SANY SRT95C Off-Highway Truck. Service Manual

e. If the contact area is along the top edge
of the driven spiral bevel gear teeth, see
Fig.15, move the drive spiral bevel gear in by
removing shims.

Installation

Numbers in parentheses refer to Fig.1.
1. Be sure truck wheels are chocked securely.
2. If the body is not already raised, raise body
and install body prop pins. Refer to Section
23, BODY AND MOUNTING.
3. Clean mating surfaces of the banjo and
main reducer and differential assembly with
a hydrocarbon solvent to remove dirt, oil,
grease, or other foreign matter. Wipe cleaned
surfaces dry. Apply the sealant cord as follows:
The adhesive side of the cord is applied to
the banjo face, starting at the top, looping

once around the first stud, then to the second

stud, etc., ensuring not to overstretch the cord
and that the loop between the studs will be
on the inside of any of the main reducer and
differential assembly extraction holes. Working

all the way round finishing with an overlap at

the top.
4. Set screw (18) should already have been
removed from the top of the differential
housing and replaced with a lifting eye during
removal. If not, remove set screw (18) from
main reducer housing and replace it with a
lifting eye.
5. Position the main reducer and differential
assembly under the truck in front of the banjo
housing.
6. Install chain fall or come-a-long to the loop
on the body just behind the hoist brackets.
Attach the other end of the lifting device to the
eye previously installed in the main reducer
and differential assembly.
7. Lift the main reducer and differential
assembly and carefully position it on the studs
of the banjo housing.
8. Secure the main reducer and differential
assembly to the banjo with the self locking

Fig.15 Drive spiral bevel gears out Too Far -
Remove Shims

Fig.16 Correct movement for adjustment

Moving the driven spiral bevel

gear outwards to correct the

situation in Figure 12

Moving the drive spiral bevel gear inwards to correct the situation in Figure 15

Moving the drive spiral bevel gear outwards to correct the situation in Figure 14

Move the driven spiral bevel

gear inwards to correct the

situation in Figure 13

Rear Axle Assembly And Installation

nuts removed at removal. Tighten the nuts

evenly in increments of 90 N•m (66 lbf•ft) to a
final torque of 541 N•m (399 lbf•ft).

9. Replace the rear driveline, aligning marks
made during disassembly. Refer to Section 19,
Rear driveline.
10. Install the axle shafts, then replace and

secure the driving flange cover to the wheels.

Refer to Section 3.1, Planetary assembly.
11. Fill the drive axle, planetary reservoirs
and main reducer anddifferential assembly
with the proper grade and quantity of lubricant

specified in Section 38.1, lubrication system.

Maintenance

Periodic inspection

Inspect regularly the flange yoke mounting
bolts, drive spiral bevel gear shaft nut,
bearing seat and bearing seat bolts and main
reducer and differential assembly stud nuts

for tightness. Tighten the stud nuts and flange

bolts weekly until they 'set' or show that they
no longer need tightening. Keep the nuts tight
to reduce the possibility of main reducer and
differential assembly or driveline failure due
to excessive vibration or wear. Replace any
mounting studs which have become stripped
or broken.
Jack up the drive axle to 'test run' the main
reducer and differential assembly and listen
for noises which may indicate the need for
adjustment or replacement of worn parts.
When doing this, lift BOTH wheels off the
ground. Both wheel brakes should be free to
allow both wheels to rotate at approximately
the same speed.

Note

: Do not operate with only one wheel

jacked up. Excessive operation in this manner
will overheat the differential spider and cause
galling or shearing of the spider trunnions and
bearings.
If the main reducer and differential assembly is
excessively noisy, it should be removed from

Rear Axle Assembly And Installation

the banjo and disassembled for inspection.

Lubrication

The main reducer and differential assembly
is splash lubricated with an extreme pressure
lubricant. The fill level plug is located in the
centre rear of the banjo housing.
The main reducer and differential assembly
should be checked and periodically drained
and filled to the bottom of the fill-level hole,
or to no more than 13 mm (0.5 in) below the

fill level, with new lubricant as recommended.

Refer to Section 38.1, lubrication system.
When the lubricant is drained, remove any
chips of steel particles that may be attached to
the magnetic drain plug located in the bottom
of the banjo housing. After draining and

refilling an axle, the planetary gearing should

be checked after 10 hours of operation.
1. Check the level in planetaries at oil level
plug. If the oil level is low, add oil. This check
point is a minimum check point only. If the oil
level is above the check point, do not drain off
oil.
2. Add oil if needed. The oil level is correct

when oil flows from the lube level check plug

in the banjo. These checks should be made
every 10 hours until oil level in the differential
is maintained.

SPECIAL TORQUE SPECIFICATIONS

FIG. NO.

ITEM NO.

ITEM NAME

Torque

N•m

lbf·ft

Bolt

270

198

Bolt

270

198

Bolt

900

663

Bolt

Nut

900

663

Bolt

900

663

Bolt

580

428

Rear Axle Assembly And Installation

Table of fault diagnosis

Condition

Reason

Remedy

Vibration

Broken gear teeth.

Replace the damaged gear.

The drive spiral bevel gear or bearing seat
are excessively worn.

Disassemble, correct or replace
faulty part.

Continuous noise

Bearing worn.

Replace worn parts.

Gears damaged or worn.

Replace gears.

Noise on drive.

The drive and driven gears adjustment
tight.

Adjust.

Noise on coast.

Bearing damaged.

Replace the bearing.

Loose the drive and driven spiral bevel
gear adjustment.

Readjust it.

Excessive drive spiral bevel gear end play.

Readjust it.

Noise on turns.

Worn axle shaft bevel gears or planetary
bevel gears.

Replace the gear.

Worn or damaged spider bushings.

Replace the bearing.

Loss of lubricant.

Oil seals worn.

Replace seal.

Loose nuts.

Tighten nuts to correct torque.

Cracked housing.

Repair or replace housing.

Rear Axle Assembly And Installation

1. Thread gasket

10. Snap ring

19. oscillation Stop

2. A-frame assembly

11. Bearing

20. Link nut

3. Bearing

12. Link

21. Washer

4. Gasket

13. Shaft

22. stud

5. Bolt

14. Washer

23. Breather

6. Steel wire

15. Washer

24. Screw plug

7. Washer

16. Bolt

25. Washer

8. Bolt

17. Bolt

26. Screw plug

9. Spacer

18. Washer

27. Axle housing component

Fig.1 Rear axle housing assembly

3.1.4 Rear axle housing assembly

Rear Axle Assembly And Installation

Description and operation

The rear axle assembly consists of axle
housing assembly(27) , A-frame (2) and
Link(12). The axle housing assembly provides
the housing for the differential and axle shafts
which drive the wheels, and spindles to which
the wheels are mounted. The axle housing
assembly also connects the rear wheels to the
chassis through A-frame (2), Link(12), and the
rear ride cylinders.

Removal and disassembly

See Fig.1 for the numbers in the brackets.

warning

To prevent personal injury and property

damage, be sure lifting equipment is of

dequate capacity and properly secured to

dothe job safely.

1. Remove the bolt (5) from A-frame assembly
(2), take down the gasket (4) and thread
gasket (1). Then remove the bearing (3). If

necessary, the grease fitting can be removed

from the A-frame assembly (2).
2. Remove the A-frame assembly (2) from the
axle housing assembly (27) by Disassembly
bolt (8) and washer (7). Before Disassembly,
use the proper hoist device to lift up A-frame.
3. Remove the bolt (17), Washer (18) and take
down the oscillation stop (19).
4. Remove the bolt(16), washer(15), (14)
and shaft(13). Take down the spacer (9) and
link(12).
5. Remove the Snap ring (10) and bearing (11)
from the link (12).
6. Remove the breather (23) from the axle
housing assembly (27).

Inspection

1. Clean all metal parts in a suitable solvent,
using a brush to clean bearings. Dry all parts

Rear Axle Assembly And Installation

on a clean surface and allow bearings to dry
naturally. Make sure parts are free from dirt.
2. Check all inner and outer grooves for
cleanliness. Check components for cracks,

scores, blemishes or burrs. Use a fine stone to

smooth out defective areas. Replace any parts
that show excessive wear.
3. Inspect fittings, plugs, studs and their
seating positions for thread wear. If threads
in any of these parts are damaged, replace
parts.
4. Check the bush, bearing and snap ring for
wearing or deformation. Replace the defective
parts and components.
5. Replace the used gasket.

Assembly and installation

See Fig.1 for the numbers in brackets.

Note

: Tighten all fasteners without special

torques specified to standard torques listed
in Section 38.2 'Standard bolt and nut torque

specifications', unless it is otherwise noted.

Note

: If heating of axle housing is required

to assemble spindles and axle housing, axle
housing interference areas must cool to 66° C
(150° F) maximum before welding. For welding
spindles to axle housing preheat spindles and
axle housing to 150° C (300° F) minimum in
weld area and maintain during welding.
1. Install the washer (25), Screw plug (24)
and Screw plug (26) onto the axle housing
assembly (27).
2. Install the breather (23) onto the axle
housing assembly (27).
3. Install the bearing (11) onto the link (12) and

use the Snap ring (10) for fixing. Then, install

the assembled link components onto the axle
housing component (27) and install the spacer
(9) and the articulated shaft (13). Then use the

washer (14) , (15) and bolt (16) to fix the link

(12) onto the axle housing components (27).

4. Use the bolt (17) and washer (18) to fix the

oscillation Stop (19) onto the axle housing
component (27).

Rear Axle Assembly And Installation

5. Install the bearing (11) onto the A-frame
assembly (2), and install the thread gasket

(1) and gasket (4). Use the bolt (5) to fix them

onto the A-frame assembly (2) and use steel
wire (6) to lock the bolt (5).
6. Use a proper hoist device to install the
A-frame assembly (2) onto the axle housing
components (27) and use the bolt (8) and

washer (7) for fixation. The tightening moment
of bolt (8) is 3640 N•m.

warning

To prevent personal injury and property

damage, be sure lifting equipment is of

adequate capacity and properly secured to

do the job safely.

Rear Axle Assembly And Installation

1. O-ring

20. Bolt

38. Friction disc

2. Driving wheel

21. washer

39. Friction plate

3. Hardened washer

22. Spring housing

40. Service brake piston

4. Bolt

23. Socket head screw

41. Bolt

5. O-ring

24. O-ring

42. Mounting plate

6. Lockwire

25. OG seal ring

43. Spring

7. Bolt

26. Guiding belt

44. Pin

8. washer

27. Spring

45. Return pin

9. Outer seal housing

28. Spring

46. D-ring

10. O-ring

29. Pin

47. D-ring

11. Seal ring

30. Parking brake piston

48. Service brake piston housing

12. Dynamic seal assembly

31. OD seal ring

49. Bleeder screw

13. O-ring

32. Guiding belt

50. Dust boot

15. Inner seal housing

33. Pin

51. Plug

16. O-ring

34. Housing

53. Stud

17. O-ring

35. O-ring

54. Locknut

18. Seal ring

36. Driving disc

19. Dynamic seal assembly

37. damper plate

Rear Axle Assembly And Installation

Fig.2 Structure of brake

13. O-ring

43. Spring

47. D-ring

24. O-ring

44. Pin

49. Bleeder screw

33. Pin

45. Return pin

51. Plug

42. Mounting plate

46. D-ring

52. Plug

port “A”

port “B”

port “D”

port “C”

port “D”

port “C”

Rear Axle Assembly And Installation

Operation overview

Refer to Fig.1 and Fig.2 for numbers in
brackets.

Service brake

Note

: The service brakes are of 'Upright

Design', i. E. requiring pressure to hold the
brakes on.
The rear service brake utilizes hydraulic force
to slow or stop the driving wheel. When the
pedal of foot brake in the cab is pressed down
or the retarder control lever on the central
operating console is operated and the retarder
selector switch (if equipped) is turned into the
position of rear disc brake, the hydraulic oil
will be transmitted to the port ‘C’ on the rear
disc brake, referring to Fig.2. The hydraulic
oil entering into the port ‘C’ forces the service
brake piston (40) against the brake disc pack
consisting of the damper plate (37), friction
disc (38) and friction plate (39).
The  friction  plate  is  clamped  between  the
friction disc (38) and it is driven by the wheel via
the driving wheel (2) and driving disc (36). To
decelerate or stop the driving wheel, pressing
force applied onto the brake disc component
directly depends on the pressed level of brake
pedal.
When  the  service  brake  pedal  or  retarder
control lever is released, the pressure asainst
the service brake piston (40) is immediately
relieved. The force of brake return spring (43)
tightly against the head of the return pin (45)
makes the return pin pull the piston (40) back
to  the  original  position,  and  consequently
the pressure against the brake disc pack is
released.

Parking brake

Note

: The parking brake is of 'Inverted

Design', i. E. requiring pressure to hold the
brakes off.
This brake is operated with the parking/
emergency brake control button mounted on

Rear Axle Assembly And Installation

the instrument panel. It is applied with spring
force and released with hydraulic force. When
the control button is released, the hydraulic
oil enters into the port ‘D’, referring to Fig.2.

And it flows into the oil passage in front of the

parking brake piston (30) via the guide groove
inside the brake disc housing (34). At the
moment, the hydraulic oil will push the piston
(30) to overcome the tension of springs (27

and 28) and to remove pressure on the baffle

(37). Consequently, the release of the brake
disc component is maintained. If the control
button is pressed, the oil pressure at the port
‘D’ and that tightly against the parking piston
(30) will be immediately released. The tention
of springs (27, 28) recovers and forces against
the damper plate (37) and disc pack consisting
of friction disc(38)and friction plate(39). At the
moment, the rotating friction plates clamped
between friction discs are immediately pressed
tightly, thus keeping the wheels from rotating.

Removal

Refer to Fig.1 and Fig.2 for numbers in
brackets.

Note

: Before the disc brake assembly is

removed and disassembled, the wear extent of

friction plates and baffles should be recorded

referring to the specifications on measuring
procedure and maximum allowed wear limit
described in the 'Measuring procedure for disc
brake assembly wear' under 'Inspection' in this
section.

Rear Axle Assembly And Installation

warning

To prevent personal injury and equipment

loss, it should be ensured that the hoist

equipment has sufficient carrying capacity

and the wheels are reliably fixed and

chocked to enable safe operation.

After the engine is shut down, the hydraulic

oil still remains in the brake system. Before

the brake system is operated, the pedal

valve should be continuously operated

until the pressure is completely released,

so that severe personal injuries can be

avoided.

Use extreme caution when removing

wheels. Specific operation procedure must

be complied with as describedi in 'tyre and

rim assembly'.

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

brake, turn off the engine, turn the steering
wheel in the two directions for several times,
and release the pressure of the steering
system.
2. Continuously press down the brake pedal to
release the brake system pressure. Chock the
wheels and set the main switch of battery into
the ‘OFF’ position.
3. Remove the plug (51). Drain the cooling oil
inside the disc brake assembly into a clean
container and then reinstall the plug.
4. Remove the bleeder screw (49) at the
bottom. Drain the brake hydraulic oil into a
clean container. Then reinstall the bleeder
screw.

Note

: To reduce the loss of hydraulic oil during

removing of oil pipe from the brake assembly,
the air breather on steering and brake control
oil tank can be removed in advance and the
port can be connected to the vacuum pump to
evacuate the air in the tank to vacuum of 0.5 -
0.7 bar.
5. Remove the brake cooling pipe from the

Rear Axle Assembly And Installation

SANY SRT95C Off-Highway Truck. Service Manual - page 10