SANY SRT95C Off-Highway Truck. Service Manual

washers (24).
3. Ensure transmission output shaft is in
the most outward position and the bearing
between the shaft shoulder and the flange is
tight against the shaft shoulder.
4. Coat splines of input shaft with EP, NLGI
molybdenum grease and fit input flange (33)
on input shaft.
5. Install input flange (8) on transmission
(1) securing with flange nut (2) and retainer

plate(9). Tighten flange nut (2) to a torque of
1300 N•m.

6. Coat splines of output shaft with EP, NLGI
molybdenum grease and fit output flange (4)
on output shaft.

7. Install output flange (4) on transmission (5)

securing with flange nut (2) and retainer

plate(3). Tighten flange nut (2) to a torque of
1300 N•m.

Installation

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.

1. Position transmission (5) assembly under
the truck and attach a suitable lifting device to
the eye bolts on top of transmission (5).
2.  Carefully  lift  transmission  (5)  into  its
mounting  position  and  secure  trunnion  (7)
to  the  frame  with  bolts  (10),  washers(11),
plates(12) and nuts (15). Tighten bolts (10) to

a torque of 507 N•m-557N•m.

3. secure brackets (25) to the frame with
bolts (17), washers(18), plates(19) and nuts

(22). Tighten bolts (17) to a torque of 790N•m-
860N•m.

4. Remove lifting device and lifting eye bolts

Transmission And Mounting

from top of transmission (5).

5. Install filler hose (1) to transmission(5).

6.  Connect  all  electrical  connections  and
cables  to  transmission  (1)  as  tagged  at
removal.
7.  Connect  transmission  oil  cooler  lines
to  transmission  (1)  and  oil  filter  lines  to

transmission oil filter as tagged at removal.

8. Connect any remaining hydraulic lines
which were removed during removal. Ensure
all hydraulic lines are securely tightened.
9. Connect transmission retarder cables at
transmission (1).

10. Install rear driveline to output flange (4) at

the rear of transmission (5) and secure with
mounting hardware removed during removal.
Refer to Section 19, 'Driveline Installation'.

11. Install front driveline to input flange (8) at

the front of transmission (5) and secure with
mounting hardware removed during removal.
Refer to Section 19, 'Driveline Installation'.
12. Using suitable lifting equipment, support
transmission guard and secure guard to the
frame with mounting hardware removed during
removal.
13. Fill transmission (5) with oil specified
in Section 36.1,' LUBRICATION AND
MAINTENANCE', and check the oil level as
described under 'Oil Level Check'.

Note

: It is important that the electrical

connections are made in the order listed in
step 14 to prevent damage to the electrical
components.
14. Connect electrical connections at the ECU.
Connect battery equalizer positive connection.
Connect battery cables to battery terminal
posts (ground cable last). Connect battery
equalizer ground connection.
15. Start the engine and make an operational
c h e c k o f a l l l i n e s a n d c o m p o n e n t s
disconnected during removal. Check all

hydraulic lines and fittings for leaks and tighten

as required.
16. Ensure parking brake is applied, remove

Transmission And Mounting

the body safety pins and lower the body.
Remove wheel blocks from all road wheels.
Refer to Section 24,'Body and Installation'.

warning

When checking the oil level, be sure that

the parking brake is applied and all road

wheels are securely blocked.

Maintenance

Periodic inspections

For easier inspection, the transmission should
be kept clean. Make periodic checks for loose
bolts and leaking oil lines. Check the condition
of  electrical  harnesses  and  connections
regularly.
The transmission breather should be checked
regularly  and  as  frequently  as  necessary,
depending on the operating conditions of the
vehicle. A badly corroded or plugged breather
restricts  proper  breathing  and  causes  a
buildup of condensation and subsequent oil
deterioration.

Oil level check

Check the transmission oil level and add oil if
low, every 10 hours/daily. Use only oil of the

type specified in Section 36.1, 'LUBRICATION

A N D M A I N T E N A N C E ' . B e c a u s e t h e
transmission oil cools, lubricates and transmits
hydraulic power it is important that the proper
oil level be maintained at all times. If the oil
level is too low, the converter and clutches
will not receive an adequate supply of oil. If
the oil level is too high, the oil will aerate and
the transmission will overheat. It is absolutely
necessary that the oil put into the transmission
be clean. Oil must be handled in clean
containers to prevent
foreign material from entering the system.

Note

: Containers or fillers that have been

Fig.2 Visual Level Indicator

Full liquid level and

safe operating

chamber

Invisible red line

(Over-filling)

Red line

Invisible red line;

oil level too low

Transmission And Mounting

used for antifreeze or engine coolant solution
must not be used for transmission oil.

Visual level indicator

A visual level indicator is mounted on the lower
left side of the transmission main housing and
provides a method of checking the oil level.
Refer to Fig.2.

Cold oil level check

Before starting the engine, check the visual
level indicator or remove the ADD (lower)
plug. If oil is present in the indicator or if oil

flows from the plug opening, the transmission
has sufficient oil to permit safe starting of the
engine. If no oil is present, add sufficient oil to

bring the level within the indicator or to cause
a flow from the plug opening. Replace the
plug.

Hot oil level check

Note

: Observe the condition of the oil in the

visual level indicator or the type of flow from
the plug opening. Foaming or spurting may
indicate a false level.
A hot oil level check is made to determine
if there is sufficient oil for working operation
of  the  transmission.  Select  neutral  on
the  transmission  range  selector  and  start
the  engine.  Operate  the  vehicle  until  the
transmission  reaches  a  normal  operating
temperature of 82° C - 103° C (180° F - 220°
F). Idle the engine, apply the parking brake
and block all road wheels. Check the visual
level indicator or remove the FULL (upper) oil
level check plug. The oil should be within the
indicator limits shown in Fig.2 or at or near the
level of the plug opening. Add or drain oil as
necessary to bring the oil level within these
limits.

Note

: The transmission may be operated

safely as long as the oil level is above the
ADD (lower) plug.

Transmission And Mounting

warning

Be sure to apply the parking brake, switch

off the engine and block all road wheels

before troubleshooting the vehicle. If

it is necessary to run the engine, it is

imperative that an operator be present in

the cab at all times, even at idle.

Oil and filter change

After the first 200 hours of operating a new or

rebuilt transmission, the transmission oil and

filters should be changed. The transmission oil
and filters should be changed at the intervals

specified  in  Section  36.1,  'LUBRICATION
AND MAINTENANCE', or sooner, depending
on operating conditions. Also, the oil must be
changed whenever there are traces of dirt
or  evidence  of  high  temperature  indicated
by discoloration or strong odour. The screen
and  magnet  assembly  in  the  sump  should
be removed and cleaned with mineral spirits
at  each  oil  change.  Metal  particles  in  the
oil (except for the minute particles normally

trapped in the oil filters) indicate damage has

occurred in the transmission. When these
particles are found in the filters, the cause

must be established and rectified immediately

to prevent damage to the transmission. At
each oil change, examine the used oil for
evidence of dirt or water. A normal amount
of condensation will emulsify in the oil during
operation of the transmission. However, if
there is evidence of water or engine coolant
in the oil, the cause must be established and

rectified immediately to prevent damage to the

transmission.

Welding on vehicles equipped with CEC

When frame or other welding is required, the
following precautions are to be taken to protect

Transmission And Mounting

the electrical components.
a.  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.

warning

The ECU can be damaged by improper

welding procedures. Any time the battery

equalizer is disconnected from the

batteries, remove ground cable first, and

reconnect last, to prevent damaging the

component.

b.  If  additional  system  ground  wires  are
connected  to  the  frame,  they  must  be
disconnected also.
c. Cover electrical components and wiring to
protect from damage.
d. Do not connect welding cables to electrical
components.  Do  not  weld  on  electrical
components. If welding is to be done close to
electrical components, the components should
be removed prior to the welding process.
e.  On  completion  of  all  welding  reconnect
electrical connections in the reverse order to
step a.

Troubleshooting

Converter stall test

A stall test should be conducted when the
power package (engine and transmission)
is not performing satisfactorily. The purpose
of the test is to determine the engine power
output and establish if the transmission is the
malfunctioning component.

warning

When conducting a stall test, the vehicle

Transmission And Mounting

must be positively prevented from moving.

The parking brake must be applied and

the vehicle should be blocked to prevent

movement forward or reverse. Keep people

safely away from the vehicle path. Do not

maintain the stalled condition longer than

30 seconds due to rapid heating of the

transmission oil. With the transmission

in neutral, run the engine at 1200 - 1500 r/

min for two minutes to cool the oil between

tests. Do not allow the converter-out

temperature to exceed 135° C (275° F).

Keep a close check to prevent overheating

of the engine cooling system.

1. Position the vehicle on a level area with
room for movement all round.
2. Apply the parking brake and block all road
wheels. Turn the manual mode key switch
to the 'On' position and the mode selection
switch to the 'Power' mode.
3. Apply the service brake, release the parking

brake and select fifth gear on the transmission
shift selector. The transmission will shift to fifth

gear and deactivate the lockup clutch. Apply
the parking brake and release the foot pedal.
4. Accelerate the engine to full throttle and,
using a tachometer of known accuracy, note
the maximum rev/min the engine will attain.
Converter-out pressure should be 2 bar (30
lbf/in²).

Note

: The stall speed of each vehicle is noted

on the final inspection records prior to the
vehicle leaving the factory. This can be used
as a guide when checking the stall speed. It
is recommended to keep a record of the stall
speed after each major service and use the
previous recorded value as a guide.
5. When the stall check is complete, return the
accelerator to the idle position and move the
shift selector to the neutral position.

Note

: Engine power will decrease with an

increase in elevation (altitude), becoming more

Transmission And Mounting

pronounced at greater elevation. This will
result in a lower engine speed under converter
stall conditions.
6. During the stall check the transmission oil
temperature should rise while the engine is
under load and drop when the transmission is
returned to neutral. Should the temperature
fail to drop it indicates that there is a problem
with the converter.
7. After making allowances for elevation, a low
engine speed may indicate the engine is not
delivering full power. Refer to engine service
manual for engine repair information.

Electrical troubleshooting

Refer to troubleshooting manual TS3353 for
commercial electronic controls 2(CEC2) of
Allison transmission.

Mechanical troubleshooting

It is recommended to follow the procedures
laid down for mechanical troubleshooting, as
outlined in the 'Mechanical Trouble Shooting'
charts.

Special tools

There are no special tools required for the
procedures outlined in this section. Refer to
Section 38.3, 'Service tools' for part numbers
of service tools which should be used in
conjunction with procedures outlined in the
transmission manufacturers service manual,
and, general service tools and adhesives
required.

Transmission And Mounting

Problem

Cause

Remedy

A - Transmission overheats

High or low oil level

Restore proper oil level

Aerated (foaming) oil

Refer to condition 'B'

Truck overloaded

Reduce load

Engine coolant overheated

Correct engine overheating

Transmission oil cooler or

Clean or replace oil cooler or lines

Low coolant level

Add coolant, check for leaks

Oil leaking

Check transmission and lines for leaks

Low main pressure

Refer to condition 'V'

Low converter-out pressure

Refer to condition 'U'

Truck brakes dragging

Check parking and service brakes

Torque converter stator
locked

Check for low top speed of vehicle.
Check torque converter components.

Clutch slipping

Overhaul transmission. Replace worn
piston seal rings or clutch plates.

B - Oil is aerated (foaming)

Incorrect type of oil used

Change oil. Use only oil specified
in Section 36.1, ‘Lubrication and
Maintenance’.

High or low oil level

Restore proper oil level

Air entering suction side of
oil pump

Check oil pump bolts and gasket

Water in oil

Check for source, clean system

C - Heavy metal debris found
in oil

Transmission internal failure

Completely disassemble, clean and

repair in oil transmission. Replace filters

and clean lines

and oil cooler.

D - Coolant found in oil

Transmission oil cooler
leaking

Completely disassemble and thoroughly
clean transmission. Replace all friction
faced clutch plates. Repair or replace oil

cooler. Replace filters and clean external

lines.

E  -  Transmission  will  not
o p e r a t e   i n   a n y   r a n g e
r e g a r d l e s s   o f   s e l e c t o r
position

Loss of electrical power

Refer to Electrical Troubleshooting

Internal mechanical failure

Overhaul transmission

Driveline failure

Check transmission input and output

Low oil level

Restore proper oil level

Low main pressure

Refer to condition 'V'

Transmission And Mounting

F - Transmission continues
in the same forward gear
r e g a r d l e s s o f s e l e c t o r
position

Loss of electrical power

Refer to Electrical Troubleshooting

G - Shifting is erratic

Refer to Electrical Troubleshooting

H - Transmission operates
only in first, neutral and
reverse

Refer to Electrical Troubleshooting

II - Transmission shifts
to neutral during reverse
operation, but will operate
normally in all other ranges

Refer to Electrical Troubleshooting

J   -   V e h i c l e   o p e r a t e s
i n   r e v e r s e   a n d   m o v e s
backwards in neutral when
engine is accelerated, but
stalls  in  all  other  gears
when engine is accelerated
- Electrical Troubleshooting
OK

Reverse clutch has failed
(won't release)

J - Vehicle operates in reverse and
moves backwards in neutral when
engine is accelerated, but stalls in all
other gears when engine is accelerated
- Electrical Troubleshooting OK

K  -  Vehicle  operates  in
first and second gears and
moves  forward  in  neutral
when engine is accelerated,
but stalls in all  other gears
when engine is accelerated
- Electrical Troubleshooting
OK

First and second gear
clutch failed (won't release)

Overhaul transmission

Transmission And Mounting

L - Vehicle operates in
third and fourth gears and
moves forward in neutral
when engine is accelerated,
but stalls in all other gears
when engine is accelerated
- Electrical Troubleshooting
OK

Third and fourth gear clutch
failed (won't release)

Overhaul transmission

M  -  Vehicle  operates  in
fifth  and  sixth  gears  and
moves  forward  in  neutral
when engine is accelerated,
but stalls in all other gears
when engine is accelerated
- Electrical Troubleshooting
OK

Fifth and sixth gear clutch
failed (won't release)

Overhaul transmission

N - No power is transmitted
in any one range - Electrical
Troubleshooting OK

Range clutch failed (won't
apply, slipping)

Overhaul transmission. Check for worn
piston seals, broken piston housing, or
worn clutch plates in that range.

O - Vehicle will operate in
second,  fourth,  sixth  and
reverse  gears  but  will  not
operate  in  all  other  gears
-Electrical Troubleshooting
OK

Splitter-overdrive clutch
won't release or splitter-
direct clutch won't apply,
slipping

Overhaul transmission. Check splitter
clutches for worn components.

P  -  Vehicle  will  operate  in
first,  third  and  fifth  gears
but  will  not  operate  in  all
other  gears  -Electrical
Troubleshooting OK

Splitter-direct clutch won't
release or splitter-overdrive
clutch won't apply, slipping

Overhaul transmission. Check splitter
clutches for worn components.

Q - Slow clutch engagement

Low oil level

Add oil to proper level

Foaming oil

Refer to condition 'B'

Worn piston seals

Overhaul transmission

Low main pressure

Refer to condition 'V'

Transmission And Mounting

R - Vehicle lacks power and
acceleration

Engine malfunction

Check engine. Refer to engine service
manual.

Aerated oil

Refer to condition 'B'

L o w e n g i n e s p e e d a t
converter stall

Refer to condition 'T'

High engine speed at
converter stall

Refer to condition 'S'

Hydraulic retarder partially
applied

Check retarder linkage

Truck brakes dragging

Check parking and service brakes

Stator freewheel clutch
failed

Overhaul transmission

S - High engine speed at
converter stall

Low oil level

Add oil to proper level

Low converter-out pressure Refer to condition 'U'
H i g h o i l t e m p e r a t u r e
(above 135

C; 275

Refer to condition 'A'

C l u t c h s l i p p i n g , m a i n
pressure normal

Overhaul transmission. Replace clutch
piston seal rings or clutch plates.

Foaming oil

Refer to condition 'B'

T - Low engine speed at
converter stall

Low engine output torque

Tune engine and check output

C o n v e r t e r e l e m e n t
interference

Check for noise at stall; overhaul
converter if necessary

Transmission oil not up to
operating temperature

Warm up transmission to 82

C -

103

C (180

F - 220

U - L o w c o n v e r t e r - o u t
pressure

Low oil level

Add oil to proper level

Oil line leakage (oil cooler
or filter)

Check for leaks, correct as required

Plugged oil strainer

Clean oil strainer

Defective oil pump

Rebuild/replace oil pump assembly

High oil temperature

Refer to condition 'A'

Foaming oil

Refer to condition 'B'

Transmission And Mounting

V - Low main pressure

Low oil level

Add oil to proper level

Leaks in hydraulic system

Check all external points for leaks;
check each range for localizing internal
leaks

F a i l u r e i n p r e s s u r e
regulator

Overhaul valve assembly

W o r n i n p u t o i l p u m p
assembly

Rebuild/replace pump assembly

Clogged oil strainer

Clean oil strainer

Air leaks at suction side of
input pump

Check input pump, correct as required

W - D o w n s h i f t o f
transmission is permitted
during lockup operation

Refer to Electrical Troubleshooting

X - S h i f t q u a d r a n t n o t
illuminated

Failed light bulb

Replace the light bulb

Y - Reverse signal not
energized

Refer to Electrical Troubleshooting

Special torque specifications for transmission
and mounting

FIG. NO. No.

Name

Torque

Ib. Ft

Bolt

507~557

373~410

Bolt

790~860

582~633

Bolt

217~240

160~177

Flange

Nut

1300

958

Transmission And Mounting

12 13

Fig.1 Transmission retarder control

1. Linear actuator

8. Washer

2. Nut

9. Plate

3. Washer

10. Nut

4. Washer

11. Bolt

5. Bolt

12. Washer

6. Bolt

13. Washer

7. Bolt

14. Fixed plate

6.2 Transmission retarder control

Transmission And Mounting

Overview

Numbers in parentheses refer to Fig.1.
Retarder control is the term used for applying
a continuous braking force to hold the truck
to  a  safe  steady  speed  when  descending
grades. The truck fitted with disc brake and
transmission retarders, introduce transmission
retarder in this section.
Transmission retarder control is compose of
linear actuator (1), fixed plate (14) and plate
(9). Retarder control switch is installed on the
centre console of the operator.
If  operating  retarder  brake  during  truck
operation, pushing the control switch. The
linear  actuator  (1)  will  drive  plate  (9)  and
transmission  retarder  pole  upwards,  open
transmission retarder for hydraulic retarder.

Removal

WARNING

The retarder may be used anytime to slow

down. If additional braking is required

apply the service brakes. The retarder is

not meant for bringing the truck to a halt,

or for sudden deceleration - the service

brakes should be employed for this

purpose. Retarder control can not last for

more 3 minutes.

1. Position the vehicle in a level work area,
apply the parking brake and switch off the
engine.
2. Block all road wheels. Set the battery in the
' off ' position.
3. Disconnect wiring harness attached to linear
actuator(1).
4. Remove bolt (6, 7), washer (3, 8), nut (2,10)
and remove plate (9).
5. Remove bolt (5), washer (3, 4), nut (2)

securing linear actuator (1) to fixed plate (14),

remove linear actuator (1).

Transmission And Mounting

6. Remove bolt (11) and washer (12,13)
securing fixed plate (14) to transmission,

remove fixed plate (14).

Installation

Note

:Tighten all fasteners without special

torques specified to standard torques.

WARNING

To prevent personal injury and property

damage, be sure wheel blocks are properly

secured and of adequate capacity to do the

job safely.

1. Secure fixed plate (14) to transmission with

bolts (11) and washers (12,13).

2. Secure linear actuator (1) to fixed plate (14)

with bolts (5), washers (3,4) and nuts (2).
3. Secure plate (9) to fixed plate (14) and
transmission retarder pole with bolts (6,7) ,
washers (3,8) and nuts (2,10).
4. Connect wiring harness attached to linear
actuator(1).
5. Set the battery in the 'on' position. Start
the engine and make an operational check of
retarder.
6. Ensure parking brake is applied. Remove
wheel blocks from all road wheels.

Special tools

There are no special tools required for
procedures outlined in this section. Refer to
Section 38.3, ' Service Tools '.

Transmission And Mounting

SANY SRT95C Off-Highway Truck. Service Manual - page 16