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4.

PROPELLER SHAFT

SECTION 4

PROPELLER SHAFT

1. INTRODUCTION ...................................................................................................................... 3

2. GENERAL
2-1. MAIN DATA AND SPECIFICATIONS ............................................................................... 4
2-2. INSTALLATION TIGHTENING TORQUE ......................................................................... 5
2-3. TIGHTENING TORQUE .................................................................................................... 8
2-4. RECOMMENDED GREASE ............................................................................................ 10

3. PROPELLER SHAFT ASSEMBLY


3-1. DISASSEMBLY ............................................................................................................... 11
3-2. INSPECTION AND REPAIR ........................................................................................... 18
3-3. DIAGNOSIS ..................................................................................................................... 20
3-4. CARDAN SHAFT ............................................................................................................ 21

4. SPECIAL TOOLS .................................................................................................................. 28

1
4. PROPELLER SHAFT

2
4. PROPELLER SHAFT 4. PROPELLER SHAFT

1. INTRODUCTION
A propeller shaft is a steal tube normally consisting if two unversal joints and a slip joint. The propeller
shaft transfers power from the transmission output shaft to the rear drive axle.
A differential in the axle housing transmits the power to the rear wheels, which then move the car
forward for backward. Propeller shafts differ in construction, lining, length, diameter, and type of slip
joint. Typically, the propeller shaft is connected at one end to the transmission and at the other end to
the rear axle, which moves up and down with wheel and spring movement.

PS0600
PS0590

Movement of universal joints Movement of slip joints

3
S1610 S1710 S1810 C2060 INTER INTER INTER
MODEL UJ250 (CARDAN C2040) (KASCO) (KASCO)

Item COUPLING DRIVE COUPLING DRIVE DRIVE COUPLING DRIVE COUPLING DRIVE DRIVE DRIVE DRIVE
SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT

Tube-outside dia. x
ø 88.9 x 4 ø 101.6 x 5 ø 114.3 x 6.6 ø 120x 6.6 ø130 x 6 – – –
2. GENERAL

wall thickness mm
4. PROPELLER SHAFT

Universal joint Spider


137 154.8 191.8 152 166 135.2 154.8 177.9
length mm
Spider outside dia. mm 47.6 49.2 57 68 47.6 49.2 49.2

Flange yoke bolt dia. mm M14 x 1.5 M16 x 1.5 M14 x 1.5 M16 x1.5

Spline outside dia. x


Number of teeth – ø 50.8 x 16 – ø 63.5 x 16 ø 76.2 x 16 – ø78.0 x 30 ø81.7 x 40 ø61.5 x34 63.5 x16 ø78 x30

Max. value of

4
150/3,000 200/3,000 200/3,000 225/3,000 340/2,000 330/2,000 400/2,000 176/2,000 200/2,000 200/2,500 100/2,500
2-1. MAIN DATA AND SPECIFICATIONS

.
unbalance g cm/rpm

Applicable vehicle 8 Ton super long 11.5 Ton Cargo long 15Ton dump 55 Ton tractor 24 Ton Dump Model no Model no
19.5 Ton cargo short
8 Ton cargo long 14 Ton cargo long 15Ton mixer S1710 UJ250
19 Ton cargo long vehicle
8.5 Ton cargo short 16 Ton Cargo short 22.5Ton 19 M pull cargo S1810
Cargo 19 Ton Dump
8.5Ton cargo 16 Ton cargo standard UJ250
25 Ton cargo
21Ton cargo
8.5Ton cargo long 15 Ton dump vehicle

40Ton tractor
4. PROPELLER SHAFT
4. PROPELLER SHAFT

2-2. INSTALLATION TIGHTENING TORQUE


• 4 X 2 SERIES TRUCK INSTALLTION

• 8Ton Cargo Long / Super Long, 8.5Ton Super Long

• 8.5Ton Cargo short

• 8.5Ton Cargo standard

• 40Ton tractor

18~20.8kgf.m(40T tractor : 28~32kgf.m)

7.6~9.3kgf.m

TO TRANSMISSION TO REAR AXLE TO CENTER BEARING

PS0041

5
4. PROPELLER SHAFT

• 6 X 4 SERIES TRUCK INSTALLATION

• 11.5Ton cargo / 14Ton cargo

• 16Ton cargo short / Standard

• 15Ton dump / mixer

• 19M pull cargo

• 55Ton tractor

28~32kgf·m
(Full cargo/tractor:18~20.8kgf·m) 28~32kgf·m

14.2~17.4kgf·m
(Full cargo:18~20.8kgf·m)

TO TRANSMISSION, TO INTER SHAFT TO CENTER BEARING


REAR AXLE PS0051

6
4. PROPELLER SHAFT

• 8 X 4 / 10 X 4 SERIES TRUCK INSTALLATION

• 19, 19.5, 22.5, 25Ton cargo

• 19Ton, 24Ton Dump/ 21, 22.5Ton Cargo

18~20.8kgf·m 18~20.8kgf·m 28~32kgf·m

TO TRANSMISSION, TO CENTER BEARING TO INTER SHAFT


REAR AXLE

PS0061

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4. PROPELLER SHAFT

2-3. TIGHTENING TORQUE

• 4 X 2 SERIES TRUCK TIGHTENING TORQUE

2.4~3.3kgf·m

COUPLING PROPELLER SHAFT To Rear axle

To Transmission

2.4~3.3kgf·m

DRIVE PROPELLER SHAFT

18~20.8kgf·m

PS0040

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4. PROPELLER SHAFT

• 6 X 4 SERIES TRUCK TIGHTENING TORQUE

To forward
rear axle

To forward
rear axle

4.4~5.8kgf·m

#1 Propeller Shaft

To Transmission
28~32kgf·m

4.4~5.8kgf·m

Inter-Propeller shaft

To rearward
rear axle
28~32kgf·m

PS0050

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4. PROPELLER SHAFT

• 8 X 4 / 10 X 4 SERIES TRUCK TIGHTENING TORQUE

Coupling propeller shaft

18~20.8kgf·m

Drive propeller shaft

18~20.8kgf·m

PS0062

2-4. RECOMMENDED GREASE

Lubrication point

• Universal joints and sliding sleeve • Center bearing

Type of Iubricants

ALVANIA ALVANIA
EP #2 EP #2
grease grease

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4. PROPELLER SHAFT

3. PROPELLER SHAFT ASSEMBLY


3-1. DISASSEMBLY
3-1-a. DISASSEMBLY STEPS (4 X 2 SERIES TRUCK)

8
7
Coupling Propeller Shaft
4
5 2
3
9 6
9
1

3 10

11

2 3
Drive Propeller Shaft

2 PS0100

1. Journal bearing kit 5. Companion flange 9. Shaft tube


2. Flange yoke 6. Center bearing kit 10. Felt ring
3. Spider 7. Dust cover, center bearing 11. Sleeve yoke
4. Lock nut 8. Retainer
Reassembly is inverse of disassembly
*
3-1-b. DISASSEMBLY STEPS (6 X 4 SERIES TRUCK)

#1 Propeller Shaft

2
4

3 1

2 Inter Propeller Shaft


4

3 1 PS0150

1. Bolt 3. Flange
2. Journal bearing kit 4. Spider

* Reassembly is inverse of disassembly


11
4. PROPELLER SHAFT

3-1-c. DISASSEMBLY STEPS (8 X 4 / 10 X 4 SERIES)

Coupling Propeller Shaft

2
3

3 Drive Propeller Shaft

PS0170

1. Bolt spcer 4. Yoke shaft


2. Journal bearing kit assembly, spider 5. Center bearing assembly
3. Flange yoke 6. Flange

* Reassembly is inverse of disassembly

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4. PROPELLER SHAFT

IMPORTANT OPERATIONS (DISASSEMBLY)

Needle roller bearing


• Needle roller bearing
• Tap out the bearing by applying a shock to
the shoulder of the yoke.
• Remove the needle roller bearing remain-
ing in position by tapping lightly on the spi-
der.
• Remove the remaining bearings in the simi-
lar manner.
• Care should be so taken that the needle
PS0110 rollers may not be broken or lost.

• Lock nut
• Flange yoke bracket
Type Hex nut
P50, P60 50

Remove the lock nut and flange yoke braket


from propeller shaft using a hex wrench.

PS0120

• Cushion rubber assembly


Remove the cushion rubber assembly from
end of the propeller shaft using a special
tool(puller).
(Special tool: CA21041)

Puller

PS0130

• Center bearing, rear case and oil seal


Remove the bearing from the case carefully
so as not to cause damage to the oil seal.

PS0140

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4. PROPELLER SHAFT

• How to remove propeller shaft(#1 and #2 shafts)


Bolt Flange yoke Nut • Place the front and rear wheels on the
wooden block.
• Place gearshift lever in the 1st or reverse
position.
• To prevent parts of the propeller shaft fall-
Companion ing down to the floor, install a pad under
flange
the propeller shaft or support the pad with
cable.
Front axle Rear axle
PS0171 • Make direction marks at all the propeller
shaft connecting portions to indicate correct
assembly direction.
• Loosen the flange yoke bolt.
Nut Flange yoke Bolt
• Loosen the flange yoke nut.
• Remove the propeller shaft from the ve-
hicle.

Companion
flange

Transmission Front axle


PS0172

Snap ring disassembly direction


• Journal bearing kit
Insert a " " type hook into the " " shaped
Snap ring hole of snap ring and pull it to split the kit.

PS0173

• Remove the bearing race assembly from


Hammer
the yoke. If it is difficult to disassemble
these parts from each other, tap the reverse
side of yoke with a hammer to remove jour-
nal bearing kit.

PS0174

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4. PROPELLER SHAFT

IMPORTANT OPERATIONS (REASSEMBLY)

• Flange yoke
The flange yoke at end of the propeller shaft
should be in alignment with the spline yoke as
Correct illustrated. The direction of the flange yoke at
each end of the propeller shafts(O-mark)
should be in alignment.
Reassemble the yoke so that its LH and RH
Incorrect are aligned within ±1° degree.

PS0260

• 4 X 2 SERIES TRUCK

O-mark

O-mark
PS0270

• 6 X 4 SERIES TRUCK

O-mark

O-mark

PS0350

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4. PROPELLER SHAFT

• 8 X 4 / 10 X 4 SERIES TRUCK

O-mark

O-mark

PS0420

• Cushion rubber reassembly


Center bearing
The center bearing must be installed without
force.

PS0280

• Spider
Install the bearing cover to spider.
Oil seal

Bearing cover

PS0300

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4. PROPELLER SHAFT

Install the grease fitting at an angle of approxi-


mately 45° degrees to the spider. The parts
should be so installed that all grease fittings
are pointed upward.

PS0310

• Needle roller bearing


Apply bearing grease to lip of the oil seal and
needle roller bearing.
Assemble the spider to the flange yoke. Us-
ing the spider as a guide, install the needle roller
bearing into the hole in the arm of the flange
yoke by tapping with a soft-faced hammer.
The needle roller bearing should move
smoothly.
PS0320

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4. PROPELLER SHAFT

3-2. INSPECTION AND REPAIR


Make necessary correction or parts replacement
• Spider if wear, damage or any other abnormal conditions
• Needle roller bearing are found through inspection.
• Cushion rubber
Inspect the following parts for wear, damage or
• Bracket
• Yoke other abnormal conditions.
• Flange
• Center bearing

Outside diameter of spider


• Fix the spider and measure its free play with
a dial indicator.
Pin diameter

• If the free play is beyond the following value,


replace with a new one.
(mm)
Standard 0.03~0.07
Limit 0.25

PS0180

Spider end play


• Measure the width “A” of the flange yoke.
• Measure the width “B” of the spider with the
needle roller bearing installed on opposed
ends of the spide.
Spider end play = Width of yoke “A”
- Width of spider “B”
(mm)

Limit 0.02 ~ 0.15


PS0190

PS0200

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4. PROPELLER SHAFT

Propeller shaft run-out


Support the propeller shaft at its ends and check
for run-out by holding the probe of a dial indicator
against the center part of the shaft.
If the amount of run-out is beyond the standard
value for assembly, use a bench press to heat or
abruptly cool the shaft or replace with a new one.
(mm)
Standard Limit
PS0210
0.3 0.5

Play in splines in normal direction of rotation


Check the amount of play in the sleeve yoke and
propeller shaft splines in direction of rotation using
Spline yoke
a pointed feeler gauge.
(mm)
Standard Limit
Spline
0.15 0.5

Use limit
PS0220

Inspection for out-of-balance


Measure the amount of out-of-balance at a point
between spiders.

PS0230

Center bearing
Dial indicator
• Support the center bearing assembly and in-
spect the movement in the shaft direction us-
ing dial indicator.
• Replace with a new one if the measured value
exceeds the following standards. (mm)

Standard 0.18 ~ 0.25


Limit 0.25
PS0240

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4. PROPELLER SHAFT

3-3. DIAGNOSIS
Complaints Cause Correetion

Misaligned yoke Rearrangement to mark

Worm unversal joint needle roller bearing Replace the spider kit

Length propeller shaft bending Replace the propeller shaft


High
speed Beyond the balance of propeller shaft Adjust the balance

Loosely tightened flange bolts Fit fixing torque


Vibration Wear, hardness of ball bearing Replace the ball bearing
of propeller
shaft
High of transmission Shafting of adequate position

Excessive toward shaft free play of Adjust clearance with shim


Low
speed unverasl joint spider

Excessive free play of slip joint spline Replace the yoke sleeve or

propeller shaft

Loosely tightened flange bolts Fit fixing torque

Loosely tightened flange bolts Fit fixing torque

Weaked or transformed of center bearing Replace the cussion


Starting
Wear of universal joint needle roller bearing Replace with spider kit

Excessive free play of slip joint spline Replace yoke sleeve or propeller
Noise
of propeller shaft
shaft
Excessive toward shaft free play of Adjust clearance with shim

universal joint spider

Driving Wear of universal joint needle roller Replace with spider kit

bearing

Wear handness of ball bearing Replace the ball bearing

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4. PROPELLER SHAFT

3-4. CARDAN SHAFT


3-4-a. TRANSPORT AND STORAGE
To prevent injuries of persons and damage to the cardan shafts always make sure that the shafts are
safely transported and stored.

PS0471

Please consider the following precautions


(1) Use strong nylon ropes or lifting belts. when using steel cords,protect the edges.

(2) Cardan shafts should be transported in horizontal position. For non-horizontal transportation addi
tional precautions must be taken to prevent the splined parts from separating.

(3) When lifting or putting down the shaft the moving parts (flange yoke and journal cross) may tilt and
lead to injuries.

(4) Avoid bumps and shocks during transport and storage.

1. Cover tube 2. Sealing tube

PS0481

(5) Do not store or handle the shaft with any stress or load on the cover tube (1) or sealing tube diameter
(2).

(6) Use appropriate frames or racks for storage


When cardan shafts are stored on pallets stacked up on top of one another the supports must be
one below the other because otherwise the tubes may bend and the result may be uneven running
or unbalance of the shaft.
The supports must only be used for the area of cardan tubes but never touch the cover tube or
sealing tube diameter of the length compensation.

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4. PROPELLER SHAFT

PS0491

When cardan shafts are stored in an up right position make sure, they cannot fall over.

Keep cardan shafts in a dry place.

3-4-b. INSTALLATION / DISASSEMBLY

1) Installation
(1) Safety relevant components of the vehicle and brake lines electric lines hydraulic and fuel lines
must be arranged in such a way that they cannot be damaged by a defective cardan shaft.

Danger of breakdown of important units!


Danger of fire!

(2) Suitable safety devices (e.g: catch bows,solid safety guards) must be provided to prevent the
parts of the shaft from being thrown around and to prevent damage to other parts of the unit if the
cardan shaft should become defective.

Danger to life!

(3) Cardan shafts are elastic and flexural bodies. Their bending vibration strength and their critical
whirling speed must be calculated. If necessary contact our specialists.

(4) For reasons of smooth running and safety of the shaft the n x b value (speed x deflection angle)
of the relevant joint size must not be exceeded.

2
PS0501

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4. PROPELLER SHAFT

(5) Check position of the yokes(1) of the shaft. Observe the arrow markings(2). (They must be in
alignment.)
The spline components are matched for a smooth fitting and must not be interchanged or re
mounted by 180° .
(6) Before installation remove the transport retainer device if any in case of doubt please contact the
supplier.
(7) Check the side and radial runout as well as the fit of the mounted flanges and the connected units.
(8) Do not turn the joints of the cardan shafts with assembly levers because this may damage the
grease nipples or sealing arrangement of the bearings. Use bolts and nuts of the prescribed
quality (strength)
(9) Only use bolts and nuts in accordance with the supplier's specification.
(10) The bolts should be evenly tightened crosswise with a torque wrench.
(11) When using cardan shafts wuthout length compensation one of the connecting units must be
flexible because otherwise there may be a distortion in the drive shaft with resulting damage.
(12) Midship shafts must have an axially movable center bearing.

La

La : Length compensation

PS0511

(13) If cardan shafts with length compensation or drive lines are used the companion flanges must
be firmly fitted on the shafts of the connected units.
(14) The journal cross assemblies of cardan shafts that have been stored for more than 6 months
must be relubricated with the prescribed grease before operation.
(15) When painting or putting on a noise-reducing compound make sure to protect the sliding range
of the seal (length compensation La)
To avoid unbalance the coatings must be put on evenly
(16) Protect rilsan coated splines (sleeve muff or sleeve yoke) against
-heat, solvents, mechanical damage
(17) When cleaning cardan shafts do not use aggressive chemical agents or pressurized water or
steam jets because the seals may be damaged and dirt or water may penetrate.
(18) Cardan shafts can be used for a temperature range between -25°C(-13°F) and +60°C(+140°F)
up to 80°C(176°F) but only for limited periods and not on a frequent basis.
There are special designs of cardan shafts for other ranges of temperature deviates from these
values.
(19) If cardan shafts are subjected to higher temperatures, e.g. due to noise reduction measures or
retarders provide for suitable cooling.

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4. PROPELLER SHAFT

*Installation of drive lines


-Midship shafts are supplied complete with center bearings ready for installation.
-The center bearing and the flange shaft are fixed on the midship shaft by means of bolts which
are secured against working loose
-For reasons of safety these bolts must never be loosened or retightened on new shafts. They may
only be loosened for repair work but they must be properly secured again after the repair.

Midship shaft without length compensation with center bearing


PS0521

-To avoid greater non-uniformity the drive lines consisting of the midship shaft with the center bear
ing and the normal cardan shaft must be installed in accordance with the prescribed yoke position
of the joints.

*Sturdy support/centre bearing bracket.

X-S

Sturdy support

Center bearing bracket

PS0531

-When installed the center bearing must be vertical in all directions and in centerlposition with re
gard to the horizontal axis of the midship shaft. Suitable mounting supports must be provided on
the frame side. A continuous sturdy support must be provided between the center bearing bracket
and the mounting support.

(20) To guarantee a safe bolting of the center bearing bracket of the midship shaft with the frame of
the vehicle always use the bolting prescribed by the manufacturer of the vehicle.
These bolts must by all means be secured against working loose in accordance with the in
structions of the vehicle manufacturer.
(21) The center bearing of the midship shaft must be installed without force.
Therefore the center bearing must not be bolted to the frame of the vehicle until the drive and
the driven sides of the drive line have been bolted down.

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4. PROPELLER SHAFT

Cardan shaft

Midship shaft
Support by e.g:
an assembling trestle or rope

PS0541

(22) With regard to the maximum permissible operating temperature cleaning etc. the center bear
ings must be handled in the same way as the bearings of cardan joints.

*Flange bolting
-To connect the cardan shaft with the companion flanges it is imperative to use high tensile
bolts of the quality 10.9 T and the corresponding all metal self locking nuts of the quality 10T
or such bolts and nuts that the manufacturer of the vehicle has prescribed.
Complete sets of bolting are available for all DIN and X-Serration flanges.
-All bolts must be tightened with the specified torque. The tightening torques Ta given in the
table are based on a 90% utilization of the elastic limit and apply to slightly oiled bolts.(Friction
coefficient µ = 0.13).
Do not use molycote paste or any other grease on the bolts and nuts.
Max. permissible tolerance for Ta: ±7%

X-Serration flanges (XS)

G1 G2 h

ød

Joint flange
PS0551

Thread Length Wrench Flange Flange Grip Height Torque


Shaft connection I size thickness thickness G1+G2 of nut Ta
ø (mm) (mm) (mm) G1 (mm) G2 (mm) (mm) h (mm) (N·m)

XS 120 M 10 40 17 14 10 24 9 70

XS 150 M 12 45 19 16 12 28 11 120

XS 180 M 14 50 22 18 14 32 12 190

XS 200 M 14 55 22 22 16 38 12 190

* XS180 : Dump

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4. PROPELLER SHAFT

*Companion flanges
As a rule cardan shafts are connected with the units by companion flanges. The material of the
companion flanges must have a tensile strength of min. 750N/mm2.
Design A - Connection with staggered teeth according to ISO 8667

øB
øA

H
A B Design
Shaft connection I1)xH2)
(mm) (mm)
XS 120 1223) 100 4x11 A
XS 150 155 4)
130 4x13 A
XS 180 180 150 4x15 A
XS 200 200 165 4x15 A

1) Number of boltholes per flange 2) Tolerance +0.2mm


3) ø120mm also possible 4) ø152mm also possible PS0561

1) Disassembly
*Before disassembly protect cardan shaft from spline separation
*Before removing the shaft from the companion flange make sure it cannot fall down.
Caution
The yoke may be damaged when removing the cardan shaft from the companion flange.
*Observe the directions for transport storage and installation of cardan shafts.
2) Maintenance
Maintenance work on cardan shafts used in vehicles and industrial equipment must be done
at regular intervals.
The scope and the intervals of maintenance work depend on the individual operating condi-
tions of the vehicle or the equipment.
Maintenance intervals
Depending on the type of vehicle the mileage or the service life and the operating conditions two
different scopes and intervals of maintenance are required. These are the "minor inspection" and
the "major inspection".

Inspections intervals
Use of vehicle
Minor Inspection Major Inspection

Commercial vehicle Every 100,000km or Every 500,000km or


in long distance traffic or similarly used vehicles after 1 year max. after 5 year max.

Commercial vehicle Every 300,000km or


used on road and off road and in city traffic and Every 50,000km or
after 1 year max. after 5 year max.
similar

Commercial vehicle
used on sites communal vehicles construction Every 25,000km or Every 100,000km or
machines,cranes,vehicles used in agriculture after 6 months max. after 2 year max.
and forestry,tractors,military vehicles and similar.

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4. PROPELLER SHAFT

Minor Inspection

Minor Inspection Correction

1.Check the bolts of the flanges and of the center bearing * If necessary retighten the bolts with a suitable torque
bracket for tightness. wrench and the torques prescribed by the manufacturer
of the vehicle or equipment.

2.Check whether there are snap rings on all bearing bushes. * Visual inspection of the seals of bearing bushes and
the length compensation. Defective seals may result in
excessive grease loss and breakdown of the cardan
shaft.
3.Check whether the rilsan coat on the sleeve is damaged or
shows abrasion.

4.Center bearing.

Outer flinger

Flange shaft
Rubber cushion
Center bolt
Center bearing bracket
PS0571

* Visual inspection of the center bearings of drive lines with * If the distance between the rubber cushion and the
regard to: outer flinger is greater the center bolt may work loose.
-Correct position of the rubber cushion in the center In this case checking should be done in connection with
bearing bracket. a major inspection.
-Correct position of the flange shaft.

5.Carry out a visual inspection for possible damage * Damaged paint coat
* Dents or notches
* Deformed tubes
* Eccentric cover tube of length compensation
* Cracks in component parts and tube

6.Check the joints and the length compensation for visible


or tangible back lash.

45
A B
PS0581

* Extend the cardan shaft for approx. 45mm and place the lugs
of the inner yokes at points A and B on a solid support.

* Fix the dial gauge holder at point C next to the weld on the
tube and place the dial gauge. directly next to the weld of the
protective sleeve(cover tube). Lift the cardan shaft at its
center of gravity so that the supports at points A and B
become free.

* Read axial backlash on the dial gauge.(The max.permissible


value is 0.17mm.)

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4. PROPELLER SHAFT

3) Regreasing intervals for joints

Use of vehicle Regreasing intervals

Commercial vehicle
Every 50,000km or after 1 year max.
in long distance traffic or similarly used vehicles

Commercial vehicle
used on road and off road and in city traffic and Every 25,000km or after 6 months max.
similar

Commercial vehicle
used on sites communal vehicles construction
machines,cranes,vehicles used in agriculture Every 12,500km or after 3 months max.
and forestry,tractors,military vehicles and similar.

* If drive through water shorter greasing intervals are necessary.

4. SPECIAL TOOLS

NO Tool name Tool number Configuration

1 3Rd Collar puller CA21041

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