Danfoss TMM 070, TMM 084, TMM 089 Service guide

MAKING MODERN LIVING POSSIBLE

Service Manual

Transit Mixer Axial Piston Motor

Size 070/084/089

powersolutions.danfoss.com

Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Revision history Table of revisions

Date Changed Rev

Apr 2014 Converted to Danfoss layout – DITA CMS AC

10 Aug. 2012 New TMM image AB

15 Feb. 2012 First edition AA

2 L1211037 • Rev AC • Apr 2014

Service Manual

Reference literature Introduction

Operation

Operating parameters

Technical Specifications

Fluid and Filter Maintenance

Initial Start-up

Troubleshooting

Adjustments

TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Overview..............................................................................................................................................................................................6

Warranty.............................................................................................................................................................................................. 6

Symbols used in Danfoss literature............................................................................................................................................6

General instructions........................................................................................................................................................................ 6

Remove the unit.......................................................................................................................................................................... 6

Keep it clean..................................................................................................................................................................................7

Replace all O-rings and gaskets............................................................................................................................................. 7

Secure the unit.............................................................................................................................................................................7

Safety precautions............................................................................................................................................................................7

Unintended machine movement..........................................................................................................................................7

Flammable cleaning solvents.................................................................................................................................................7

Fluid under pressure..................................................................................................................................................................7

Personal safety............................................................................................................................................................................. 8

Hazardous material.................................................................................................................................................................... 8

Design...................................................................................................................................................................................................8

The System Circuit............................................................................................................................................................................8

The Basic Closed Circuit............................................................................................................................................................8

Case drain and heat exchanger..............................................................................................................................................9

High pressure relief valve (HPRV) and check valve............................................................................................................10

Loop flushing shuttle spool........................................................................................................................................................10

Loop flushing relief valve............................................................................................................................................................11

Anti-cavitation valve.....................................................................................................................................................................11

Overview........................................................................................................................................................................................... 12

Output speed...................................................................................................................................................................................12

System pressure............................................................................................................................................................................. 12

Case pressure...................................................................................................................................................................................12

Temperature and Viscosity.........................................................................................................................................................13

Temperature...............................................................................................................................................................................13

Viscosity........................................................................................................................................................................................13

Technical specification.................................................................................................................................................................14

Fluid and filter recommendations........................................................................................................................................... 16

Port Locations and Gauge Installation...................................................................................................................................16

Start-up procedure........................................................................................................................................................................18

Overview........................................................................................................................................................................................... 19

Safety Precautions......................................................................................................................................................................... 19

System operating hot...................................................................................................................................................................19

System will not operate in either direction.......................................................................................................................... 20

System noise or vibration........................................................................................................................................................... 20

Sluggish system response...........................................................................................................................................................20

Transmission operates normally in one direction only....................................................................................................20

Low motor output torque...........................................................................................................................................................21

Improper motor output speed..................................................................................................................................................21

Standard procedures....................................................................................................................................................................22

Speed sensor PPU adjustment..................................................................................................................................................22

L1211037 • Rev AC • Apr 2014 3

Service Manual

Contents

Minor Repair

Torque Chart

TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Standard procedures, removing the motor......................................................................................................................... 23

Disassembly................................................................................................................................................................................23

Inspection....................................................................................................................................................................................23

Reassembly................................................................................................................................................................................. 23

Shaft Seal Replacement...............................................................................................................................................................24

Removal........................................................................................................................................................................................24

Inspection....................................................................................................................................................................................24

Reassembly................................................................................................................................................................................. 24

High Pressure Relief Valves (HPRV)..........................................................................................................................................24

Removal........................................................................................................................................................................................24

Inspection....................................................................................................................................................................................24

Reassembly................................................................................................................................................................................. 25

Loop Flushing Relief Valve..........................................................................................................................................................25

Removal........................................................................................................................................................................................25

Inspection....................................................................................................................................................................................25

Reassembly................................................................................................................................................................................. 25

Loop Flushing Valve......................................................................................................................................................................26

Removal........................................................................................................................................................................................26

Inspection....................................................................................................................................................................................26

Reassembly................................................................................................................................................................................. 26

Anticavitation Valve......................................................................................................................................................................26

Removal........................................................................................................................................................................................26

Inspection....................................................................................................................................................................................26

Reassembly................................................................................................................................................................................. 27

Speed Sensor PPU..........................................................................................................................................................................27

Removal........................................................................................................................................................................................27

Inspection....................................................................................................................................................................................27

Reassembly................................................................................................................................................................................. 27

Speed and Temperature Sensor (H1)......................................................................................................................................28

Removal........................................................................................................................................................................................28

Inspection....................................................................................................................................................................................28

Reassembly................................................................................................................................................................................. 28

Fasteners, plugs and torques.....................................................................................................................................................29

4 L1211037 • Rev AC • Apr 2014

Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Reference literature

Further available literature

Description Order number

Series TM Transit Mixer Axial Piston Motor, Size 070/084/089; Technical Information L1108123 Speed and Temperature Sensor; Technical Information 11046759 Hydraulic Fluids and Lubricants, Technical Information 520L0463 Design Guideline for Hydraulic Fluid Cleanliness, Technical Information 520L0467 Experience with Biodegradable Hydraulic Fluids, Technical Information 520L0465

L1211037 • Rev AC • Apr 2014 5

Service Manual

TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Introduction

Overview

This manual includes information on the installation, maintenance, and minor repair of TM Motors. It includes a description of the unit and its individual components, troubleshooting information, and minor repair procedures.

Performing minor repairs requires the unit to be removed from the vehicle/machine. Thoroughly clean the unit before beginning maintenance or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system filter and when removing hoses or plumbing.

A worldwide network of Danfoss Authorized Service Centers is available for major repairs. Danfoss trains and certifies Authorized Service Centers on a regular basis. You can locate your nearest Authorized Service Center using the distributor locator at www.danfoss.com.

Warranty

Performing adjustments and minor repairs according to the procedures in this manual will not affect your warranty. Major repairs requiring the removal of a unit’s center section, or front flange voids the warranty unless a Danfoss Authorized Service Center performs them.

Symbols used in Danfoss literature

Service symbols used in Danfoss literature

Symbol description

General instructions

WARNING may result in injury

CAUTION may result in damage to product or property

Non-reusable part, use a new part

External hex head

Internal hex head

Lubricate with hydraulic fluid

Pressure measurement/gauge location or specification

Clean area or part

Be careful not to scratch or damage

Note correct orientation

Torque specification

Pull out with tool – press fit

Cover splines with installation sleeve

Inspect for wear or damage

The symbols in the table above are in the illustrations and text of this manual. They communicate helpful information at the point where it is most useful to the reader.

Follow the general procedures below when repairing TMM constant displacement closed circuit motors:

Remove the unit

Prior to performing major repairs, remove the unit from the vehicle/machine. Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the pump and fittings for damage. Cap hoses and plug ports after removal to prevent contamination.

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Service Manual

Introduction

Safety precautions

TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Keep it clean

Cleanliness is a primary means of assuring satisfactory motor life on both new and repaired units. Clean the outside of the motor thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, you must keep all parts free of foreign material and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. If left unattended, cover the pump with a protective layer of plastic.

Replace all O-rings and gaskets

We recommend you replace all O-rings and seals during service. Lightly lubricate O-rings with clean petroleum jelly prior to assembly.

Secure the unit

For repair, place the unit in a stable position with the shaft pointing downward. It will be necessary to secure the motor while removing and torquing fasteners and components.

Always consider safety precautions before beginning a service procedure. Take the following general precautions whenever servicing a hydraulic system:

Unintended machine movement

Warning

Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.

Flammable cleaning solvents

Warning

Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

Fluid under pressure

Warning

Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek medical attention immediately if you are cut by hydraulic fluid.

L1211037 • Rev AC • Apr 2014 7

Anti-cavitation valve

High pressure relief valve

Loop flushing relief valve

Loop flushing valve

Valve plate

Piston

Conical bearings

Output shaft

Fixed swashplate

Cylinder block

Service Manual

Introduction

Design

TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Personal safety

Warning

Protect yourself from injury. Use proper safety equipment including safety glasses at all times.

Hazardous material

Warning

Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state and federal environmental regulations.

Danfoss fixed displacement motor (TMM) is designed to convert an input of hydraulic power into an output torque. It operates in the reverse manner of the pump.

The high pressure hydraulic fluid enters through the input port. The fluid pressure builds behind the pistons causing them to move down the swash plate (the path of least resistance). As the piston returns up the swashplate again, the fluid is allowed to exit through the exit port. The spinning pistons are housed in a cylinder which is connected to the output shaft. The output torque can be applied to a mechanical function.

The motors include a loop flushing feature that provides additional cooling and cleaning of fluid in the working loop.

Cross-section view of TMM

The System Circuit

The Basic Closed Circuit

Hydraulic lines connect the main ports of the pump to the main ports of the motor. Fluid flows in either direction from the pump to the motor and back. Either of the hydraulic lines can be under high pressure. In pumping mode the position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow.

8 L1211037 • Rev AC • Apr 2014

B B

L2 M3

TMMTMP

M2L2SM2

M10

C2C1

M1 L1 M1

Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Introduction

Case drain and heat exchanger

The pump and motor require case drain lines to remove hot fluid from the system. The pump and motor drain from the topmost port to ensure the cases remain full of fluid. The motor case drain can connect to the lower drain port on the pump housing or it can tee into the case drain line upstream of the heat exchanger. A heat exchanger with bypass valve cools the case drain fluid before it returns to the reservoir.

The schematic below shows the function of a hydrostatic transmission using an TMP axial variable displacement pump with electric proportional displacement control (EDC) and an TMM fixed displacement motor with integrated loop flushing device.

TMM with TMP EDC

Legend:

A, B – System ports: Ø 25.4 mm L1, L2 – Case drain ports: M22x1.5 M1, M2 – System A/B gauge ports: M12x1.5

L1211037 • Rev AC • Apr 2014 9

M3 – Charge gauge port, after filtering: M12x1.5 M4, M5 – Servo gauge ports: M12x1.5 M10 – Charge pump inlet pressure port: M12x1.5 S – Charge inlet port: M42x2

L2 M3 M2

High-pressure relief valve

Anticavitation valve

Service Manual

TMM Transit Mixer Axial Piston Motor, Size 070/084/089

Operation

High pressure relief valve (HPRV) and check valve

The TM Motors are optionally equipped with a combination high pressure relief and check valve. The high-pressure relief function is a dissipative pressure control valve for the purpose of limiting excessive system pressures. Each side of the transmission loop has a dedicated HPRV valve that is non-adjustable with a factory set pressure.

When system pressure exceeds the factory setting of the valve, oil is passed from the high pressure system loop, into the gallery, and into the low pressure system loop via the check valve. The HPRVs are used in motor, when pump is without HPRVs.

HPRVs are set at low flow condition. Any application or operating condition which leads to elevated HPRV flow will cause a pressure rise with flow above the valve setting. Consult factory for application.

Pressures marked on HPRV valve:

•

35 – means 350 bar [5076 psi]

•

42 – means 420 bar [6092 psi]

TMM with HPRVs and anticavitation valve

HPRV and check valve in charging mode HPRV and check valve in relief mode

Loop flushing shuttle spool

An integral loop flushing shuttle spool is used to separate system A and system B pressures, see the schematic below.

System delta pressure will cause the shuttle spool to shift, allowing the low side system pressure to flow to the loop flushing relief valve.

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