SANY SRT95C Off-Highway Truck. Service Manual

2. Turn the steering wheel in both directions
several  times  to  relieve  pressure  in  the
steering system. Block all road wheels.
3. With a suitable container in position, remove
plug  (6)  and  drain  all  lubricant  from  the
planetary assembly.
4. Remove bolts (8), cover (34) from carrier
cover(39). Remove and discard 'O' ring (5).
Planetary assembly.
5. Pull out sun gear(13), snap ring (42) and
axle  shaft(41)  assembly  from  planetary
housing. Remove snap ring (42) from axle
shaft (41) and remove sun gear(13) from the
axle shaft (41).

Thrust washer (24) is a press fit on the shoulder

of sun gear (13) and should be removed only
if worn or damaged.
6.  Support  the  planetary  assembly  with
suitable  lifting  equipment  and  remove
planetary assembly mounting nuts  from the
wheel studs. The planetary assembly can now
be removed from the wheel by threading three
set screws into the puller holes in planetary
carrier (28) to force the planetary assembly
outward.  Set  the  planetary  assembly  on  a
clean work surface with planetary carrier (28)
downward.
7. Remove and discard 'O' ring (36). Remove
ring gear assembly (26, 27, 9, & 25) from the
wheel spindle by removing lockwire, bolts, and
retainer plate attaching ring gear carrier (25)
to the spindle.
8. Match mark cover (39), ring gear (38), and
planetary carrier (28) to aid assembly. Remove
bolts (12) and hardened washers(1) and lift
carrier  cover  (39)  and  ring  gear  (38)  from
planetary carrier (28). Remove and discard 'O'
rings (29) from carrier cover (39) and planetary
carrier (28).9. Lift up the component of primary
planetary gear carrier (17) from the secondary
planetary gear carrier (28).
9. Lift assembled first stage planetary carrier
(17) from planetary carrier (28).
10.  Remove  lockwire  (33)  from  bolts  (7).

Rear Axle Assembly And Installation

Remove bolts (7) and Sun Gear Retainer (31)
from sun gear (32). Lift first stage planetary
carrier (17) from sun gear (32).
11. Remove lockwire (33), bolts (7) and pin
retainer (31) from planet pinion pins (37) in
planetary carrier (17) assembly. Remove
planet pins (37) from planetary carrier (17)
assembly.
12. Slide planet pinions (35), thrust plates
(14), thrust spacers (15), roller (3) and roller
spacers (16) from planetary carrier (17)
assembly. Use care to avoid dropping and/or
damaging rollers (3).
13. Turn planetary carrier (17) assembly over
and remove thrust washer (30).
14. Turn planetary carrier(28 ) over. Remove
lockwire (33), bolts (10) and pin retainer (21)
from pinion pins (23). Remove pinion pins (23)
from planetary carrier (28).
15. Slide planet pinions (22), thrust plates
(18), thrust spacers (19), rollers (4) and rollers
spacers (20) from planetary carrier (28).
16. If necessary, remove lockwire (33), bolts
(9) and Ring Gear Retainer (26) and separate
ring gear (27) and ring gear carrier (25).

Inspection

Numbers in parentheses refer to Fig.2.
1. Clean all parts thoroughly in suitable solvent
and dry with moisture-free compressed air or
a clean, lint-free cloth. Allow rollers to air dry
and dip in clean planetary lubricant.
2. Inspect all parts for damage. Repair or
replace as necessary.
3. Inspect all pinions, gears and splines for
excessive wear, cracked or broken teeth and
pitted or scored surfaces. If replacing planet
pinions or sun gear, be sure the new pinions
or gear have the same number of teeth as the
old ones so torque multiplication will remain
the same.
4. Inspect roller for damage or excessive wear.

In addition, check for free fit in planet pinions

and on the planet pins. Replace any parts

Rear Axle Assembly And Installation

which are in questionable condition.
5. Inspect for pitted, scored or worn thrust
surfaces and burrs on the two planetary gear
carriers (17&28) .
6. Inspect ring gear (27&38) and planetary
carrier (17&28) for cracks and wear.

1. Hardened washer

16. Roller spacer

31. Sun gear retainer

2. Washer

17. Planetary carrier

32. Sun gear

3. Roller

18. Thrust plate

33. Lockwire

4. Roller

19. Thrust spacer

34. Cover

5. O-ring

20. Roller spacer

35. planetary gear

Fig.2 Exploded View of Two-Stage Planetary Assembly

Rear Axle Assembly And Installation

6. Plug

21. Pin retainer

36. O-ring

7. Bolt

22. Planetary pinion

37. Pinion pin

8. Bolt

23. Pinion pin

38. Ring gear

9. Bolt

24. Thrust washer

39. Carrier cover

10. Bolt

25. Ring gear carrier

39. Baffle

11. Screw

26. Ring gear retainer

41. Axle half

12. Bolt

27. Ring gear

42. Snap ring

13. Sun gear

28. Planetary carrier

43. Screw

14. Thrust plate

29. O-ring

15. Thrust spacer

30. Thrust washe

Assembling and installing

Numbers in parentheses refer to Fig.1and
Fig.2.

Note

: Tighten all fasteners to standard torques

listed below.

Table of bolt torque (Unit: N•m)

Specifications

Grade

5.8

8.8

10.9

12.9

6.1

9.8

14.7

M10

M12

114

136

M14

128

181

217

M16

123

197

277

333

M18

172

275

386

463

M20

240

385

541

649

M22

324

518

728

874

M24

416

665

935

1120

M27

600

961

1350

1620

M30

819

1310

1840

2210

Note

: If Ring Gear Carrier (25) is replaced, the

wheel bearing adjustment must be checked
and corrected as required, as described in
3.1.2 rear hub assembly.

Rear Axle Assembly And Installation

warning

To prevent personal injuries and property

losses, the chocking material and the hoist

device should be firm and reliable and the

hoist device should have the sufficient

hoist capacity to prevent the component

assembly from falling down or the hoist

device from tipping over for safe operation.

1.  If  disassembled,  attach  ring  gear  (27)
securely to ring gear carrier (25) with retainers
(26), bolts (9) and lockwire (33). Install ring
gear and ring gear carrier assembly on the
wheel spindle  and attach securely with its
etainer plate, bolts and lockwire. See Fig.1.
2.  Install  planet  pinions  (35)  in  planetary
carrier (17) as follows (See Figs 1 & 3):Place

thrust plates (14) on a flat surface, then place

planet pinion (35) on top of thrust plate (14).
See Fig.3. Insert thrust spacer (15) inside
planet pinion (35) then insert 22 rollers (3) as
a group in a circlerollers inside planet pinion
(35) and over roller spacer (16). Make certain
thrust spacer (15) is centred to the cage of
rollers (3)in a circlerollers. Then insert rollers
spacer (12), 22 roller (3) and thrust spacer (15)
to complete planet/roller assembly as shown
in Fig.3. Install the assembled planet pinion
with thrust plates (14) into planetary carrier
(17). Insert pinion pin (37) through planetary
carrier (17) and secure with pin retainer (40),
bolts (10) and lockwire (33).
3. According to Step 2, the rest two planetary
pinion (35) are assembled. Repeat Step 2 to
assemble and install remaining two planet
pinions (35) in planetary carrier (17).
4. Install planet pinions (22) in planetary
carrier (28) as follows (See Figs. 1 & 4): Place

thrust plates (18) on a flat surface, then place

planet pinion (22) on top of thrust plate (18).
See Fig.4. Insert thrust spacer (19) inside

Assembling fixture

Working platform

Fig.3 First Stage Planet/Rollers Assembly

3. Roller

16. Roller spacer

14. Thrust Plate

35. Planetary Pinion

15. Thrust Spacer

Assembling fixture

Working platform

Fig.4 Second Stage Planet/Rollers
Assembly

4. Roller

20. Rollers Spacer

18. Thrust Plate

35. Plandtary Pinion

19. Thrust Spacer

Rear Axle Assembly And Installation

planet pinion (22) then insert 15 rollers (4) as
a group  in a circlerollers inside planet pinion
(22) and over roller spacer (20). Make certain
thrust spacer (18) is centred to the cage of
rollers (4)in a circlerollers. Then insert rollers
spacer (20), 22 roller (3) and thrust spacer (19)
to complete planet/roller assembly as shown
in Fig.4. Install the assembled planet pinion
with thrust plates (18) into planetary carrier
(28). Insert pinion pin (23) through planetary
carrier (28) and secure with pin retainer (21),
bolts (10) and lockwire (33).
5. Assemble and install the remaining three
planet pinions (22) in planetary carrier (28) as
described in Step 4.
6. Position planetary carrier (28) on a clean,
level surface with its bolts circle upward.
7. Insert thrust washer (30) in planetary carrier
(28).
8. Install sun gear (32) in planetary carrier (28)
assembly so that its undercut teeth mesh with
the planetary carrier (17) internal teeth. Attach
sun gear (32) to planetary carrier (17) securely
with  sun  gear  retainer  (31),  bolts  (7)  and
lockwire (33).
9. Install new 'O' ring (29) in planetary carrier
(28)  groove  and  install  ring  gear  (38)  on
planetary  carrier  (28)  as  match  marked  at
'Disassembly'.
10. Install assembled planetary carrier (17)
and sun gear (32) in planetary carrier (28)
carefully meshing sun gear (32) and planet
pinion(22) teeth, and ring gear (38) and planet
pinion (35).
11. Insert new 'O' ring (29) in carrier cover (39)
and install carrier cover (39) on ring gear (38)
as match marked at 'Disassembly'.
12. Align bolt holes in planetary carrier (28)
ring gear (38) and carrier cover (39). Install
bolts  (12)  and  hardened  washers  (1)  and
tighten securely, using torque wrench.
13. Install a new 'O' ring (36) on planetary
carrier (28).
14. Attach  suitable  lift-eyes,  sling,  cables,

Rear Axle Assembly And Installation

and/or other lifting equipment to the planetary
assembly and raise it into position for
installation on the wheel.
15. Align the teeth of the four planetary pinions
(22) with their mating teeth in ring gear (27)
and carefully insert the planetary assembly
to the wheel so that planetary carrier (28)
mates with the wheel, as match marked at
'Disassembly'. Use care to prevent damage to
'O' ring(36).
16. Install nuts on wheel studs and tighten
securely.

Note

: If removed from sun gear (13), thrust

washer (24) must be pressed onto the sun
gear shoulder until completely bottomed on
the gear.
17. If removed, install sun gear (13) on axle
shaft (41) and secure with snap ring (42).
Insert shaft and sun gear assembly into the
spindle, carefully mating the teeth of sun gear
(13) and planet pinions (35), and, axle shaft
(41) teeth with the differential side gears.
18. Push axle shaft (41) and sun gear (13)
inward as far as they will go. With a steel
rule and straight edge, measure from cover
mounting surface on carrier cover (39) to the
end of axle shaft (41). Note as dimension 'A'.
See Fig.5.
19. Next, lay cover (34) on flat surface and
again use a straight edge and steel rule
to measure the height of the inside raised
surface of cover (34). Note as dimension 'B'.
See Fig.6.
20. Subtract dimension 'B' from dimension 'A'
and the clearance should be within 2 - 11 mm.

Note

: If the end play is too small, the axlf

shaft(41) is not pushed completely into
the differential side gear. If the end play is
greater than the allowable maximum, either
the axlf shaft(41) end or the cover, or both
are excessively worn. To correct this, replace

cover (34) first. If the end play is still too great,

a new axlf shaft must be installed.
21. Install new 'O' ring (5) on cover (34) and

Inspect the vertical

distancebetween

the two faces

Inspect the vertical

distancebetween

the two faces

Fig.5 Measuring dimension ‘A’

39. Cover Carrier

41. Axle Half

34 Cover plate

Fig.6 Measuring dimension ‘B’

Rear Axle Assembly And Installation

1. Rear wheel

8. Inner seal housing

2. Ring gear carrier

9. Spindle

3. Bolt

10. Wheel driver

4. Shim pack

11. ‘O’ Ring

5. Plate

12. Bolt

6. Bearing

13. Washer

7. Bearing

Fig.1 Sectional View of Drive Wheel Assembly

3.1.2 Rear wheel and installation

Description

Each drive wheel is mounted on its spindle
with  two  tapered  roller  bearings. All  the
weight of the truck resting on the drive axle is
supported by the wheels and bearings; none
of the weight is supported by, or transmitted
through,  the  axle  shafts.  This  type  of
construction is known as 'Full Floating'.
The wheel itself is a large cylindrical casting
with  the  bearing  bores  and  other  finished

Rear Axle Assembly And Installation

surfaces machined after the wheel is cast.

Removal and disassembly

Numbers in parentheses refer to Fig.1

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting device are properly

secured and of sufficient capacity to do the

job safely.

1. Place the truck in a flat area, apply parking

brake and shut down the engine.
2. The steering wheel turns for several circles
in the two directions to relieve the pressure in
steering system. Block all wheels, except the
one to be raised. Lift up the truck so that its
weight isn’t sustained by axle. Main switch of
battery is in the ‘OFF’ position.
3. Release parking brake.

4. Deflate both tyres completely, and remove

the tyre and rim assembly from the wheel.
Follow instructions under 'Removing Tyre and
Rim Assembly'. Refer to Section 4.1 'REAR
WHEEL ASSEMBLY'.
5. Drain differential and planetary gear
lubricant and remove planetary gear assembly
from the wheel. Refer to Section 3.1.1, 'TWO
STAGE PLANETARY ASSEMBLY AND AXLE
HALF'.

warning

To prevent personal injury and property

damage, completely deflate tyre by

removing the valve cap and core. Insert

a thin wire through the valve to be sure

the valve is not plugged. Even a flat tyre,

in some cases, will retain sufficient air

pressure to blow off a rim component with

enough force to cause injury or death.

Rear Axle Assembly And Installation

6. Remove lockwire, bolts (3), plate (5) and
shim pack (4) from spindle (9). Retain shim
pack (4).
7. Pull ring gear carrier (2) from end of spindle
(9).
8. With suitable lifting device, pull wheel (1) off
of spindle (9), being careful that outer bearing
(6) cone does not fall.
9. Remove and discard 'O' ring (11) from
wheel operator (10).

Note

: The wheel operator (10) portion of the

disc brake assembly is bolted to inner face
of wheel (1), when the wheel is removed, the
attached disc brake wheel operator (10) will
also be removed. Refer to Section 3.1.3, Rear
Brake Assembly and Installation, if necessary
to remove wheel operator.

Note

: Bearing cups and cones must always be

replaced as a matched set, never separately.
10. Remove inner bearing (7) cone from
spindle (9).
11. If required, remove bearing (6 & 7) cups
from wheel (1).

Inspection

1. Thoroughly clean all metal components,
except bearing cones, in a suitable solvent.
Dry with compressed air and coat all threaded
components with light oil to facilitate assembly.
2. Clean bearings in volatile mineral spirits
and wipe dry with a lint free cloth. Lubricate
lightly with light oil and spin by hand, to check
for wear and roughness. Replace with new
bearings if excessively worn, or if operation is
rough or noisy.
3. Inspect all machined surfaces of all parts
for scoring, pitting, corrosion and burring.
Resurface or replace with new parts as
necessary.
4. Inspect all threaded components, and repair
or replace as necessary.

Assembly and installation

Numbers in parentheses refer to Fig.1.

Rear Axle Assembly And Installation

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting device are properly

secured and of sufficient capacity to do the

job safely.

1. If removed, install bearing (6 & 7) cups
in their respective wheel (1) bearing bores
with care to avoid damaging their raceways.

Installation by press fit at ambient temperature

is best. Note that cups must seat fully against
shoulders of cup bores in the wheel hub to
assure  retention  of  bearing  adjustment.  If
carbon dioxide, or dry ice, freezing of the cup
is used, remember to permit the cup and hub
to warm to ambient temperature after insertion
and then to tap them with a soft steel drift and
hammer to seat.
2 .   L u b r i c a t e   i n n e r   b e a r i n g   ( 7 )   c o n e
with  lubricant  specified  in  Section  38.1,
LUBRICATION SYSTEM. Install inner bearing
(7) cone onto spindle (9).
3. If removed, install wheel operator (10) on
wheel (1). Refer to Section 3.1.3, Rear Brake
Assembly and Installation.
4. Install new 'O' ring (11) on wheel operator
(10).  Refer  to  Section  3.1.3,  Rear  Brake
Assembly and Installation.
5. With suitable lifting device slide wheel (1)
assembly onto spindle (9), carefully mating
splines of wheel operator (10) with splines
of disc brake disc operator. Refer to Section
3.1.3, Rear Brake Assembly and Installation.
6 .   L u b r i c a t e   o u t e r   b e a r i n g   ( 6 )   c o n e
with  lubricant  specified  in  Section  38.1,
LUBRICATION SYSTEM. Install outer bearing
(6)  cone  on  spindle  (9)  and  seat  in  outer
bearing cup (8).
7. Install ring gear carrier (2) on end of spindle

Rear Axle Assembly And Installation

(9).

Note

: Ensure all dirt, grease and oil is

completely removed from plate (5), shim pack
(4) and end of spindle (9) to allow accurate
setting of the bearing pre-load.
8. Install plate (5), without shim pack (4) on
end of spindle (9), and secure with eight bolts
(3). Tighten bolts (3) evenly in equal increments
to  'Gauging  Bolt  Torque',  as  specified  in
'Bearing Adjustment Table', while rotating and
bumping wheel (1) assembly.
9. Remove bolts (3) and tap the wheel (1)
assembly to free bearings.
10. Reassemble plate (5) without shim pack
(4) and using only two bolts (3) located 180°
apart, adjacent to gauging holes in plate (5).
Tighten bolts (3) evenly in equal increments to
'Gauging Bolt Torque' (ref. 'Bearing Adjustment
Table'), while rotating and bumping wheel (1)
assembly.
11.  Determine  gap  between  plate  (5)  and
end of spindle (9) at both gauging holes. To
determine gap, use a depth micrometer in both
gauging holes to measure distance from outer
face of plate (5) to end of spindle (9). Measure
thickness  of  plate  (5)  with  a  micrometer.
Subtract plate thickness reading from depth
gauge readings.
12. Average the two readings, obtained at
Step 11, in increments of 0.03 mm (0.001 in)
and round off to the next higher 0.03 mm (0.001
in). This is the average gap. The required shim
pack (4) thickness is equal to the average gap
plus the tabulated constant as shown in the
'Bearing Adjustment Table'.
13. Install required shim pack (4), plate (5) and
bolts (3) on end of spindle (9). Tighten bolts
(3) evenly in equal increments to 'Final Bolt
Torque' (ref. 'Bearing Adjustment Table'), while
rotating  and  bumping  wheel  (1)  assembly.
Secure bolts (3) with lockwire.
14.  Install  planetary  gear  assembly  and
fill  planetary  and  differential  assemblies
with  lubricant  specified  in  Section  38.1,

Rear Axle Assembly And Installation

LUBRICATION SYSTEM. Install tyre and rim
assembly as described under 'Mounting Tyre
and Rim Assembly on Wheel'.

Table of special torque

Initial seating bolt torque

Gauging bolt

Shim pack thickness

Final bolt torque

No. of

Bolts

N. M

No. of

Bolts

N. M

No. of

Bolts

N. M

200

Ave. Gap

+0.18

Ave. Gap

+0.007

940

Rear Axle Assembly And Installation

3.1.3 Main reducer and differential

assembly

5 6

22 23

1. Lockwire

14. Bearing

27. Driven spiral bevel gear

2. Bolt

15. Shim

28. Nut

3. Plate

16. Main reducer housing

29. Bolt

4. Yoke

17. Screw

30. Thrust washer

5. Sleeve

18. Screw

31. Dowel pin

6. Dust shelter

19. Bushing

32. Axle shaft bevel gear

7. Screw

20. Bearing cap

33. Spider

8. Bearing seat

21. Bolt

34. Planetary bevel gear

9. Bolt

22. Lock

35. Bearing

Fig.1 Main reducer and differential assembly

Rear Axle Assembly And Installation

10. Shim

23. Bolt

36. Left differential housing

11. Oil seal

24. Bearing Adjuster

37. Bolt

12. Bearing

25. Bearing

13. Drive spiral bevel gear

26. Right differential housing

Overview and operation

Numbers in parentheses refer to Fig.1.
The main reducer and differential have three
functions:
1. It multiplies torque delivered by the driveline
and change the torque direction;
2. It transmits this torque to the axle shafts;
3. It allows the drive wheels to rotate at
different speeds. When the truck is making
a turn, one drive wheel must travel a greater
distance than the other. If the wheels were
connected by a single axle shaft, the wheel
turning the larger radius of the turn circle
would have to override the wheel making the
shorter turn. Thus, one wheel would have to

skip or hop causing tire scuffing and strain on

the power train.
The Main reducer and differential assembly
eliminates wheel skip by allowing separate
axle  shafts  inserted  into  axle  shaft    gears
(32) to rotate at different speeds as the drive
wheels  rotate.  spider  (33)  and  planetary
bevel gears (34) are meshed with axle shaft
bevel gears (32), as shown in Fig.2&3. This
assembly  is  enclosed  in  Left    differential
housing  (36) and Right differential housing
(26)which are bolted to driven spiral bevel
gear(27). Thus, Driven spiral bevel gear(27),
Left    differential  housing    (36)  and  Right
differential housing (26) rotate as an assembly
when driven by input drive spiral bevel gear
(13). However, axle shaft bevel gears (32),
into which each axle shaft is inserted, are
free to rotate independently about planetary
bevel gears (34) with which they are meshed.
Therefore, as each drive wheel travels through
a different arc as the truck makes a turn, axle

Shim thickness: 0.10, 0.15 and 0.50mm

Fig.2 Differential

Fig.3 Differential assembly

Note

: See Fig.1 for the serial numbers in

brackets.

Rear Axle Assembly And Installation

SANY SRT95C Off-Highway Truck. Service Manual - page 8