Series TM Transit Mixer Drive System Service Manual

Series TM Transit Mixer Drive System Service Manual Contents

FUNCTIONAL DESCRIPTION General ............................................................................................................................................................... 4 Transit Mixer Pump TMP........................................................................................................................... 4 Cross Section TMP ...................................................................................................................................... 4 Charge Pump ................................................................................................................................................... 5 Charge Relief Valve ........................................................................................................................................ 5 Multi-Function Valve ..................................................................................................................................... 5 Input Shaft ........................................................................................................................................................ 6 Auxiliary Mounting Pads.............................................................................................................................. 6 Transit Mixer Motor TMM ......................................................................................................................... 7 Cross Section TMM ..................................................................................................................................... 7 Loop Flushing Device ................................................................................................................................... 8 Transit Mixer Gearbox TMG ..................................................................................................................... 9 Cross Section TMG ...................................................................................................................................... 9 Speed Sensor .................................................................................................................................................10 Transit Mixer Electronic TME .................................................................................................................11 Transit Mixer Drive System TM .............................................................................................................12 Circuit Diagram TM...................................................................................................................................12 General Specications ................................................................................................................................13 Specic Data ..................................................................................................................................................13 Technical Data ...............................................................................................................................................13 Electrical Proportional Valves...................................................................................................................13 Circuit Diagram .............................................................................................................................................14 Determination of Nominal Pump Sizes ................................................................................................14 Axial Piston Pumps Size 070 and 089 ................................................................................................15

TECHNICAL SPECIFICATIONS AXIAL PISTON PUMPS TMP

DIMENSIONS AXIAL PISTON PUMPS TMP TECHNICAL SPECIFICATIONS AXIAL PISTON MOTORS TMM

General Specications ................................................................................................................................18 Specic Data ..................................................................................................................................................18 Technical Data ...............................................................................................................................................18 Circuit Diagram .............................................................................................................................................19 Determination of Nominal Motor Sizes................................................................................................19 Axial Piston Motors Size 070 and 089 ................................................................................................20

DIMENSIONS AXIAL PISTON MOTORS TMM TECHNICAL SPECIFICATIONS GEARBOX TMG DIMENSIONS GEARBOX TMG

General Specications ................................................................................................................................21 Specic Data ..................................................................................................................................................21 Technical Data ...............................................................................................................................................21 Gearbox Size 51.2 .........................................................................................................................................22 Gearbox Size 61.2 .........................................................................................................................................23 Gearbox Size 71.2 .........................................................................................................................................24

2002, Sauer-Danfoss Sauer-Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations can be made without subsequent changes being necessary in specications already agreed. All trademarks in this material are properties of the respective companies. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group. All rights reserved. Front page: P4050028, P000853, P4050027, P000854, P4050026, P000861, P003001

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Series TM Transit Mixer Drive System Service Manual Contents (continued)

INSTALLATION INSTRUCTIONS General .............................................................................................................................................................26 Mounting the Motor ...................................................................................................................................26 Mounting the Speed Sensor ....................................................................................................................26 Mounting the Pump ....................................................................................................................................26 Mounting the Gearbox ...............................................................................................................................27 Mounting the Water Tank ..........................................................................................................................27 Mounting the Drum Flange ......................................................................................................................28 Mounting Controller TME ..........................................................................................................................29 Wiring Diagram TME ...................................................................................................................................30 Installation Space TME ................................................................................................................................30 Fluid Specication........................................................................................................................................31 Hydraulic Fluid ..............................................................................................................................................31 Cleanliness ......................................................................................................................................................31 Suction Filtration ..........................................................................................................................................31 Required Tools ...............................................................................................................................................32 Port Location Pump .....................................................................................................................................32 Port Location Motor ....................................................................................................................................32 General .............................................................................................................................................................34 Gearbox ...........................................................................................................................................................34 Hydrostatics....................................................................................................................................................34 Gearbox TMG .................................................................................................................................................36 Safety ................................................................................................................................................................36 Hydrostatic TMP and TMM ........................................................................................................................36 Troubleshooting ...........................................................................................................................................38 Emergency Discharging.............................................................................................................................41

HYDRAULIC FLUID

PRESSURE MEASUREMENT

START-UP PROCEDURE

MAINTENANCE

TROUBLESHOOTING EMERGENCY DISCHARGING

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Series TM Transit Mixer Drive System Service Manual Functional Description

GENERAL This section describes the operation of pump, motor, gearbox and controller to drive the transit mixer drum in an electrical closed loop control system. It is a useful reference for readers, which are not familiar with the functioning of transit mixer drive systems.

TRANSIT MIXER PUMP TMP

The variable displacement pump TMP is designed to convert a mechanical input power into hydraulic power. The input shaft, driven by the engine PTO, turns the pump cylinder block, which contains a ring of pistons. The pistons run against a tilted plate, called swash plate. This causes the pistons to compress the hydraulic uid, which imparts the input energy into hydraulic uid. The high-pressure uid is then ported out to provide the hydraulic pressure and ow to the xed displacement motor TMM. The swash plate angle can be varied by the actuating piston via the electrical proportional control valves depending on the current value, which is generated by the TME controller.
Variable Displacement Pump TMP

F300 692

F300 691

CROSS SECTION TMP

ACTUATING CYLINDER ACTUATING PISTON JOINT FLANGE

CYLINDER BLOCK PISTON

CHARGE PUMP INPUT SHAFT VALVE PLATE BEARING PLATE

SWASH PLATE

P001 981E

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Series TM Transit Mixer Drive System Service Manual Functional Description

CHARGE PUMP The charge pump is necessary to compensate internal leakages and supply cool uid to the system, to maintain positive pressure in the main system loop, as well as pressure to operate the control system. Charge pressure must be at its specied pressure under all conditions of acceleration and deceleration of the drum to prevent damage to the transmission. The charge pump is a xed-displacement, gerotor type pump integral in the variable displacement pump and driven by the main shaft. A charge pressure relief valve limits charge pressure.
Cross Section

F300 691

P001 982

CHARGE RELIEF VALVE

The charge pressure relief valve on the charge pump serves to maintain charge pressure at a designated level. A direct-acting poppet valve relieves charge pressure whenever it surpasses a certain level which is nominally set at zero ow, means in neutral position. The setting level is specied on the model code.
Cross Section

CHARGE RELIEF VALVE

F300 691 P001 983

MULTI-FUNCTION VALVE

The multi-function valve incorporate the system check valve and also the high-pressure relief valve function. The system check valves allow pressurized ow from the charge pump to enter the low-pressure side of the loop whenever system pressure dips below a certain level. Two system check valves are used to direct the charge ow into the low-pressure side of the closed circuit system. The high-pressure relief valves are designed as direct operating poppet valve, which are a xed setting for differential pressure of 420 bar [6090 psi]. If the pressure reachs the setting value the valve will be open immediately by cross-porting the system ow to the low-pressure side of the closed circuit system.
Cross Section HIGH PRESSURE RELIEF VALVE SYSTEM CHECK VALVE MULTI FUNCTION VALVE

F300 691

HIGH PRESSURE CHARGE PRESSURE

P001 984E

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Series TM Transit Mixer Drive System Service Manual Functional Description

INPUT SHAFT The standard input shaft is designed with a joint ange diameter of 100 mm [3.94 in] (DIN/ISO) and allows the direct assembling to the joint shaft from the engine power take off. An optional splined shaft is available for direct assembling to engine power take off.
TMP with Joint Flange TMP with Splined Shaft

F300 693

F300 688

AUXILIARY MOUNTING PADS

Auxiliary mounting pads are available in size A and B to drive auxiliary hydraulic pumps.
TMP with PTO A Cross Section

F300 683 P001 985

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Series TM Transit Mixer Drive System Service Manual Functional Description

TRANSIT MIXER MOTOR TMM The xed displacement motor TMM is designed to convert an input of hydraulic power into a mechanical torque and speed output power. The high-pressure hydraulic uid enters through the input port. The uid pressure builds behind the piston causing them to move down the swash plate. As the pistons returns up the swash plate again, the uid is allowed to exit through the exit port. The spinning pistons are housed in a cylinder bloc, which is connected to the output shaft. The mechanical output is used to turn the gearbox TMG.
Fixed Displacement Motor TMM

F000 857

F300 698

CROSS SECTION TMM

SHUTTLE SPOOL ORIFICED LOOP FLUSHING VALVE CYLINDER BLOCK

OUTPUT SHAFT

BEARING PLATE VALVE PLATE

PISTON
P001 953E

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Series TM Transit Mixer Drive System Service Manual Functional Description

LOOP FLUSHING DEVICE The integrated loop-ushing device in the motor is used to ush out a certain oil ow from the closed circuit system for cooling. The orice loop ushing valve denes a xed ow value from the closed circuit system on the low-pressure side only when there is a pressure differential in the main loop. The spring centered loop ushing shuttle spool, controlled through the high-pressure side, provides a circuit between the low-pressure side of the closed loop and the orice loopushing valve. At the time of rst operation a rapid air separation from the closed circuit is also achieved by the ushing device and in addition, it is ensured that unavoidable installation dirt is ushed out at the same time and can be picked up by the suction ltering
LOOP FLUSHING DEVICE X

F000 857

VIEW X
F000 857

Cross Section ORIFICED LOOP FLUSHING VALVE

LOOP FLUSHING SHUTTLE SPOOL

P001 954E

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Series TM Transit Mixer Drive System Service Manual Functional Description

TRANSIT MIXER GEARBOX TMG The two-stage planetary gearbox has to turn and to carry one side of the drum of transit mixer. It is assembled to the mixer frame of base supports, which also carry the torque force of the drive. It also provides the option to carry a water tank which is located in the upper part of the housing. The dynamic swivel angle of the output/drum ange will be compensating for the deection of the truck frame mainly under off-road conditions. The optional water pump drive is on the left or right drum ange side, if you see from drum ange side.
TMG 61.2 with Water Pump Drive on the left side TMG 61.2 without Water Pump Drive

F000 860

F000 872

CROSS SECTION TMG 61.2

WATER PUMP DRIVE SHAFT (90 degree turned) DRUM FLANGE

MAIN BEARING

INPUT SUN GEAR

2-ND STAGE 1-ST STAGE

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

CURVED TEETH COUPLING

P001 986E

Series TM Transit Mixer Drive System Service Manual Functional Description

SPEED SENSOR All the available gearboxes TMG s are prepared to offer the required speed sensor option. At the factory an oil-tight cover closes the receiving bore for the speed sensor. The location of the speed sensor at TMG s with water pump drive is dependent on the conguration - left or right water pump side - of the gearbox. On the right side, the speed sensor will be at the top of the motor, on the left side it is under the motor.
TMG with Water Pump Drive on the right side and installed Speed Sensor Cross Section Speed Sensor

F000 861

P001 987

10

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Series TM Transit Mixer Drive System Service Manual Functional Description

TRANSIT MIXER ELECTRONIC TME The controller constitutes a ready-to-install, operating unit, in dashboard design. The controller is available as a remote and cab mounted controller to supply the electrical pump control. The cab unit is an additional slave device and can be operated only in conjunction with the remote master unit. Using the rotary switch on the operating unit, the direction and speed rotation of the drum are selected and, corresponding to the position of the rotary switch, a current value is supplied to the electrical pump control. The pump output ow, which is established, determines the reference motor speed at the input of the gearbox. The speed sensor in the gearbox measures the actual speed as feedback for the controller. The desired and actual values are compared and the pump ow is controlled until both values equal. This is in operation at any selected drum speed. With the yellow touch switch on the remote controller, it is possible to stop and start the drum speed independent of the rotary switch position. In this case, the LED indicates changes from lighted to ashes. The yellow touch switch on the cabin controller permits a change over to the remote controller and vice versa. In this mode the cabin LED is off and all operatings are transfered to the remote controller. The ashing LED indicates stand by mode. When moving to the other control station the rotary switch position must be set to neutral. Touching the yellow switch with ashing LED will change to full light, which means the controller is switched on.
TME Remote Station ROTARY SWITCH LED TME Cabin Station ROTARY SWITCH LED

TOUCH SWITCH

P001 956

TOUCH SWITCH

P001 957

Symbol used on the Controller

P001 958

= Charging/Transport

= Memory Switch Stop/Start Remote Station

P001 960

P001 959

= Discharging = Changeover Switch Cabin Station

P001 961

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Series TM Transit Mixer Drive System Service Manual Functional Description

TRANSIT MIXER DRIVE SYSTEM TM In accordance with the rotary switch position on the TME controller unit (13), a current set point is generated and provides to the electrical proportional valve (6) of the TMP main pump (2) with a PWM signal. The necessary control oil supply is provided by the feed circuit of the charge pump (3) and is delivered to the actuating cylinder (7) via the electrical proportional valve (6). Depending on the current value, a proportional actuating pressure is established on the actuating cylinder (7) and therefore a stroke, which adjusts the swash plate angle and denes the ow delivery of the main pump (2). Depending on the speed of the pump and displacement, the pump ow determines the output speed of the TMM motor (9) as well as the input speed to the TMG gearbox (10). The selected drum speed of the controller keeps the drum speed constant. Independent of the engine speed or charging state. In order to meet the demand for a constant drum speed the actual value is measured via the speed sensor (14) in the TMG gearbox (10) and provided as an input signal to the TME controller unit (13). The electronic device compares the actual value with the preselected set point of the drum speed and controls the current to the electrical proportional valves (6) which sets the swashplate of the pump to the appropriate ow to keep the drum speed constant. The system presented completely meets the demand for a constant drum speed in accordance with the pre-selection on the rotary switch of the TME controller unit. The integrated charge pump (3) supplies the closed circuit via two multi-function valves (5) - feed and high-pressure protection - using cooled (14) and ltered (12) oil. The integrated ushing device (11) in the TMM motor, comprising an alternating slide and permanently set nozzle ushing valve, ensures a dened exchange of oil in the closed circuit. The oil led via the cooler (15) is feed in again via the charge pump (3) by means of a suction ltering system (12) connected upstream. At the time of rst commissioning rapid air separation from the working circuit is also achieved by the ushing device (11) and, in addition, it is ensured that unavoidable installation dirt is ushed out at the same time and can be picked up by the suction ltering system (12).

CIRCUIT DIAGRAM TM
TMP TME TMM TMG

13

6
M3 M5 M4

L1

M1 A

L1

M1
n

10

14

5 2 1 7
B M10 S L2 M2

3 4 5 8
B L2 M3 M2
P001 962

9 11

12

15

12

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Series TM Transit Mixer Drive System Service Manual Technical Specications Axial Piston Pumps TMP
GENERAL SPECIFICATIONS Specications for axial piston variable displacement pump are listed on these pages. For denitions of the various specications, see the related pages in this publication.
General Specifications
Pump type Direction of rotation Istallation position Other system requirements Axial piston pump with variable displacement swashplate axial piston design Clockwise or counter-clockwise Discretionary, the housing must always be filled with hydraulic fluid Circuit overpressure protection, suitable reservoir

SPECIFIC DATA

Specific Data
Dimension Displacement Maximum flow Maximum corner power Weight Mass moment of inertia of the internal rotation parts Type of mounting Pipe connections Shaft configuration Frame size 070 70 [4.27] 203 [54] 142 [190] 089 89 [5.43] 258 [68] 180 [242]

cm3 Vg [in3] l/min Qmax [US gal/min] kW p cornermax [hp] kg 61 m [lb] [134] 0.01777 k g m2 J [lbfft2] [0.42] Four (4) bolt flange, SAE flange configuration Main pressure ports: SAE flange Remaining ports: SAE straight thread O-ring boss 100 mm [3.94 in] joint flange (DIN/ISO) or Splined ANSI

TECHNICAL DATA

Case Pressure
Rated pressure Maximum pressure (cold start) bar 3 5 [psi] [44.0] [73.0] Frame size Minimum speed Rated speed Maximum speed

Speed Limits
min-1 (rpm) 070 500 2500 2900 089

Theoretical Torque
Frame size At. maximum displacement Nm/bar [lbfin/1000 psi] 070 1.11 [680] 089 1.42 [864]

System Pressure Range, Input

Maximum delta pressure bar 420 [psi] [6090]

ELECTRICAL PROPORTIONAL VALVES

General Data Protection class: Electrical connections: Supply pressure pPmax: Electrical Data Insulation material: Duty cycle:
Electrical Data
Voltage R20 in I1 in mA I2 in mA 12 V 5.35 % 60010 150010

DIN VDE 0470: IP65/IPX7 AMP Junior Power Timer 50 bar [725 psi]

Class H, 180 C [356 F] 100 %

24 V 21.25 % 30010 75010

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Series TM Transit Mixer Drive System Service Manual Technical Specications Axial Piston Pumps TMP
CIRCUIT DIAGRAM
CB Ports: A, B = Main pressure lines L1, L2 = Case pressure or drain ports M1,M2 = Gage port system pressure port A + B M3 = Gage port charge pressure M4,M5 = Gage port servo pressure M10 = Gage port charge pump inlet pressure S = Charge pump inlet CA, CB = Electrical proportional valve

CA

L1

M1 A

M3 M5 M4

M10

L2

M2
P001955E

DETERMINATION OF NOMINAL PUMP SIZES

Metric System Output ow: Vg n v Qe = _________ 1000 Vg p Me = __________ 20 mh Qe p Me n Pe = ______ = ______ 9550 600 t Qe 1000 v n = _____________ Vg l/min

Inch System Vg n v Qe = _________ 231 Vg p Me = _________ 2 mh Vg n p Pe = ___________ 396 000 t n Qe 231 v = ___________ Vg [US gal/min]

Input torque:

Nm

[lbfin]

Input power:

kW

[hp]

Input Speed:

min-1

min-1 (rpm)

Vg p v mh t pHD pND

= = = = = = =

Pump displacement per rev. pHD - pND Pump volumetric efciency Pump mechanical-hydraulic (Torque) efciency Pump overall efciency High pressure Low pressure

cm3 bar

[in3] [psid]

bar bar

[psid] [psid]

14

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Series TM Transit Mixer Drive System Service Manual Dimensions Axial Piston Pumps TMP
AXIAL PISTON PUMPS SIZE 070 AND 089
Connector CA AMP Junior Power Timer 15.0 +0.8 -0.3 [0.591+0.31] -0.12 49.0 [1.92] Case drain port L1 use highest port as outlet M22x1.5 11.0 min. [0.433] depth

106.0 [4.175] 12.0 [0.472] 17.0 [0.679]

Size and rotation direction are machinde beside the name plate; as example 7L for 70 cc, left hand.

54.8 [2.157] 12.4 [0.49]

Split flange boss DN 25 Typ I 40MPa series per ISO 6162 4 Thread: M12 21 [0.83] full thread depth

mm [in]

95.0 [3.73]

90.0 [3.56]

57.2 [2.25] 60.0 [2.362]

163.0 [6.44] 114.5 [4.508] 57.25 [2.25]

(CCW)

(CW)

126.9750.025 [5.0] 100.00.3 [3.940.01] 84.0 [3.31]

27.8 [1.09] 110.0 [4.33]

2.3 [0.091] 8.5 [0.335]

M42x2 20.0 [0.79] depth 57.0-0.019 [2.244-0.001] 8.0 [0.315]

Connector CB AMP Junior Power Timer

57.25 [2.25] 114.5 [4.51] 146.0 [5.75] 216.0 [8.50]

Case drain port L2 M22x1.5 11.0 min. [0.433] depth

149.0 [5.86] 254.0 [9.98] 262.0 [10.32] 304.0 [11.96] 313.0 [12.32]

P001 988E

Direction of Rotation
Port "A" Port "B" Clockwise Output (cw) Counterclockwise Input (ccw) Input Output NFPE valve CA CB

X
105.00 [4.13] 89.00 [3.50] Gage port M4 Servo pressure M12x1.5 High pressure relief valve port A Charge pressure relief valve Charge pump inlet S High pressure relief valve port B Gage port M3 Charge pressure M12x1.5 12.7 [0.5] min. depth Gage port M5 Servo pressure M12x1.5 P001 989E

Gage port M1 System pressure port "A" M12x1.5 12.7 [0.5] min. depth

Gage port M10 Charge pump inlet pressure M12x1.5 12.7 [0.5] min. depth

Gage port M2 System pressure port "B" M12x1.5 12.7 [0.5] min. depth

292.0 [11.5]

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Series TM Transit Mixer Drive System Service Manual Dimensions Axial Piston Pumps TMP
AXIAL PISTON PUMPS SIZE 070 AND 089 (continued)
Option Spline Shaft Size 070 Option Spline Shaft Size 089

mm [in]
56.00 [2.207] 33.00 [1.31] Full spline lenght 34.5 0 -0.17 [1.358 0 -0.007 ] 45.00 max [1.772] 33.00 [1.31] Full spline lenght 37.600.09 [1.480.004] 56.00 [2.207] 45.00 max [1.772]

80.00 max [3.15]

M10

80.00 max [3.15]

R6 [0.24]

R6 [0.24]

29.00 [1.13]

M10

Spline data Pitch dia

: 33.338 [1.313] Pressure angle : 30 Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970 class 5 fillet root side fit

Spline data Pitch dia 20.00 [0.792] 28.50 max [1.122] 51.00 [2.00] P001 990E

: 36.513 [1.438] Pressure angle : 30 Number of teeth : 23 Pitch : 16/32 ANSI B92.1-1970 class 5 fillet root side fit

20.00 [0.792] 28.50 max [1.122] 51.00 [2.00] P001 991E

Option Auxiliary Pad SAE A Size 070 and 089

331.00 [13.05] 317.00 [12.49] 10.50 [0.41]

15.00 [0.591] 1.20 [0.05]

Thread (2x) M10, 19.0 [0.748] deep

82.6 +0.13 0 [3.25 +0.005] 0

87.12 [3.43]

32.00 [1.26] 106.375 [4.188] P001 992E 106.375 [4.188]

for O-ring 1.78x82.3 [0.07x3.24] Spline data Pitch dia

: 14.288 [0.563] Pressure angle : 30 Number of teeth : 9 Pitch : 16/32 ANSI B92.1-1970 class 6 fillet root side fit Full spline lenght : 17.0 [0.669]

16

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Series TM Transit Mixer Drive System Service Manual Dimensions Axial Piston Pumps TMP
AXIAL PISTON PUMPS SIZE 070 AND 089 (continued)
Option Auxiliary Pad SAE B Size 070 and 089

mm [in]
334.00 [13.15] 15.00 [0.591] 10.50 [0.41] 1.20 [0.05]

317.00 [12.49]

Thread M12 (2x) deep min. [0.787]

101.65 +0.13 0 [4.002 +0.005] 0

106.80 [4.2]

for O-ring 1.78x101.35 [3.99 x 0.07] Spline data Pitch dia

: 20.6375 [0.8125] Pressure angle : 30 Number of teeth : 13 Pitch : 16/32 ANSI B92.1-1970 class 6 fillet root side fit Full spline lenght : 34.0 [1.330]

P001993E

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

146.00 [5.75]

17

Series TM Transit Mixer Drive System Service Manual Technical Specications Axial Piston Motors TMM
GENERAL SPECIFICATIONS Specications for axial piston xed displacement motors are listed on these pages.

General Specifications
Motor type Direction of rotation Istallation position Other system requirements Axial piston motor with fixed displacement swashplate axial piston design Clockwise or counter-clockwise (bi-directional) Discretionary, the housing must always be filled with hydraulic fluid Circuit overpressure protection, suitable reservoir

SPECIFIC DATA
Specific Data
Dimension Displacement Maximum flow Maximum corner power Weight Mass moment of inertia of the internal rotation parts Type of mounting Pipe connections Shaft configuration Frame size 070 70 [4.27] 203 [54] 142 [190] 089 89 [5.43] 258 [68] 180 [242]

cm3 Vg [in3] l/min Qmax [US gal/min] kW p cornermax [hp] kg 35 m [lb] [77] kgm2 0.01777 J [lbfft2] [0.42] Four (4) bold flange, SAE flange configuration Main pressure ports: SAE flange Remaining ports: SAE straight thread O-ring boss Splined ANSI

TECHNICAL DATA
Case Pressure
Rated pressure Maximum pressure (cold start) bar 3 5 [psi] [44.0] [73.0] Frame size Rated speed Maximum speed

Speed Limits
min-1 (rpm) 070 2500 2900 089

Theoretical Torque
Frame size At. maximum displacement Nm/bar [lbfin/1000 psi] 070 1.11 [680] 089 1.42 [864]

System Pressure Range, Input

Maximum delta pressure bar 420 [psi] [6090]

18

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Series TM Transit Mixer Drive System Service Manual Technical Specications Axial Piston Motors TMM
CIRCUIT DIAGRAM
A

L1

M1

Ports: A, B = Main pressure lines L1, L2 = Case pressure or drain ports M1,M2 = Gage port system pressure port A + B M3 = Gage port loop ushing pressure

B L2 M3 M2
P003 021

DETERMINATION OF NOMINAL MOTOR SIZES

Metric System Input ow: Vg n Qe = ________ 1000 v l/min

Inch System Vg n Qe = _______ 231 v Vg p mh Me = ___________ 2 [US gal/min]

Vg p mh Output torque: Me = ___________ 20

Nm

[lbf-in]

Me n Qe p t Output power: Pe = ______ = __________ kW 9550 600 Qe 1000 v Output Speed: n = _____________ Vg Vg p v mh t pHD pND = = = = = = = Motor displacement per rev. pHD - pND Motor volumetric efciency Motor mechanical-hydraulic (Torque) efciency Motor overall efciency High pressure Low pressure min-1

Vg n p t Pe = ____________ [hp] 396 000 n Qe 231 v = ___________ Vg min-1 (rpm)

cm3 bar

[in3] [psid]

bar bar

[psid] [psid]

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Series TM Transit Mixer Drive System Service Manual Dimensions Axial Piston Motors TMM
AXIAL PISTON MOTORS SIZE 070 AND 089
249.00 [9.803]

mm [in]
207.00 [8.150] 118.00 [4.650]

Size identification are machined here : 7 for 70 cc 9 for 89 cc

L2

Case drain port L2 use highest port as outlet M22x1.5 12.40 [0.490] 12.00 [0.470] 31.20 Full spline lenght [1.228] 15.00 +0.8 -0.3 [0.591 +0.031 -0.012] 127.00 -0.05 [4.999-0.002 ]

Orificed loop flushing valve

66.50 max. [2.618]

85.00 [3.346]

190.30 [7.492]

114.50 [4.508] P001 996E 27.80 [1.09]

95.00 [3.740]

L1
Case drain port L1 M22x1.5 72.00 [2.835] 122.00 [4.803] 218.00 [8.583] 251.00 [9.882] 46.30 max. [1.823] 55.00 [2.169] Spline data Pitch dia : 33.338 [1.313] Pressure angle : 30 Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 5 fillet root side fit

85.00 [3.346]

114.50 [4.508] 146.00 [5.748]

Direction of Rotation
Clockwise (cw) Counterclockwise (ccw) Port "A" Output Input Port "B" Input Output

Gage port M2 System pressure port B M12x1.5

Gage port M1 System pressure port A M12x1.5 Loop flushing shuttle spool

Split flange boss DN 25 Typ I 40MPa series per ISO 6162 4 Thread: M12 21 [0.83] full thread depth

41.60 [1.64]

Gage port M3 Loop flushing pressure

164.00 [6.460]

57.20 [2.250]

20

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

164.00 [6.457]

L (ccw)

R (cw)

Series TM Transit Mixer Drive System Service Manual Technical Specications Gearbox TMG
GENERAL SPECIFICATIONS
General Specifications
Gearbox Direction of rotation Purpose Options Others Size 51.2 and 61.2: Two-stage planetary Size 71.2 : Two-stage planetary with initial spur gear stage Clockwise and counterclockwise Drive the drum, carry the torque forces and a part of the drum weight With or without water pump drive Prepared to carry a water tank

SPECIFIC DATA
Specific Data
TMG 61.2 71.2 i 111.5 131.3 0.96 0.95 7 7 15 15 up to 7 m3 : max. 15 8 and 9 m3 : max. 12 Max. drum installation angle 10 m3 : max. 11 (adjusted through frame support) 12 m3 : max. 11 kg 253 325 333 Weight [lb] [558] [717] [735] l/min 12 16 16 Lubricant volume [US gal/min] [3.2] [4.2] [4.2] Lubricant type EP-Gear lubricant 1) API-class GL-5 FZG powerstage acc. to DIN 51 354 >12 Vicosity grade SAE 90 1) Attention: Gear lubricant w/o EP-Additives reduce the life by 80 %. 51.2 101.9 0.96 6 15 Gearbox type Gearbox size Gearbox ratio Gearbox efficiency Max. dynamic swivel angle of the drum flange Slope of the gearbox main shaft (design)

TECHNICAL DATA
Technical Data
Gearbox size Max. output torque Permissible weight of the full drum Permissible static radial load to the drum flange Permissible dynamic radial load to the drum flange (intermittent) Permissible static axial load to the drum flange Permissible dynamic axial load to the drum flange (intermittent) Output speed TM-performance Max. output speed w/o water pump drive Max. output speed with water pump drive Min./max. operating temperature Nm [lb-ft] t [lb] kN [lbf ] kN [lbf ] kN [lbf ] kN [lbf ] min-1 (rpm) min-1 (rpm) min-1 (rpm) C [F] 51.2 51 000 [37 600] 21.5 [47 410] 130 [29 224] 265 [59 572] 50 [11 240] 160 [35 968] 15 18 18 61.2 61 000 [45 000] 32 [70 563] 180 [40 464] 350 [78 680] 65 [14 612] 230 [51 704] 14 18 16 71.2 71 000 [52 350] 32 [70 563] 180 [40 464] 350 [78 680] 65 [14 612] 230 [51 704] 14 16 16

-20 [-4] up to +85 [+185]

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

21

Series TM Transit Mixer Drive System Service Manual Dimensions Gearbox TMG
GEARBOX SIZE 51.2
458.0 [18.03] 200.0 [7.87] 159.0 [6.260]
12 x 30

200.0 [7.87] Cover for speed sensor connection Oil dip stick and oil inlet

mm [in]

30

114.6 [4.51]

6x

60

60

M8 16.0 [0.63] deep

120.0 [4.72]

114.6 [4.51]

M12 20.0 [0.79] deep

20.0 max. [0.787]

70.0 [2.756] 200.0 [7.87] 200.0 [7.87]

Connection for waterpump i = 0.41 26.0 [1.02] 13.0 [0.51] 5.0 [0.20]

194.5 [7.66]

0 75.0 -5.0 0 ] [2.953-0.2

Lubrication oil outlet

Parallel key A 6x6x20 DIN6885 Cover for water-pump-connection

0 (h6) 18.0 -0.011

[0.7087

0 -0.0004 ]

(H8) 100.0 +0.054 0 [3.937 +0.0021 ] 0

198.0 [7.78 ] 110.0 [4.43 ]

Air breather

Securing device during transport Displayed position turned 62.5 17.0 [0.67] Variation of drum flange Dynamic swivel 41.0 angle max. [1.63 ]

15.0 [0.59 ]

21.0

R225.0 [8.86]

426.0 [16.77]

14.0 [0.55]

22.0 [0.87 ] 31.5 [1.24 ]

(H7) 127.0 +0.04 0

[5.00

50.0 [1.97 ]

Spline data Pitch dia

57.0 [2.24] 205.0 [8.06]

17.0 [0.67 ]

: 33.34 [1.313] Pressure angle : 30 Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 6 fillet root side fit

74.5 [2.93 ] 22.0 [0.87 ]

18.0 [0.71]
246.3 [9.70 ]

53.0 [2.09 ]

67.0 [2.64 ] 30.0 [1.18 188.0 ] [7.4]

10.5 [0.41] 55.0 [2.165]

400.0 [15.7 5]

40.0 [1.57 ]

15

454.0 [17.87]

P001 997E

22

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

500.0 0.2 [19.685 0.008]

0 [20.87 -0.0061 ]

+0.002 ] 0

R168 .0 [6.61 4]

40.0 [1.57 ]

105.0 [4.13]

0 (h9) 530.0 -0.155

O-ring 124x4 [4.88x0.16] NBR 70

[0.84

+0.1 0 2]

10.0 [0.39 ]

+3.0 0

Series TM Transit Mixer Drive System Service Manual Dimensions Gearbox TMG
GEARBOX SIZE 61.2
200.0 [7.87] 147.5 [5.81] 458.0 [18.03] 200.0 [7.87] 24x 15 15 81.5 [3.209]

mm [in]
Cover for speed sensor connection Oil dip stick and oil inlet

7.5

114.6 [4.51]

6x

60

60
120.0 [4.72] M8 16.0 [0.63] deep

114.6 [4.51]

M12 20.0 [0.79] deep Connection for waterpump i = 0.41 26.0 [1.02] 13.0 [0.51] 5.0 [0.2]

200.0 [7.87]

200.0 [7.87]

20.0 max. [0.787]

70.0 [2.76]

215.0 [8.5]

0 75.0 -5.0 0 ] [2.953-0.2

Lubrication oil outlet

Parallel key A 6x6x20 DIN6885 Cover for water-pump-connection

0 (h6) 18.0 -0.011

[0.7087

0 -0.0004 ]

(H8) 100.0 +0.054 0 [3.937 +0.0021 ] 0

Air breather

R245.0 [9.65]

241.0 [9.488]

465.0 [18.31]

17.3 [0.68 ]

14.0 [0.55]

130'
Variation of drum flange Dynamic swivel angle max. 419.0 [16.5]

192.0 [7.57 7] 110.0 [4.33 ] 35.0 [1.37 9] 6.0 [0.23 6]

Securing device during transport Displayed position turned 62.5 17.00.2 [0.670.01]

O-ring 124x4 [4.88x0.16] NBR 70 (H7) 127.0 +0.04 0

22.0 [0.87 ] 40.0 [1.57 ]

12.0 [0.48 4]

500.0 0.2 [19.685 0.008]

[5.00 +0.002 ] 0

Spline data Pitch dia

17.0 [0.67 ]

: 33.34 [1.313] Pressure angle : 30 Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 6 fillet root side fit

57.0 [2.24] 252.0 [9.92]

50.0 [1.97 ]

94.0 [3.68 9] 22.0 [0.87 ]

53.0 [2.09 ]

505.0 [19.88]

67.0 [2.64 ] 32.6 [1.28 ] 190.0 [7.48 ]

18.0 [0.71] 66.0 [2.6] P001 998E

241.7 [9.51 6]

400.0 [15.7 5]

40.0 [1.57 ]

18.5 [0.73]

0 [20.87 -0.0061 ]

129.0 [5.08]

0 (h9) 530.0 -0.155

15

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

23

Series TM Transit Mixer Drive System Service Manual Dimensions Gearbox TMG
GEARBOX SIZE 71.2
200.0 [7.87] 154.0 [6.063] 458.0 [18.03] 200.0 [7.87] 24x1 5 15

mm [in]
Cover for speed sensor connection Oil dip stick and oil inlet

7.5

114.6 [4.51]

6x

60 60

M8 16.0 [0.63] deep M12 20.0 [0.79] deep Connection for waterpump i=0.41 26.0 [1.02] 13.0 [0.51] 5.0 [0.2]

120.0 [4.72]

114.6 [4.51]

20.0 max. [0.787]

200.0 [7.87] 215.0 [8.5]

123.5 [4.86] 200.0 [7.87]

70.0 [2.76]

215.0 [8.5] Lubrication oil outlet

0 75.0 -5.0 0 ] [2.953-0.2

Parallel key A 6x6x20 DIN6885 Cover for water-pump connection

0 (h6) 18.0 -0.011

[0.7087 100.0

0 -0.0004 ] +0.054 0

(H8)

[3.937 +0.0021 ] 0 17.00.2 [0.670.01]

1.5

Air breather

192.0 [7.57 7] 110.0 [4.33 ] 6.0 [0.23 6]

Securing device during transport Displayed position turned 61.5

R245.0 [9.65] 241.0 [9.488]

465.0 [18.31]

14.0 [0.55]
17.3 [0.68 ] 22.0 [0.87 ]

35.0 [1.37 9] 12.0 [0.48 4]

O-ring 124x4 [4.88x0.16] NBR 70 (H7) 127.0 +0.04 0

Variation of drum flange Dynamic swivel angle max. 419.0 [16.5] 129.0 [5.08]

40.0 [1.57 ]

0 (h9) 530.0 -0.155

[5.00 +0.002 ] 0

500.0 0.2 [19.685 0.008]

17.0 [0.67 ]

: 33.34 [1.313] Pressure angle : 30 Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 6 fillet root side fit

50.0 [1.97 ]

18.5 [0.73]
53.0 [2.09 ] 67.0 [2.64 ] 32.6 [1.28 ]

57.0 [2.24] 252.0 [9.92]

190.0 [7.48 ]

18.0 [0.71] 66.0 [2.6] P001 999E

505.0 [19.88]

24

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

241.7 [9.51 6]

400.0 [15.7 5]

Spline data Pitch dia

40.0 [1.57 ]

94.0 [3.68 9] 22.0 [0.87 ]

0 [20.87 -0.0061 ]

15

Series TM Transit Mixer Drive System Service Manual Notes

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

25

Series TM Transit Mixer Drive System Service Manual Installation Instructions

GENERAL Prior to the system installation please inspects the units for damage occuring during shipping and handling. Remove plugs and covers just before you start to assemble ttings and hoses. Make sure that all the other system components (reservoir, ttings, hoses, heat exchanger) are cleaned.

MOUNTING THE MOTOR

Remove the plastic protective cover on the motor side of the gearbox drive in a sealing of the motor with an O-ring. Case has to be taken that there is no axial load on the pinion with the motor mounting into the gearbox. Fasteners for the motor: 4 bolts M12, grade 8.8, tighten to a torque of 80 Nm [708 lbfin] Hardened washers (acc. to DIN 6916) are necessary under the bolt heads.

F000 874

F000 861

MOUNTING THE SPEED SENSOR New self-sealing screw must be use to x the speed sensor. Tightening torque: 8 2 Nm [71 18 lbfin] MOUNTING THE PUMP

Remove the screw holding the sealed sensor cover plate. Remove the cover plate. Assemble the new O-ring on speed sensor and position into place.

If the pump is driven from the rear of the engine via a joint shaft, case has to be taken that the pump and engine power take off is correctly aligned. This means the joint shaft is exactly in conguration Z or W. A misalignment will reduce the life of both the pump bearings and joint shaft. The pump support must have a solid structure to prevent any unnecessary noise. Fasteners for the pump: 4 bolts M12, grade 8.8, tighten to a torque of 80 Nm [708 lbfin]. Hardened washers (acc. to DIN 6916) are necessary under the bolt heads (and the nuts if through bolts are used).

26

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive System Service Manual Installation Instructions

MOUNTING THE GEARBOX Gearbox mounting must be on a solid, distortion free, and at support face. Min. tensile strength of material: 400 N/mm [57 200 psi] Mounting surface roughness average peak-to-valley height: Ra = 3,2 m in acc. to DIN 4768, part1 Allowable atness over the whole mounting area is 0.15 mm [0.006 in]. Fasten the gear box foot with 3 bolts M20 (on each side); min. grade10.9; tightening torque 540 Nm [4780 lbfin] Hardened washers are necessary under the bolt heads (and the nuts if through bolts are used). Mounting plate stops are required to absorb the axial load of the drum when the truck decelerates, so that the bolt force is relieved. Stops should be welded in front of the foot, shown here for a rear discharge truck. Front discharge trucks must have the welded stops on the opposite side.
WASHER IN ACC. TO DIN 6916-21

GEARBOX FOOT MIXER FRAME

0.15 A 3.2

10+5x70 (Stops)

STOPS (REAR DISCHARGE)

P001 497E

MOUNTING THE WATER TANK

A water tank with max. 1500 l [396 US gal] volume can be attached to the upper part of the housing. Fasten the water tank with 2 bolts M20 on each side; min. grade 8.8; tightening torque 540 Nm [4780 lbfin] Hardened washers are necessary under the bolt heads and the nuts:
mm [in]
410.0 [16.14]

WATER TANK

500.0 max. [19.7]

0,3 P001 498E

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

27

Series TM Transit Mixer Drive System Service Manual Installation Instructions

MOUNTING THE DRUM FLANGE Unit will be shipped with the ange locked in the zero degree position. This is to protect the main bearing and the ange seal from damage. Tolerances of the drum t are showed below.
mm [in]

The bolt must not be removed until adjusting the drum

6.3 530.1+0.6 Drum flange dia [20.87+0.024]

1.5 max. x 45 [0.6] DRUM FLANGE 6.3

GEARBOX OUTPUT FLANGE Drum flange A P001 499E

The total run-out tolerance of max. 1 mm [0.04 in] for the drum rotation axis is strictly required. Fastening the drum to the ange TMG 51.2 with 12 bolts TMG 61.2 / 71.2 with 24 bolts M16; min. grade 8.8; tightening torque 195 Nm [1726 lbfin] The exact alignment of gearbox and drum is required. Both must be in line with a gap tolerance TMG 51.2 : 10.5 0.5 mm [0.41 0.02 in] TMG 61.2 / 71.2 : 18.5 0.5 mm [0.73 0.02 in] between the drum ange and gearbox housing for the whole circumference; see below
TMG 51.2 TMG 61.2 / 71.2

The exact alignment of gearbox and drum is required for proper component life.

140.0 max. Drum flange dia [5.51]

10.5 [0.41]

P003 002

18.5 [0.73]

P003 003

If there is misalign of drum and gearbox or a wide total run-out tolerance, the main bearing and the ange sealing will have reduced life.
28
DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive System Service Manual Installation Instructions

MOUNTING CONTROLLER TME Machine wiring, see guidelines below: The wiring must be done according to the connection diagram. All wires must be protected from mechanical abuse. Wires can be run in exible metal or plastic conduits. Use 85 C [185 F] wire with abrasive resistant insulation. 105 C [221F] wire should be considered near hot surfaces The minimum wire gage should be 1 mm [0.002 in2] Separate high current wires - >0,3 A - such as solenoids, lights, alternator or fuel pumps from control wires. Run wires along the inside of, or close to, metal machine frame surface, where possible. This simulates a shield, which will help minimize the effects of EMI/RFI radiation. Do not run the wires near sharp metal corners. Consider running the wire through a grommet when rounding corners. Avoid running wires near moving or vibrating components. An experienced person should carry out the installation of CB-radios and mobile phones. Special attention should be paid to the routing of the wires and the position of the antenna. In any case, the wiring should be separated from other wiring. TME controllers from Sauer-Danfoss are insensitive to electromagnetic elds up to a level of 100V/m. Should there be a problem, the radiation interference is probably too high. Possible reasons could be the antenna position, reection or interference through the wiring. The electronics should be mounted in a way that the wiring is facing down. Unused cavities in connectors must be lled with cavity plugs.

Recommended tools for assembling wires to pins are available and help insure that the connections are mounted in the correct way. See below Crimp Tool for Power Timer - AMP/16-pin: Die Set for 509 575: Id. No. 509 575 Id. No. 509 576

If you push in the pin into a wrong connector position you can remove the mechanical locked pin with the following tool: Contact Extraction Tool for Power timer: Id. No. 517 024

The tools below are also available to assemble wire-pins for the proportional valve connectors: Crimp Tool for Micro Timer - AMP/2-pin: Die Set for 515 895: Contact Extraction Tool for Micro Timer: Id. No. 515 895 Id. No. 515 896 Id. No. 517 023

The wiring diagram is on the next page.

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

29

Series TM Transit Mixer Drive System Service Manual Installation Instructions

WIRING DIAGRAM TME
F 4A + External stop switch Batt. 12/24VDC -

Remote Station
Battery (+) Battery (-) VCC Voltage (+) Setpoint from Cabin 12V Valve (-) 24V Valve (-) Remote/ON Memoblink PPU (-) VCC/2 PPU signal GND 1 2 3 4 5 6 7 8 9 10 11 12 Option: Safety function can be invalidate by connecting. (+) PPU (2-wire) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Proportional valve 0 CHARGE 15 16

Cabin Station

VCC Voltage (+) Setpoint to Remote

Remote/ON Memoblink

VCC/2

GND

Disable lost of feedback 13 Ext. Stop Valve 0 (+) Valve 1 (+) 14 15 16

AMP connector, 16-pin

AMP connector, 16-pin Proportional valve 1 DISCHARGE

P003 022E

INSTALLATION SPACE TME

In order to accommodate the TME in the customer-specic housing, it is necessary to produce a cutout as illustrated below. Tightening torque max. 1 Nm [0.7 lbfft].
mm [in] min. 50 [1.97]

72.4 0.3 [2.85 0.01]

max. 5 [0.20] min. 1 [0.04]

R3 0.1 [0.12 0.004] P001 937E P001 938

30

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

93.4 0.3 [3.68 0.01]

Series TM Transit Mixer Drive System Service Manual Hydraulic Fluid

FLUID SPECIFICATION
Temperature Range1)
C [F] Minimum -40 [-40] intermittent, cold start Rated 104 [220] Maximum 115 [240] intermittent 1) At the hottest point, normally the motor case drain port. Minimum Recommended operating range Maximum

Viscosity
mm2/s 7 12-80 1600 [SUS] [49] [70-370] [7500] intermittent cold start intermittent

Cleanliness Level and x-Ratio

Required fluid cleanliness level Recommended x-ratio for suction filtration ISO 4406 Class 18/13 35-45=75 (102)

HYDRAULIC FLUID

Please see Sauer-Danfoss literature

520L0463

Also refer to Sauer-Danfoss literature 520L0465

(Hydraulic Fluids and Lubricants, Technical Information). (Experience with Bio Fluids, Technical Information).

CLEANLINESS

Please see Sauer-Danfoss literature

520L0467 (Design Guideline for Hydraulic Fluid Cleanliness, Technical Information).

SUCTION FILTRATION

The proper suction lter should be placed in the circuit between the reservoir and the inlet to the pump.
MANOVACUUMMETER

Improper lter selection can cause charge pump cavitation.

HYDRAULIC FLUID RESERVOIR FILTER

CHARGE PUMP

TO LOW PRESSURE SIDE AND CONTROL

ADJUSTABLE CHARGE PRESSURE RELIEF VALVE TO PUMP CASE

P000 797E

Recommended -ratio can be found on cleanliness level table.

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

31

Series TM Transit Mixer Drive System Service Manual Pressure Measurement

REQUIRED TOOLS The service procedures described in this manual for Series TM pumps and motors can be performed using common mechanics tools.

PORT LOCATION PUMP

The following is a list of the ports for each type of hydraulic unit. The recommended pressure gage and tting are also specied.
Port Location Pump
Port M1 M2 M3 M4+M5 M10 L1+L2 S Function System pressure port "A" System pressure port "B" Charge pressure Actuating piston pressure Vacuum charge pump Case pressure or drain ports Charge pump inlet Gage size 600 bar [10 000 psi] 600 bar [10 000 psi] 60 bar [1000 psi] 60 bar [1000 psi] 10 bar [100 psi] Fitting M12x1.5 O-ring boss M12x1.5 O-ring boss M12x1.5 O-ring boss M12x1.5 O-ring boss M12x1.5 O-ring boss M22x1.5 O-ring boss M42x2 O-ring boss X M1

L1

M4 A

S X M10

M2 M5

M3
P003 004

L2

PORT LOCATION MOTOR

Port Location Motor
Port M1 M2 M3 L1+L2 Function System pressure port "A" System pressure port "B" Loop flushing pressure Case pressure or drain ports L2 Gage size 600 bar [10 000 psi] 600 bar [10 000 psi] 60 bar [1000 psi] 10 bar [100 psi] M2 Fitting M12x1.5 O-ring boss M12x1.5 O-ring boss M12x1.5 O-ring boss M22x1.5 O-ring boss X M1

X M3

P003 007

L1

32

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive System Service Manual Notes

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

33

Series TM Transit Mixer Drive System Service Manual Start-Up Procedure

GENERAL

Pump, motor and gearbox are shipped without oil! GEARBOX Before start-up ll with EP-Gear lubricant SAE 90, API-Classication GL 5, FZG power stage > 12 acc. DIN 51 354 (see table gear box Specic Data). Fill the lubricant up to the mark of the oil dipstick and check oil level regularly.

Level measurement by screwed in dipstick. HYDROSTATICS Before start-up ll the system in following way with oil acc. to Sauer-Danfoss literature 520L0463. After installing the transmission and corresponding pipeline connections, remove the plug from the gage pressure port M3 of the variable displacement pump. Fit a gage with a measuring range up to 60 bar [1000 psi] at this port. Disconnect the charge pump inlet line from the charge pump inlet connection pipe. Fill the pump and motor housing by pouring ltered oil into the upper case drain port. Fill the reservoir with recommended hydraulic uid. As soon as oil emerges from the end of the disconnected charge pump inlet line tighten the pipe connection and continue to ll the reservoir. Remove both connectors on the proportional valves of the variable displacement pump. Allow the engine to turn app. 15 seconds by using the starter. Then start the engine and allow the pump to turn at idle speed [app. 650-700 min-1 (rpm)]. After initial uctuations in pressure the charge pressure should be settle down to 191 bar [27514.5 psi]. Check the oil level in the sight glass. Rell, if necessary. Raise the speed to normal operating speed. The gage should now indicate the pressure setting of the charge pressure relief valve. If charge pressure is not maintained at the proper setting, stop the engine and nd the fault in accordance with the troubleshooting guide. Stop the engine and t the connectors to the proportional valves of the variable displacement pump. Restart the engine, check the pump should remain in the neutral position (no drum rotation). With engine at normal operating speed, app. 1500-1600 min-1 (rpm), select the lowest position of on the TME rotary switch for the drum rotation direction for charge and discharge. If the drum turns in the wrong direction, stop the engine. Remove the connectors for the proportional valves on the variable displacement pump. Switch and connect again. Restart the engine and check the rotation direction of the drum once more. If okay, turn the drum slowly in both directions for 5 minutes. Check all joints and connections for leaks. Check CSD-function with the pre-selected Transport Mode on the controller while varying the engine output speed. Under these circumstances, the drum speed should

The pump must be in zero position.

Check and make sure that the rotary switch on the controller - Remote and Cabin - are in neutral position

34

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive System Service Manual Start-Up Procedure

HYDROSTATICS (continued) be constant at 2 min-1 (rpm). Check the functions for TME controllers at a engine speed approximately 1500-1600 min-1 (rpm) (direction/speed/stop-start on the remote/switch over from the cabin to remote). Warm up the system and check again for leaks. Stop the engine. Remove the gage from the connection port M3. Replace the plug and tighten with the proper torque. Check oil level in the sight glass of the reservoir and ll to the proper level, if necessary.

Tighten up any leaking joints and other connections while system is not under pressure.

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

35

Series TM Transit Mixer Drive System Service Manual Maintenance

GEARBOX TMG First oil change should be after 100 hours, then after every 1000 hours, but at least once a year. Use only recommended gear lubricants; see Sauer-Danfoss literature 520L463 (Hydraulic Fluids and Lubricants, Technical Information). The level of the oil should be checked daily. In case of loss of oil, the leak should be rectied and rell oil, if necessary. Periodically clean the gear housing and inspect for loosened screws and bolts.

When cleaning with a high pressure water jet do not direct the jet onto the ange shaft seal, because this may lift the seal lip and force contamination underneath the seal lip, resulting in premature wear and damage of the lip seal. SAFETY

Gearboxes Series TMG 51.2, 61.2 and 71.2 are designed and manufactured for safe operation and the highest level of technology. However, there are certain dangers inherent if they are improperly operated or if they are used for other purposes than they were intended, for example, by unskilled personnel. This may result in dangers for life and limb dangers for machines and other company assests adverse effects on the efciency of the operation Any person involved in the start up, maintenance, and inspection of the gearbox TMG or the hydrostatic transmission, must read and understand the appropriate Service Manual. Sauer-Danfoss offers training programs.

HYDROSTATIC TMP AND TMM

The lter must be also changed if the inlet vacuum pressure is less than 0.7 bar absolute [-9 in. Hg] with oil operating temperatures higher than 50 C [122 F]. A continuous inlet pressure of less than 0.5 bar absolute [-15 in. Hg] is not permissible. The lter may require changing, or the oil temperature is to low, or the viscosity of the oil is too high (too thick oil). The oil should be changed after maximum 100 hours of operation. The second oil change should be after 500 hours. Thereafter, every 1000 hours or at least once a year. It is not permissible to mix oils of different brands. Change oil lters when changing the oil. Carry out a leak test on transmission (inlet line, lter, pipe- and hose lines, valves, pump and motor) giving due consideration to service life, environmental protection and reduction of oil consumption. Check the reservoir for proper oil level via the sight glass and rell, if necessary.

Tighten up any leaking joints and other connections while system is not under pressure. Replace defective seals.

36

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive System Service Manual Maintenance

HYDROSTATIC TMP AND TMM (continued) Check hydraulic hoses periodical and change when there is any damage or ageing (see manufacturers instruction). Replacement hoses should be in accordance to specications. When reassembling do not exchange connection ports of pipes and hoses. When exchanging system pressure ports, the direction of drum rotation will be changed.

Without this safety precautions there could be danger for body and life e. g. danger for machines and property.

Make certain that the oil lter for ventilation of the oil reservoir is regularly cleaned, since the input pressure may be affected if it is dirty. The cooler surface should be kept free from contamination. Cotton rags or lint cleaning cloths must not be used for cleaning. Use lint-free materials only. When changing the oil, be sure the area around the cap is free from foreign objects. The level of the oil should be checked daily using the gage glass. In case of loss oil, the leak must be rectied and relled, if necessary.

Use only recommended uids acc. Sauer-Danfoss literature 520L0463. It is not permissible to mix oil of different brands.

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Series TM Transit Mixer Drive System Service Manual Troubleshooting

DRUM SPEED DOESN T REACHED MAXIMUM SPEED Check Pump input speed. Description Engine speed to low. Action Select required engine speed.

Charge pump pressure in neutral Values: 21.51bar [31214.5 psi // 1500 rev/min // suction line temperature 503 C [12237 F // Gage Port M3.

Incorrect setting on the charge pressure relief valve.

Stop the engine. Install gage in port M3 Start the engine and measure the pressure in neutral. If the pressure is low, turn the screw clockwise to the correct value. If not, please check and change the relief valve.

Proportional Valve Value: 20 bar [290 psi] at maximum current.

Control pressure to low.

Stop the engine. Disconnect the speed sensor, install gage port in M4 (M5) Start the engine. Select maximum position on the TME rotary switch. If the control pressure is less than 20 1 bar [29014.5 psi], change the proportional valve.

Charge pump inlet vacuum Values: > 0,7 bar [10 psi] // 1500 rev/min // suction line temperature 50 3 C [12237 F // Gage Port M10.

Dirty lter will increase the inlet vacuum.

Check inlet pressure. If too high, change the lter.

SYSTEM OPERATING HOT

Oil cooler.

Dirty oil cooler will be inuence cooling capability.

Clean the cooler.

Electrical fan drive.

Temperature switch failed.

Change temperature switch.

Change electrical motor. Electrical fan drive. Electrical motor failed.

Action
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Series TM Transit Mixer Drive System Service Manual Troubleshooting

DRUM SPEED DROOPS DOWN DEPENDING ON INCREASED LOAD Check Charge pump pressure in neutral Values: 21.51bar [31214.5 psi // 1500 rev/min // suction line temperature 503 C [12237 F // Gage Port M3. Description Change the transmission, Drum speed will be go pump and motor. slower if the load increases and charge pressure droops too low.

DRUM ROTATING IN ONE DIRECTION ONLY

Loop ushing shuttle spool.

Pre-selected direction and speed but the drum doesn t turn.

Check loop ushing shuttle spool which maybe sticking in one direction Check the springs of the shuttle spool, too.

Make cross-check with both Pump displacement control. Electrical proportional valve controller (Remote/Cabin). is operating improperly. If the problem changed, replace the failed controller. If not, use the Emergency Tool Kit1) to discharge the drum and later, change the proportional valve.

Multifunction valve.

Interchanging the valve to see and how the failure is related to the valve function.

If the problem changes direction, replace the valve.

DRUM DOESN T STOP IF THE ROTARY SWITCH TURNED TO NEUTRAL

Stop the engine immediately!

Proportional valve is sticking from contamination.

Using the Emergeny Tool Kit1) for discharging and later on, replace the proportional valve.

REMOTE STATION IN STAND BY; SIGNALLED BY FLASHING LED

Set the rotary switch to neutral; touch the yellow switch; conrmed by lights up LED.

Light on signalls active status. If not, this means continuously ashing and the switch operating improperly. Description

Replace the Remote Station.

Action

1)

Or valve manual override on units with this options.

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Series TM Transit Mixer Drive System Service Manual Troubleshooting

CABIN STATION ACTIVE; SIGNALLED BY LIGHTS UP LED Check Set the rotary switch to neutral; touch the yellow switch; conrmed by off LED. Means, function transfer to LED still on, the switch is operating improperly.

If not, the required supply DRUM STOPPED DURING OPERATION Active controller signalled through lighted LED. voltage is not present. LED indicats active status.

Check the fuse in the supply wire. If destroyed, replace the fuse and check the reason for the short circuit. Disconnect the speed

HOW TO REPLACE THE TME-CONTROLLER

RED FIXTURE

SCREW DRIVER

P001 938

F000 873

Open the control panel in order to get access to back of TME -Controller. Disconnect AMP wire connector from the TME controller (use screw driver to unlock red xture). Remove the (4) screws. (Use Allen-Key Torx T9 or 2 mm metric). Remove the (2) clamp-caps. Remove the TME-controller and install the new one in the reverse method. Remark: Torque screws to max. 1 Nm.

Active controller signalled through lighted LED.

sensor connector and operate once more. If the system works now - but in open loop control- change the speed sensor. After change check the correct function again.

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DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive System Service Manual Emergency Discharging

EMERGENCY DISCHARGING
Rear Cover Actuating cylinder A

STOP the truck engine at rst!

Main pressure port A

Main pressure port B Actuating cylinder B

F000 876 F300 684

Remove plug M12x1.5 from the actuating cylinder B 1)

F000 875

F300 689 P001 963 TMP, right hand rotation

TMM, main ports show downwards 1)

F300 685

Install screw M12x1.5 with seal lock nut into the actuating cylinder until (appr. 80mm [3.15 in]) you feel noticeable resistance, (when the screw comes in contact with actuating piston).

IMPORTANT: The special tool is an essential part of the truck mixer emergency tool kit.

F300 690

F300 686

Start truck engine (low idle is recommanded for slow discharge). Turn screw clockwise against actuating piston so the pump displacement increases and the drum turns in discharge direction at desired speed. Tighten lock nut to prevent external leakage during operation.
F300 687
1)

This description concerns to our recommended standard installation. If drums turns with the tool on servo cylinder B in wrong direction, change the tool to servo cylinder A.

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Series TM Transit Mixer Drive System Service Manual Notes

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Series TM Transit Mixer Drive System Service Manual Notes

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Sauer-Danfoss Hydraulic Power Systems Market Leaders Worldwide Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market. Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others. We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them. Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design. Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Sauer-Danfoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239-6000, Fax: +1 515 239 6618 Sauer-Danfoss (Neumnster) GmbH & Co. OHG Postfach 2460, D-24531 Neumnster Krokamp 35, D-24539 Neumnster, Germany Phone: +49 4321 871-0, Fax: +49 4321 871 122 Sauer-Danfoss ApS DK-6430 Nordborg, Denmark Phone: +45 7488 4444, Fax: +45 7488 4400

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

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