance.

• 100% magnetic flow inspection on all spindles

ensuring zero defect.

• Removable end cap caters for tire inflation systems

fitment.

The seal & bearing

• Stemco double lips grease seal with auto gyration

has better leak protection, dirt and moist exclusion &

proven to be longer lifespan.

• Separate tapered roller bearing configuration

HM518445/10 optimized for strength, durability

and long life whilst retaining industry standard

sizes.

The brake

• Bolt-on flange mounted brake spider for ease of

service and replacement.

• High precision 3-points broaching process on spider

brackets to correct distortion and ensure consistency

of brake performance caused by welding.

• E-coated fabricated brake shoes to maximize

corrosion protection.

• Swift-change shoe, thicker & high performance

friction material for optimum wear rate, thus

reduce vehicle down time.

• Induction hardened on brake shoe pivot and roller

pins to have better wear resistance.

The wheel-end

• Single or twin wheel with 0mm wheel offset and

suitable for 22.5” wheel.

• High grade cast material with higher tensile strength

for stringent environment & off-road conditions.

• Advance CNC machining to reduce tolerances for

best fit, form & function.

• Outboard mounted drum configuration eliminates

risk of contamination during brake servicing.

Trailer Axles Standard Series Durability and Performance

C-01 AX 103 / 107 C-01 AX 109 / 110

Axle capacity 11 t

Beam diameter Round ø127 mm

Axle track 1,920 mm 2,140 mm

Total length 2,229 mm 2,449 mm

Distance of brake chamber 233 mm 453 mm

Spring centre 1,060 mm (Mech. Suspension)1,000 mm (Air Suspension)

1,280 mm (Mech. Suspension)1,220 mm (Air Suspension)

Weight (inclusive ASA) ~340 kg ~351 kg

Brake configuration S-Cam, Fabricated brake shoe

Pitch circle diameter 335 mm

Pilot hole diameter 281 mm

Drum configuration Outboard mounted

Brake size S420 x 180

Wheel fixing 10 - M22 x 1.5 ISO

Bearing type 2 x HM518445/10

Lubrication Grease

Slack adjuster Automatic, 37 splines

ABS Optional

General Specifications

• Rated loading capacity of 11 t per axle

• Availability in different track lengths with ø127 mm round beam profile

• Outboard mounted drum design with 420x180 mm S-Cam brakes

• High quality HM518445/10 taper roller bearings

• Automatic slack adjuster and optional ABS kit prep

• Suitable for both air & mechanical suspension fitment

1000 Air Suspension

1060 Mechanical Suspension

233

1920 ±5

1385 ±5

2229 ±5

12

62

88

25TR 1946 ±5

ø 33

5

ø 28

1

76.2

171.

45

323.

85

38

Hub Cap

ABS

ø69.

7

681

152.

4

181

153

ø 127

ø 14

Nameplate

Air Suspension

• Maximum rated capacity of 9 t per suspension

• Ride height range 250–430 mm with 450 mm air spring offset

• High tensile steel with one-piece stamp design front hanger bracket

• Adjustable pivot eye tracking device to allow fine adjustment after system has been fitted on the chassis

• Cantilevered monoleaf trailing arm

• Standard cast spring seat

• Total travel of 190 mm with safety steel rope to limit axle travel

• High performance air spring & damper

• Dual side or single side axle lift available

C-02 AR 101 C-02 AR 100

Capacity 9 t

Ride height 250 mm 430 mm

Spring centre (max) 1,000 mm

Air spring offset 45 mm

Air spring diameter 300 mm

Axle travel (up/down) 70 / 120 mm 100 / 100 mm

Weight ~180 kg ~190 kg

Axle lift Optional

M30 torque: 900 Nm

A

M24 torque: 420 Nm M24 torque: 600 NmM16 torque: 200 Nm

M12 torque: 200 Nm

500

450

350

276

123

352

290

430

100

100

140

300

7835

160

30

95°

20°

ø127

11.00R20

641

348

ø300

45190

910

80

ø210

223˜

250

185

100

130

73

20

1000

1920

82

500

276

123

352

290

A

M30 torque: 900 Nm

310

140 300

7835

160

M24 torque: 420 Nm M24 torque: 600 NmM16 torque: 200 Nm

11.00R20

M12 torque: 200 Nm

250

40

70 ø127

ø300

120

≈31

0

641

45190

910

ø210

73

223˜

250

1000

100

1920

80

20

348

108.

5

82

Mechanical Suspension

• Maximum rated load of 22 t for tandem & 36 t for tri-axle configurations

• Synchronized swinging of durable fabricated equalizer improves load sharing in off-road environment

• High tensile steel fabricated brackets & equalizer beam with proven design for tough road environment

• Replaceable wear pad to increase product life span and durability

• Offer both under and overslung configurations

• Ease of serviceability & axle alignment

1138 1138

458 458

220 220 200

1360Nameplate

M24: 420 Nm

M12: 110 Nm

330

55

M24x2: 550 Nm

410/294

138

Unlo

ad

138

Unlo

ad

125

225

25

M12: 110 Nm

480/365 ø 127

330

37

FH1

330

1138 1138

458

55

4581360

183

265

Unlo

ad

183

Unlo

ad

FH FH

Nameplate

M24: 420 Nm

M12: 110 NmM12: 110 Nm

M24x2: 550 Nm

ø 127

544/389365/200

Nameplate

1138

ø 108511.00R208.00V-20

458 458

1138

M24: 420 Nm

M24x2: 550 Nm

M12: 110 Nm

1360

1360 1360

ø 127

220 220 220

M12: 110 Nm

330

330

330

138

FH1

50

125

125

2537

225

Unlo

ad

138

Unlo

ad

138

Unlo

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5

220

5 5

FH2

FH3

410/294 480/365 480/365

122

122

122

79

115 12

2

97

The special equipment for Standard and Prime Series

Preparation for tyre inflating system

Preparation of the DCA Family axles for deployment of a

tyre inflating system on the trailer enhances the vehicle‘s

operational safety and availability. Threaded through-bores

in the axle journals serve as compressed air connections

for a tyre inflating system, which prevents excessively low

tyre pressure. Longer service lives for the tyres, less rolling

resistance for the trailer and an attendant reduction in fuel

consumption for the truck/trailer combination lower the

required scope of maintenance work and improve the

vehicle‘s economic efficiency.

The Twin Lifts

The Twin Lifts are suitable for all applications with

medium and high ride heights. They are characterised

by their robust construction and low weight. The Twin

Lifts reduce effort to a minimum even when retrofitted

and are geared towards special usage cases.

The Wipper Lift

Wipper Lifts are designed for use in mega-trailers and

other vehicles of a low ride height. They offer maximum

ground clearance thanks to their shallow and stable

construction, even for vehicles of a low ride height.

Thanks to their lifting power, the WPs are suitable for use

with both the DCA family and the DCA Steermaster.

Hubodometer

Hubodometers are used to calculate distance

driven, independent of the truck, for all types of

wheeled vehicles. They are characterised by a

hermetically-sealed measuring unit. This prevents

the formation of condensation and makes them

maintenance-free and tamper-proof. The mileage is

shown as a six-digit display in km and can be set to

miles on request.

DCA Family – Durable Compact Axle Prime Series

The fully-modular axle construction opens up unlimited possibilities with a minimal number of different parts. For you,

the customer, this means fewer replacement parts, lower storage costs and, last but not least, lower life cycle costs

thanks to unmatched quality.

The hanger bracket

With three retaining bra-

ckets each – in some cases

also optionally available in

stainless steel – the DCA

Family in combination with

the appropriate air bellows

supports makes possible

all driving heights from 215 mm to 535 mm, from

megatrailer to tipper.

The compact bearing

Maintenance-free thanks

to the use of state-of-

the-art compact-bearing

technology that has been

proven a millionfold.

The wheel head

A robust construction for

19.5" or 22.5" wheels that

has proven itself millions of

times. The optimal heat dis-

sipation ensures a very long

lifespan for the brake discs,

brake pads and storage.

The brake discs – made out of a wear-resistant alloy –

and the wearing parts are structurally identical to those

of Mercedes-Benz lorries.

The beam

The compact axle beam gives the

axle family the name DCA –

Durable Compact Axle. Inte-

grating all the axle functions

creates a compact axle

housing that is extremely

durable and lightweight

thanks to its innovative

construction. The axle housing integrates the trailing

arm, axle tube, brake flange and axle journal, forming

a perfect unit.

The tailend

The DCA family can be

implemented with standar-

dised, weight-optimised

or application-specific

tailends, covering all areas

of usage.

The L7 disc brake

The new DCA L7 disc

brake for 22.5" use was

designed to be weight-

saving for maximal loading

capacity. Optimised for

the DCA family, the disc

brakes save more than 8 kg

per axle compared to the current systems.

DCA Weightmaster

DCA Megamaster

The DCA Weightmaster is the core member of the axle family. Its

low weight – from just 390 kg, depending on which version –

coupled with its durability, the advantage of fewer components

(due to its monocoque design) coupled to the maintenance-free

compact bearings, makes it ideal for use in the European trans-

port industry. With its modular design, it is compatible with nearly

all trailers, from platform semitrailers, curtainsiders, tippers, tan-

kers and bulk distribution. The DCA Weightmaster is compatible

with 19.5“ or 22.5“ wheels.

The DCA Megamaster was designed specifically for large-

volume semitrailers with an interior height of three metres. This

special-purpose axle and suspension is for high-volume road

haulage applications, and vehicles that require a long axle travel,

this range is based on the innovative and proven components of

the DCA Family. Despite the low ride height, loading docks can

be reached for the purpose of loading and unloading.

TE4-8N / TZ4-8N TE5-8L / TZ5-8L TE5-8K / TZ5-8K TE5-8N / TZ5-8N

Permissible axle load 9 t

Wheel offset ET 120; ET 0

Wheel track, spring centre Suitable for all standard vehicle versions

Air bellows diameter (Ø) 300 mm; 360 K; 360 L

Ride heights 225–535 mm

Lift range Depending on version

Min. wheel size 19.5” 22.5” 22.5” 22.5”

Brake SN 6 DCA L7 SK7 SN 7

Brake disc diameter (Ø) 377 mm 430 mm 430 mm 430 mm

Weight* ≥ 381 kg ≥ 394 kg ≥ 402 kg ≥ 420 kg

Type of bearing Maintenance-free cartridge bearing

Paint system Cathodic dip priming

Tyres Single





Air bellows diameter (Ø) 360 M


Lift range 280 mm

Min. wheel size 19.5” 22.5” 22.5” 22.5”



Weight* ≥ 414 kg ≥ 423 kg ≥ 431 kg ≥ 449 kg



Tyres Single

DCA Airmaster

DCA Steermaster

As the world‘s only axle that stores compressed air for the bra-

kes and air suspension in the axle housing, the DCA Airmaster

is able to dispense with the conventional compressed-air tanks

that appear on trailers or semitrailers, thereby freeing up space

beneath the trailer as well as reducing weight by up to 50 kg.

The DCA Airmaster paves the way for the introduction of trailbla-

zing vehicle concepts.

An ideal addition to the DCA Family. With a steering angle

of max. 16 degrees, it negotiates bends with consummate

ease, while the lightweight design allows high payloads. In

addition, the steering axle reduces the truck‘s tyre wear and

fuel consumption. Like the other axles in the family, the DCA

Steermaster is based on the tried-and-trusted components of

the DCA modular system and, therefore, offers the versatility you

expect when it comes to meeting your transport needs.

TE4-8N TE5-8L TE5-8K TE5-8N


Wheel offset ET 120


Air bellows diameter (Ø) 300 mm; 360 K; 360 L



Min. wheel size 19.5” 22.5” 22.5” 22.5”



Weight* ≥ 381 kg** ≥ 389 kg ≥ 397 kg ≥ 416 kg



Tyres Single

Storage volume Up to 40 l per axle

** Additional weight saving of up to 50 kg per vehicle due to absence of compressed-air tanks.

TE4-8N TE5-8L TE5-8K TE5-8N


Wheel offset ET 120

Wheel track, spring centre 2040 mm; 980 mm 2090 mm; 1030 mm 2090 mm; 1030 mm 2140 mm; 1080 mm

Air bellows diameter (Ø) 300 mm; 360 K; 360 L; 360 M



Min. wheel size 19.5” 22.5” 22.5” 22.5”



Weight* ≥ 588 kg ≥ 596 kg ≥ 604 kg ≥ 622 kg


Max. steering angle 16°

Paint system Two-component paint

Tyres Single

* Standard air bellows support instead of aluminium air bellows support corresponds to a 9-kg weight increase per axle.

DCA Railmaster

DCA Pavemaster

The new DCA Railmaster is designed for use in combined road-

rail-sea transport. If a semitrailer is lifted by crane, conventional

air bellows can be damaged while the vehicle is being set down.

That is why the air bellows of the DCA Railmaster consist of two

interlocking components which can separate during lifting or

driving without air and ensure the optimal position of the air

bellows when the semitrailer is set down.

The DCA Pavemaster unites an optimised tail end design

especially for tippers in road finisher application. The DCA

Pavemaster has been built to the highest standards to meet the

specific demands of road construction. With the new design we

were also able to reduce the weight of the DCA Pavemaster by

up to 12 kg per axle.





Air bellows diameter (Ø) 300 mm



Min. wheel size 19.5” 22.5” 22.5” 22.5”

Brake SN 6 DCA L7 SK 7 SN 7


Weight ≥ 397 kg ≥ 410 kg ≥ 418 kg ≥ 436 kg



Tyres Single





Air bellows diameter (Ø) 360 mm / 360 K

Ride heights 390–440 mm; 460–510 mm


Min. wheel size 19.5” 22.5” 22.5” 22.5”

Brake SN 6 DCA L7 SK 7 SN 7


Weight* ≥ 388 kg ≥ 391 kg ≥ 399 kg ≥ 407 kg



Tyres Single

JOST, Germany Tel. +49 6102 295-0, [email protected], www.jost-world.com

Achsen Systeme, Germany Tel. +49 5674 9237-0, [email protected], www.dca-family.com1174

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4 Modul landing gearAny customer specs can be fulfilled thanks to the landing gear’s modular construction with variable mounting and bolting heights, its differing crank and connection shaft lengths and its four different foot types. Furthermore, JOST offers a multitude of special landing gears for special applications.

3 King pinsKing pins are available in 2” and 3 ½” for all systems in various models.

2 Fifth wheel couplingsThe extremly broad selection comprises of 2” and 3 ½” fifth wheel couplings in a wide variety of mounting heights, bearing types and models. The program is completed by mounting plates, sliders and dual height fifth wheel systems.

5 HubodometerThe range of products includes various hubo do meters for calculating the distance driven, independent of the vehicle, for all types of wheeled vehicles.

1 SystemsSensor-controlled systems monitor and automate manual processes, thus providing for more safety and efficiency in your fleet.

7 TRIDECTRIDEC develops and produces – independent from axle or trailer manufacturer – mechanically, hydraulically and electronically controlled steering systems for trailers as well as axle suspension systems.

12 Towing hitchesROCKINGER offers a multi-faceted range of products for road traffic – towing hitches, hook coupling, towingeyes, accessories, the multi-functional alternatingsystem VARIOBLOC and special models.

11 Drawbars and drawbar eyesROCKINGER drawbars and towing eyes are available in various models and can be designed to suit the customer’s specific needs.

13 Agricultural hitchesSuitable for the all needs: ROCKINGER offers an extensive range of products for agriculture and forestry: Towing hitches, trailer trestles, clutch carriers, towing eyes, drawbars and accessories.

9 Container equipmentParts for alternating systems, supports, locks and bolsters, swap body lifting devices, guide rollers and bearings – all components required in a flexible fleet.

10 Ball bearing turntablesThe ball bearing turn tables and slewing rings were the first products that JOST produced. The wide range of top-quality ball bearing turntables is based on this experience.

8 On-vehicle hydraulic systems Edbro is a market leader in on-vehicle hydraulic systems including front end, underbody and ejector cylinders, waste handling equipment and customised hydraulic kit solutions.

6 Axle SystemsJOST Axles – engineered by Mercedes-BenzTrailerAxleSystems – offer weight-saving trailer axlesfor a wide range of uses. Innovative products from theaxle series DCA revolutionised the trailer market in along-lasting way.

standard durable drum brake axle prime dca family – durable disc brake … · 2016-06-05 · •...

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