SANY SRT95C Off-Highway Truck. Service Manual

5.1.1 Engine - power takeoff

(Oil feeding screw plug)

(Oil level plug

(Drain plug)

34 33

32 30

5 6

Fig.2 - Exploded View of Engine - Power Takeoff

1. Outer ring, aluminum

13. Transitional disc

25. Drive gear

37. Shell cover

2. Washer

14. Washer

26. Driven gear

38. Plug

3. Screw

15. Bolt

27. Drive shaft

39. Pin

4. Elastic body

16. Oil Seal

28. Bearing

40. Ring, retainer

5. Bolt

17. Shell seat

29. Bearing

41. Oil Seal

6. Washer

18. Rubber adaptor

30. Bolt

42. Yoke

7. Inner ring, aluminum

19. Breathing tube

31. Bolt

43. Washer

8. Screw

20. Pipe connector

32. Washer

44. Nut

9. Pressure cover

21. Pipe connector

33. Ring, retainer

45. Plug

10. Bolt

22. Breather

34. Bolt

11. Pressure cover

23. Throat collar

35. Washer

12. Sleeve, shaft

24. Pipe connector

36. Gasket

Installation of Engine

Description operation

Numbers in parentheses refer to Fig.2.
The function of the power takeoff (PTO), as
the name implies, is to provide the means of
mounting and driving auxiliary components.
The hydraulic pump on the shell cover (37)
and its input shaft is meshed with the internal
spline in the hub of driven gear (26).
The major components of the PTO assembly
are: Shell seat (17), shell cover (37), drive
shaft (27), drive gear (24) and driven gear (26).
As drive shaft (27) is driven by the engine
crankcase, drive gear (25) turns to drive driven
gears (26). The hydraulic pump drive shafts,
meshed in the hub of driven gears (26), turn
with driven gears (26) to operate the hydraulic
pump which, in turn, supplies hydraulic oil to
the body hoist system and steering system
and disc brake assemblies.

Removal

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting equipment are

properly secured and of adequate capacity

to do the job safely.

1. Position the vehicle in a level work area,
apply the parking brake and switch off the
engine.
2. Turn steering wheel in both directions
s e v e r a l t i m e s t o r e l i e v e p r e s s u r e i n
accumulator and steering system. Block all
road wheels.
3. Disconnect driveline from yoke (42) at PTO
assembly.
4. Drain oil from power takeoff housing by
removing drain plug (45) from shell seat (17).

Installation of Engine

Reinstall drain plug (45) securely.
5.  Match  mark  main  hydraulic  pump  and
combination  gear  pump  mounting  flange
and shell cover (37) so that the pump can be
installed in the same position at installation.
6. With suitable blocking or lifting equipment,
support the hydraulic pump and combination
gear pump before loosening attaching bolts.
Remove Bolts and lock washers from main
hydraulic pump and combination gear pump
clear of PTO assembly.
7. Match mark engine flywheel housing and
shell seat (17) so that PTO assembly can be
installed in the same position at installation.
8. Attach  a  suitable  lifting  device  to  PTO
assembly and remove bolts (30 & 31) and lock
washers (32) securing PTO assembly to the
engine flywheel housing. Remove the rubber
adaptor (18). Carefully lower PTO assembly

from the flywheel housing and move to a clean

work area for disassembly.
9. Remove the bolt (15) and washer (14) from
the engine flywheel. Carefully remove the
transitional disc (13).
10. Remove the bolt (3) and washer (2) from

the aluminum outer ring (1) of engine flywheel.

Carefully remove the aluminum outer ring (1).

Disassembly

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

1. Remove the locknut (44) and washer (43)
from drive shaft (27). Pull yoke (42) from drive
shaft (27).
2. Remove the pins (39) from the shell cover
(37).
3. Place shell cover (37) yoke side up on a
work bench. Pry oil seal (41) from shell cover
(37) and discard.
4. Turn over PTO assembly. Remove the bolts
(5) and washers (6) from the aluminum Inner
ring (7). Pull aluminum Inner ring (7) from
shaft sleeve (12).
5. Remove the screw (8) from the drive shaft

Installation of Engine

(27). Pull pressure cover (9) from drive shaft
(27). Remove the bolt (10) from the shaft
sleeve (12). Pull pressure cover (11) and shaft
Sleeve (12) from drive shaft (27).
6. Remove the bolts (34) and washers (35)
from the shell cover (37). Pull shell cover
(37) and gasket (36) from the shell seat (17).
Discard gasket (36).
7. Remove snap rings (33 & 40) from pump
and drive shaft bores. Drive bearings (28 & 29)
from shell cover (37) with a sleeve or soft steel
drift. Drive on the outer race of bearings (28
&29) taking care not to damage the bearings.
8. Slide drive gear (25) from drive shaft (27),
and pull driven gears (26) from shell seat (17).
9. Pull drive shaft (27) from shell seat (17). Pry
oil seal (16) from shell seat (17) and discard.
10. Pull bearings (28 & 29) from shell seat (17)
with a suitable bearing puller.

Inspection

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

1. Wash all parts thoroughly in a suitable
solvent and dry all but bearings (28 & 29) with
compressed air. Dry bearings (28 & 29) with a
clean lint free cloth.
2. Check the condition of splines and teeth on
gears (25 & 26), drive shaft (27) and yoke (42)
for burrs or signs of wear.
3. Lubricate bearings (28 & 29) with oil and
check operation by spinning bearings by hand.
Do not spin bearings with compressed air.
Inspect bearing bores for out of roundness.
Replace bearings, if required.
4. Inspect shell seat (17) and shell cover (37)
for cracks. If either shell seat (17) or shell
cover (37) are damaged, both parts must be
replaced as an assembly.
5. Visually check oil seal lip contact surfaces
on drive shaft (27) and yoke (42) for nicks,
dents, scratches, wear, or corrosion. Replace
as necessary.
6. Inspect aluminum outer ring (1) and

Installation of Engine

aluminum inner ring (7) and shaft sleeve (12)
of shaft coupling for cracks. If either aluminum
outer ring (1) or aluminum inner ring (7) or
shaft sleeve (12) are damaged, the parts must
be replaced as an assembly. At the same
time, check the elastic body (4) and bolt (5 &
10) and screw (3 & 8) and pressure cover (9 &
11).

Assembly

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

Note

: Prior to assembly, lubricate all seal lips

and surfaces with lubricant specified in Section

36.1, LUBRICATION SYSTEM.

Note

: Tighten all fasteners without special

torques specified to standard torques listed,
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.

warning

To prevent personal injury and property

damage, be sure lifting device is properly

secured and of adequate capacity to do the

job safely.

1. Press bearings (28 & 29) into their bores in
shell seat (17).
2. Install driven gears (26) and drive shaft (27)
into shell seat (17). Slide drive gear (25) over
drive shaft (27) to its proper location.
3. Install the new gasket (36) on the shell seat
(17). Install the shell cover (37) onto the shell
seat (17). Install the pins (39) into the shell
cover (37) and the shell seat (17).
4. Press bearings (28 & 29) into their respective
bores in shell cover (37). Install rings (33 & 40)
into the shell cover (37).

5. Use the bolt (34) and washer (35) to fix the

shell cover (37) onto the shell seat (17).
6. Install new oil seal (41) into centre bore in

the shell cover (37) so that it is flush with shell

Installation of Engine

cover (37) face.
7. Turn over PTO assembly. Install new oil

seal (16) in the shell seat (17) so that it is flush

with shell seat (17) face.
Note: When installing new oil seals, install them
with the oil lip (larger of the two lips with the
spring behind it) facing inward. Care should
be taken to prevent damage to seal lips during
assembly.
8. Install yoke (42) on drive shaft (27) end and
secure with hardened washer (43) and locknut
(44). Tighten locknut (44) to fasten it after the
paste is applied to it. The torque is 850 - 1050
Nm.
9. Install the pressure cover (11) of shaft
coupling onto the shaft sleeve (12). Use the
bolt (10) to fasten it after the paste is applied
to it. The torque of bolt (10) is 104Nm.Install
the shaft sleeve (12) of shaft coupling onto
the input end of drive shaft (27). Then install
the pressure cover (9) onto the drive shaft
(27). Use the set screw (8 to fasten it after the
paste is applied to it. The torque of set screw
(8) is 60Nm. Then install the aluminum inner
ring (7) of shaft coupling onto the shaft sleeve
(12). Use the bolt (5) and washer (6) to fasten
it after the paste is applied to it. The torque of
connecting bolt (5) is 350Nm.
10. Install the aluminum outer ring (1) of

shaft coupling onto the flywheel disc and use

the shaft coupling fastening screw (3) and
washer (2) to fix it. The torque of connecting
screw (3) for the aluminum outer ring (1) and

flywheel disc of shaft coupling is 170Nm. The

thread anti-loosing paste should be applied for
tightening.
11. Install the elastic body (4) in aluminum

inner ring (7). Attach a suitable rope to fix the

elastic body (4).

Installation

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

Note

:When reassembling PTO assembly.

Installation of Engine

to  the  engine  flywheel  housing,  and  main
hydraulic  and  tandem  pumps  to  PTO
assembly.  be  sure  to  align  match  marks
inscribed during disassembly.

Note

: Tighten all fasteners to standard torques

listed, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Install the transitional disc (13) onto the
flywheel housing and use the Bolt (15) and
washer (14) to fix it. Use suitable lifting
equipment, position Power take-off assembly
into the aluminum outer ring (1) of shaft
coupling. Remove the rope of elastic body (4).
Secure PTO assembly to the transitional disc
(13) with bolts (30 & 31) and washers (32).
2. Using suitable lifting equipment, position
hydraulic pump over its mounting studs and
secure with bolts removed during removal.
3. Reconnect driveline to yoke (42). Install
rubber adaptor (18) into shell seat (17).
4. Remove oil level plug and drain plug (45)
from the front shell cover (37) and the shell
seat (17) respectively. Add the lubricating oil
into the PTO assembly from the drain plug (45),
until the oil reliefs from the opening of oil level
plug (45). Then install and fasten the oil level
plug and drain plug (45) respectively.
5. Start the engine and bring oil to correct
operating temperature. Check for leaks and
correct as necessary.
6. Remove wheel blocks from all road wheels.

Maintenance

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

Note: Refer to Section 36.1, LUBRICATION
SYSTEM for recommended check and drain

intervals and lubricant specifications.

Oil level check
Remove oil level plug (45) from front part of
shell cover (37), if oil is not showing in oil level
plug (45), add lubricant until oil is to oil level
plug (45). Reinstall oil level plug (45) and
tighten securely.

Installation of Engine

5.2 Installation of Compressor

Disassembly of compressor

1. Disconnect the electrical connection from
the clutch of compressor (5).
2. Loosen the nut and washer on the adjusting
screw rod (9) and release the tension of V-belt
(7).
3. Loosen the nut (1), bolt (6) and washers (2

、

3). Regulate the adjusting screw rod (9). The
V-belt (7) should be able to freely slip from the
groove of compressor (5).
4. Remove the nut (1), screw (4) and washers
(2

、

3) from the compressor (5). Detach the

adjusting screw rod (9) from the compressor.
5. Support the compressor (5). Remove
the adjusting gasket (10), washers (2

、

and nut (1) fixing the compressor (5) onto

Fig.1 Assembly drawing of compressor

1 2 3

1. Nut

7. V-belt

2. Washer

8. Nut

3. Washer

9. Adjusting screw rod

4. Screw

10. Adjusting gasket

5. Compressor

11. Compressor support

6.Bolt

Installation of Engine

the compressor support (11). Remove the
compressor (5) from the compressor support
(11).
6. Remove the compressor support (11) from
the engine.
Note: If it isn’t required to replace the V-belt (7),
then it will be unnecessary to remove it from
the engine.

Installation of compressor

1. Install the compressor support (11) onto the

engine and use the removed fasteners to fix it

properly.
2. Install the compressor (5) onto the
compressor support (11) and use the removed
fasteners to fasten it. They can’t be completely
tightened in this step.
3. Install the V-belt (7) onto the rear groove of
engine fan pulley and then install it onto the
rear groove of compressor (5).
4. Insert the upper part of adjusting screw rod
(9) through the mounting hole of compressor
(5). Insert the screw (4) through the mounting
hole of compressor. Use the washers (2

、

and nut (1) to fasten the adjusting screw rod (9)
and compressor (5). They can’t be completely
fastened in this step.
5. Insert the lower part of adjusting screw rod
(9) through the mounting hole of base seat.
Insert the

Screw

(4) through the mounting hole

of compressor support (11). Use the washers
(2

、

3) and nut (1) to fasten the adjusting

screw rod (9) and compressor support (11).
They can’t be completely fastened in this step.
6. Fix the compressor (5). Fasten the washers
(2

、

3) and nuts (1) in Step 4 and 5.

7. Adjust the V-belt (7) of compressor with the
adjusting screw rod (9), until a deflection of
about 10mm appears when the center part
of V-belt (7) is pressed by thumb. Tighten all
fasteners.
8. Connect the electric circuit of the clutch of
compressor (5).

Installation of Engine

6 T R A N S M I S S I O N A N D

MOUNTING

6.1 Transmission Mounting

Fig.1 Transmission and Mounting

Transmission And Mounting

25 24

20
21

1. Filler hose

10. Bolt

19. Plate

2. Flange nut

11. Washer

20. Shock mount

3. Retainer plate

12. Plate

21. Ringer

4. Output flange

13. Shock mount

22. Nut

5. Transmission

14. Ringer

23. Bolt

6. Ring

15. Nut

24. Washer

7. Trunnion

16. Power take-off assembly

25. Bracket

8. Input flange

17. Bolt

26.Transmission
retarder control

9. Retainer plate

18. Washer

Description

Numbers in parentheses refer to Fig.1.
F o r   t r a n s m i s s i o n   m a k e ,   m o d e l   a n d
specification, refer to  ‘GeneralL information’.
For  transmission  switches,  sensors  and
instruments, refer to Section 8.1.7, 'Switches
and sensors'.
For transmission servicing and repair data,
refer  to  the  transmission  manufacturers
service manual.
The  transmission  is  remote  mounted  in
the frame and is supported by trunnion (7)
assembly  at  the  front  and  two  mounting
brackets  (25)  at  the  rear.Integral  with
transmission (5) assembly are torque converter
and planetary gearing. There are six forward
gears and one reverse gear with automatic
lockup in all speed ranges. Operation of the
transmission is by the Commercial Electronic
Control (CEC) Shift System. A brief description
and  operation  of  the  main  transmission
components are as follows:

Torque converter

The  torque  converter  consists  of  three
elements -pump, turbine, and stator. The pump
is the input element and is driven directly by
the engine. The turbine is the output element
and is hydraulically driven by the pump. The
stator  is  the  reaction  (torque  multiplying)
element. When the pump turns faster than
the turbine, the torque converter is multiplying
torque.  When  the  turbine  approaches  the
speed of the pump the stator starts to rotate
with the pump and turbine. When this occurs,
torque  multiplication  stops  and  the  torque

converter functions as a fluid coupling.

Lockup clutch

The lockup clutch is located inside the torque
converter and consists of three elements -
piston, clutch plate, and backplate. The piston
and backplate are driven by the engine and
the clutch plate, located between the piston

Transmission And Mounting

and  backplate,  is  splined  to  the  converter
turbine. The  lockup  clutch  is  hydraulically
engaged and released in response to electrical
signals from the ECU. It engages when the
vehicle  reaches  a  predetermined  speed.
Engagement of the lockup clutch provides a
direct drive from the engine to the transmission
gearing. This eliminates converter slippage
to  provide  maximum  fuel  economy.  The
lockup clutch releases at lower speeds (and
momentarily during shifts). When the lockup
clutch is released, drive from the engine is
transmitted hydraulically through the converter
to the transmission gearing. The lockup clutch
also releases when the ECU detects certain
undesirable conditions.

Planetary gears and clutches

A series of planetary gears and shafts provide
the gear ratios and directions of travel for the
vehicle. Power flow through the planetaries
is controlled by multiple clutch packs. The
clutches are applied and released hydraulically
in response to electrical signals from the ECU.

Hydraulic retarder

A vaned rotor and two vaned stators are the
basic components of the retarder. Application
of the retarder control valve fills the cavity
around  the  rotor  with  oil  when  the  vehicle
must be slowed on steep downgrades. When
the cavity is emptied, the rotor is free of drag.
Maximum retarder effect occurs in the lowest
gear range with foot off of the accelerator
pedal. Long continuous use of the retarder
will raise transmission oil temperature. Short
periods of full release, to interrupt continuous
application,  will  help  prevent  overheating.
During normal operation the dash mounted
transmission oil temperature gauge should
read  in  the  green  zone.  However,  during
transmission retarder operation oil temperature
can enter the yellow 'Retarder On' zone but
should not enter the red zone.

Transmission And Mounting

Transmission oil cooler

The transmission oil is cooled by a separate
oil cooler mounted between the radiator and
transmission to maintain transmission oil within
its required operating temperature range.
Refer to Section 33,'oil cooler assembly'.

Transmission oil filter

The transmission oil filter is mounted at the left

hand side of the transmission. It is installed in
the transmission oil lines to remove dirt and
other contaminants from the transmission oil to
minimise wear and provide maximum service
life for the transmission. Refer to Section 30,

'transmission oil filter'.

Removal

Numbers in parentheses refer to Fig.1.

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting equipment are

properly secured and of adequate capacity

to do the job safely.

High electrical current can cause sparks

and personal injury from burns. Switch

circuit breakers to the 'Off' position before

removing any electrical components.

Remove battery ground cable first, and

reconnect last, to prevent damaging

electrical components.

A n y t i m e t h e b a t t e r y e q u a l i z e r i s

disconnected from the batteries, remove

ground cable first, and reconnect last, to

prevent damaging the component.

1. Position the vehicle in a level work area,
raise the body and secure in place with the
body safety pins. Refer to Section 23,'Body
and Installation'.
2. Apply the parking brake and switch off

Transmission And Mounting

the engine. Turn steering wheel in both
directions several times to relieve pressure
in the steering system. Operate the treadle
valve continuously to discharge the brake
accumulators.
3. Block all road wheels.

Note

: It is important that the electrical

connections are removed in the order listed
in step 4 to prevent damage to the electrical
components.
4.  Disconnect  battery  equalizer  ground
connection  from  the  batteries.  Disconnect
battery cables from terminal posts (ground
cable  first).  Disconnect  battery  equalizer
positive  connection.  Disconnect  electrical
connections at the ECU.
5. Using suitable lifting equipment, support
transmission  guard  and  remove  mounting
hardware securing the guard to the frame.
Remove transmission guard.

6. Disconnect driveline from input flange (8) at

the front of transmission (5). Refer to Section
19, 'Driveline Installation'.
7. Disconnect driveline from output flange
(4) at the rear of transmission (1). Refer to
Section 19, 'Driveline Installation'.
8. Drain the oil from transmission (5).
9. Disconnect the transmission retarder cables
at transmission (5).
10. Disconnect transmission oil cooler lines
and oil filter lines from transmission (1). Cap
all open lines and fittings to prevent entry of
dirt.
11. Disconnect all remaining hydraulic lines
attached to transmission (5). Cap all open

lines and fittings to prevent entry of dirt.

12. Disconnect all electrical connections and
cables attached to the transmission.
13. Disconnect filler hose(1) attached to the
transmission(5).
14. Install suitable lifting eyes into the holes
provided at the top of transmission (5) housing
and secure a suitable lifting device to the eyes.
15. Remove bolts (10), washers(11),

Transmission And Mounting

Plates(12)and nuts(15) securing trunnion (7)
to the frame.
16.  Remove  bolts  (17),  washers(18),
Plates(19)and nuts(22) securing brackets(25)
to the frame.
17. Check to make certain that all hydraulic
lines  and  electrical  connections  fitted  to
transmission  (5)  have  been  disconnected
before moving transmission (5).
18.  Carefully  manoeuvre  transmission  (5)
out of the frame mounting and lower onto a
suitable dolly or pallet.
19.  Move  transmission  (5)  assembly  to  a
suitable work area or onto a work stand for
further disassembly, if necessary.

Disassembly

Numbers in parentheses refer to Fig.1.

Note

: Refer to the transmission manufacturers

Service Manual if transmission service or
repair is required.

1. Remove flange nut (2) and retainer plate (9)
securing input flange (8) on transmission (5).
Pull input flange (8) from transmission (1).

2. Pull trunnion (7) from transmission (5) and
remove ring (6) and shock mounts (13) from
trunnion (7), if required.

3. Remove flange nut (2) and retainer plate (3)
securing output flange (4) on transmission (5).
Pull output flange (4) from transmission (5).

4. Remove bolts (23) and washers(24)
securing brackets (25) on transmission (5) and
remove brackets (25).
5. If required, remove shock mounts (20) from
mounting brackets (25).

Assembly

Numbers in parentheses refer to Fig.1.

1.If removed, fit shock mounts(13) and ring (6)

to trunnion (7). Install trunnion (7) to
transmission (5).

2.If removed, fit shock mounts (20) to brackets

(25). Install brackets (25) on transmission
(5) and loosely secure with bolts (23) and

Transmission And Mounting

SANY SRT95C Off-Highway Truck. Service Manual - page 15