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
Contents
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.
6 L1211037 • Rev AC • Apr 2014
W
W
W
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
W
W
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
AA
B B
L2 M3
M3
M5
M4
TMMTMP
M2L2SM2
M10
L1
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
B
A
L1
M1
L2 M3 M2
High-pressure relief valve
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.
10 L1211037 • Rev AC • Apr 2014
Loop Flushing Shuttle Spool
Loop Flushing Relief Valve
0
4
8
12
16
20
24
28
0 2 4 6 8 10
432
1
12 14 16 18
Low system pressure minus case pre ssure (bar)
Case flow (l/min)
Case flow (US gal/min)
A3, 5 bar
A3, 13 bar
D2, 13 bar
Service Manual
Operation
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Loop flushing relief valve
Loop flushing shuttle valve section
Schematic
The loop flushing relief valve is incorporated into all TMM motors. Use the loop flushing option in
Installations that require fluid to be removed from the low pressure side of the system circuit due to
cooling requirements and also used to facilitate the removal of contaminants from the loop.
The loop flushing valve is equipped with an orificed charge pressure relief valve designed with a cracking
pressure of 5.5, 13 and 16 bar. Valves are available with several orifice sizes to meet the flushing flow
requirements of all system operating conditions.
Loop flushing flow curves
Anti-cavitation valve
The TM motors are optional equipment with anti-cavitation valve (ACV). ACV has to garantee a minimum
oil pressure in the low pressure side in case of low engine speed and high oil temperature.
L1211037 • Rev AC • Apr 2014 11
W
C
Service Manual
Operating parameters
Overview
Output speed
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
This section defines the operating parameters and limitations for TM Motors with regard to output
speeds and pressures. For actual parameters, refer to the operating parameters for each displacement.
Minimum speed is the lowest output speed. Operating below minimum speed limits the system can be
unstable.
Rated speed is the highest input speed recommended at full power condition. Operating at or below
this speed generally yields satisfactory product life.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces product
life and can cause loss of hydrostatic power and braking capacity. Never exceed the maximum speed
limit under any operating conditions.
Warning
Unintended vehicle or machine movement hazard.
Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You
must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the
vehicle or machine in the event of hydrostatic drive power loss.
System pressure
Case pressure
System pressure is the differential pressure between system ports A & B. It is the dominant operating
variable affecting hydraulic unit life. High system pressure, which results from high load, reduces
expected life. Hydraulic unit life depends on speed and normal operating—or weighted average—
pressure that you can only determine from a duty cycle analysis.
Applied pressure is the chosen application pressure in the order code for the motor. This is the pressure
at which the drive line generates maximum pull or torque in the application.
Rated pressure is the design pressure for the motor. Applications with applied pressures at or below this
pressure should yield satisfactory unit life given proper component selection.
Maximum pressure (peak) is the highest intermittent pressure allowed under any circumstances.
Applications with applied pressures between rated and maximum require factory approval with
complete application, duty cycle, and life expectancy analysis.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract low loop
pressure from gauge readings to compute the differential.
Do not exceed rated case pressure under normal operating conditions. During cold start, keep case
pressure below maximum intermittent case pressure. Size drain plumbing accordingly.
Caution
Possible component damage or leakage.
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings,
causing external leakage. This condition may also affect performance since charge and system pressure
are referenced to case pressure.
12 L1211037 • Rev AC • Apr 2014
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Operating parameters
Temperature and Viscosity
Temperature
High temperature limits apply at the hottest point in the transmission loop, which is normally the motor
case drain. Ensure the system generally runs at or below the rated temperature. The maximum
intermittent temperature is based on material properties: Never exceed it.
Cold oil will generally not affect the durability of the transmission components, but it may affect the
ability of oil to flow and transmit power: therefore ensure temperatures remain 16 °C [30 °F] above the
pour point of the hydraulic fluid. Minimum temperature relates to the physical properties of component
materials.
Size heat exchangers to keep the fluid within these limits. Danfoss recommends testing to verify that
these temperature limits are not exceeded.
Viscosity
For maximum efficiency and bearing life, ensure the fluid viscosity remains in the recommended range.
Minimum viscosity should be encountered only during brief occasions of maximum ambient
temperature and severe duty cycle operation. Maximum viscosity should be encountered only at cold
start.
L1211037 • Rev AC • Apr 2014 13
C
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Technical Specifications
Technical specification
Specifications and operating parameters for TMM motors are given here for reference:
General specifications
Design
Direction of rotation
Pipe connections
Recommended
installation position
Caution
The front shaft seal must not be exposed to oil pressure from outside of the unit.
Technical data
Features Unit Size
Displacement maximum
Flow at rated (continuous) speed
Torque (theoretical)
Mass moment of inertia of rotating
components
Weight dry (standard)
Oil volume
Mounting flange
Output shaft
Main port configuration
Case drain ports L1, L2
Other ports
Axial piston motor with fixed swashplate design with fixed displacement
Bi-directional
Main pressure ports: ISO split flange boss
Remaining ports: ISO/SAE straight thread O-ring boss
Motor installation position is discretionary
The housing must always be filled with hydraulic fluid
070 084 089
cm³ [in³] 68.3 [4.17] 83.8 [5.11] 89.0 [5.43]
l/min
[US gal/min]
N•m/bar
[lbf•in/1000 psi]
kg•m²
[lbf•ft²]
kg [lb] 34.8 [76.9] 34.8 [76.9] 34.8 [76.9]
l [US gal] 2 [0.53] 2 [0.53] 2 [0.53]
SAE ISO 3019/1 flange 127-4 (SAE C), M12x1,75
Spline shaft SAE, 21 teeth, pitch = 16/32; Spline shaft SAE, 23 teeth, pitch =
16/32
Twin ports SAE J518b Size 1, with metric or inch screws
M22x1,5 (O-ring boss) or 7/8–14 UNF-2B
ISO straight thread O-ring boss or SAE
171 [45.2] 209.5 [55.3] 222.5 [58.8]
1.09 [665] 1.33 [812] 1.42 [867]
0.0209
[0.0159]
0.0209
[0.0159]
0.0209
[0.0159]
Operating parameters
Features Unit 070 / 084 / 089
Output speed
System pressure
14 L1211037 • Rev AC • Apr 2014
Minimum
Rated
Maximum
Max. working pressure
Maximum pressure
Minimum pressure
min-1(rpm) 100
2500
2900
bar [psi] 420 [6090]
450 [6525]
10 [145]
Service Manual
Technical Specifications
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Operating parameters (continued)
Features Unit 070 / 084 / 089
Case pressure
Maximum lip seal external pressure
Rated
Maximum
Fluid specifications
Features Unit 070 / 084 / 089
Viscosity Intermittent
Minimum
Recommended range
Maximum
Temperature range †Minimum (cold start)
Recommended range
Rated
Maximum intermittent
Filtration Cleanliness per ISO 4406 (recommended minimum)
Efficiency (charge pressure filtration)
Efficiency (suction and return line filtration)
* Intermittent = Short term t < 1 min per incident and not exceeding 2% of duty cycle based load-life
† At the hottest point, normally case drain port
‡ Cold start = Short term t < 3 min, p ≤ 50 bar [725 psi], n ≤ 1000 min-1(rpm)
*
‡
bar [psi] 3.0 [44]
5.0 [73]
0.4 [5.8]
mm²/s
[SUS]
°C [°F] -40 [-40]
β-ratio β
5 [42]
7 [49]
12-80 [66-370]
1600 [7500]
60-85 [140-185]
104 [220]
115 [240]
22/18/13
= 75 (β10 ≥ 10)
15-20
β
= 75 (β10 ≥ 2)
35-45
Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing
oxidation, rust, and foam inhibitors.
L1211037 • Rev AC • Apr 2014 15
W
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Fluid and Filter Maintenance
Fluid and filter recommendations
Perform regular maintenance of the fluid and filter to ensure optimum life. Take care to maintain fluid
•
cleanliness when servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid
•
contaminated by water may appear cloudy or milky or free water may settle in the bottom of the
reservoir. Rancid odor indicates the fluid has been exposed to excessive heat.
Inspect vehicle for leaks daily.
•
Change the fluid and correct the problem immediately.Contaminated fluid is the main cause of unit
•
failure. We recommend first fluid change at 500 hours.
Change the fluid and filter per the vehicle/machine manufacturer’s recommendations or at intervals
shown in the table:
Fluid and filter change interval
Reservoir type Max oil change interval
Sealed 2000 hours
Breather 500 hours
Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease,
etc.) or if the fluid is subjected to temperature levels greater than the recommended maximum.
Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid. Change filters with the fluid or when
the filter indicator shows it’s necessary. Replace all fluid lost during filter change.
Tip
For detailed filtration information, see Danfoss publication Hydraulic Fluids and Lubricants,520L0463.
For more information on biodegradable fluids see Danfoss publication Experience with Biodegradable
Hydraulic Fluids,520L0465.
Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid.
Always dispose of used hydraulic fluid according to state and federal environmental regulations.
Port Locations and Gauge Installation
The following table and drawings show the port locations and gauge sizes needed. When testing system
pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges.
Ports description - TMM without HPRV
Identifier Description Size Wrench size Gauge size, bar [psi]
L1, L2 Case drain port M22x1.5 10 mm internal hex 10 [100]
M1, M2 System A/B gauge ports M12x1.5 6 mm internal hex 50 [1000]
M3 Flushing gage port
Optional ports description - TMM with HPRV
Identifier Description Size Wrench size Gauge size,
L1, L2 Case drain port 7/8-14 UNF-2B 3/8” internal hex 10 [100]
bar [psi]
16 L1211037 • Rev AC • Apr 2014
Gauge port M2
System pressure port B
M12x1.5
Optional: 9/16-18UNF-2B
Gauge port M1
System pressure port A
M12x1.5
Optional: 9/16-18UNF-2B
Case drain port L2
M22x1.5
Optional: 7/8-14UNF-2B
Case drain port L1
M22x1.5
Optional: 7/8-14UNF-2B, or
Speed and temperature sensor
Case drain
M22x1.5
Optional: 7/8-14UNF-2B
Port for sensor PPU
Gauge port M3
Flushing pressure
M12x1.5
Optional: 9/16-18UNF-2B
Service Manual
Fluid and Filter Maintenance
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Optional ports description - TMM with HPRV (continued)
Identifier Description Size Wrench size Gauge size,
bar [psi]
M1, M2 System A/B gauge port 9/16-18 UNF-2B 1/4” internal hex 50 [1000]
M3 Flushing gage port
Please contact Danfoss for specific installation drawings.
Ports dimensions
P005401E
L1211037 • Rev AC • Apr 2014 17
W
C
Service Manual
Initial Start-up
Start-up procedure
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Follow the procedure below when starting-up a new pump/motor installation or when restarting an
installation in which a unit has been removed and re-installed on a machine. Ensure the unit has been
thoroughly tested on a test stand before installing on a machine. Prior to installing the unit, inspect for a
damage that may have occurred during shipping.
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.
1. Ensure that the machine hydraulic oil and system components (reservoir, hoses, valves, fittings, and
heat exchanger) are clean and free of any foreign material.
2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened
and there are no air leaks.
3. Install the pump/motor. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M3 on
pump.
4. Fill the pump/motor housing by adding filtered oil in the upper case drain port.
5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron filler
filter. Fill inlet line from reservoir to pump.
6. Disconnect the pump from all control input signals.
Caution
After start-up the fluid level in the reservoir may drop due to system components filling. Damage to
hydraulic components may occur if the fluid supply runs out. Ensure reservoir remains full of fluid
during start-up.
Air entrapment in oil under high pressure may damage hydraulic components. Check carefully for
inlet line leaks.
Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered.
7. Use a common method to disable the engine to prevent it from starting. Crank the starter for several
seconds. Do not to exceed the engine manufacturer’s recommendation. Wait 30 seconds and then
crank the engine a second time as stated above. This operation helps remove air from the system
lines. Refill the reservoir to recommended full oil level.
8. When the gauge begins to register charge pressure, enable and start engine. Let the engine run for a
minimum of 30 seconds at low idle to allow the air to work itself out of the system. Check for leaks at
all line connections and listen for cavitation. Check for proper fluid level in reservoir.
9. When adequate charge pressure is established (as shown in model code), increase engine speed to
normal operating rpm to further purge residual air from the system.
10. Shut off engine. Connect pump control signal. Start engine, checking to be certain pump remains in
neutral. Run engine at normal operating speed and carefully check for forward and reverse control
operation.
11. Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush
system contaminants out of loop.
Normal charge pressure fluctuation may occur during forward and reverse operation.
12. Check that the reservoir is full. Remove charge pressure gauge. The pump is now ready for operation.
18 L1211037 • Rev AC • Apr 2014
W
W
C
W
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Troubleshooting
Overview
This section provides general steps to follow if you observe undesirable system conditions. Follow the
steps listed until you solve the problem. Some of the items are system specific. We reference the section
in this manual if more information is available. Always observe the safety precautions listed in the
Introduction section and precautions related to your specific equipment.
Safety Precautions
Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious
injury and/or infection. Relieve pressure in the system before removing hoses, fittings, gauges, or
components.
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.
Caution
System operating hot
Contamination can damage internal components and void the manufacturer’s warranty. Take
precautions to ensure system cleanliness when removing and reinstalling system lines
Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used
hydraulic fluid according to state, and federal enviroN•mental regulations.
System operating hot
Item Description Action
Oil level in reservoir. Insufficient hydraulic fluid will not meet
cooling demands of system.
Heat exchanger. Heat exchanger is not sufficiently cooling the
system.
System relief pressure
settings
System pressure Frequent or long term operation over system
For internal leakage
in motor
If the system relief valves are worn,
contaminated, or valve settings are too low,
the relief valves will be overworked.
relief setting will create heat in system.
Leakage will reduce low side system pressure
and overwork the system.
Fill reservoir to proper level.
Check air flow and input air temperature for
heat exchanger. Clean, repair or replace heat
exchanger.
Verify settings of high pressure relief valves
and replace valves as necessary.
Measure system pressure. If pressure is too
high, reduce loads.
Monitor motor case flow without loop
flushing in the circuit. If flow is excessive,
replace motor.
L1211037 • Rev AC • Apr 2014 19
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Troubleshooting
System will not operate in either direction
System will not operate in either direction
Item Description Action
System noise or vibration
Oil level in reservoir. Insufficient hydraulic fluid to supply system
loop.
System pressure Low system pressure does not provide
enough power to move load.
High pressure relief
valve
Defective high pressure relief valve cause
system pressure to be low.
System noise or vibration
Item Description Action
Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil Air in system decreases efficiency of units.
Excessive noise, foaming oil, and hot oil all
indicate air in system.
Cold oil If oil is cold, it may be too viscous for proper
function causing pump cavitation.
Shaft couplings A loose shaft coupling will cause excessive
noise.
Shaft aligN•ment Misaligned shafts create noise. Align shafts.
Fill reservoir to proper level.
Measure system pressure. Continue to next
step.
Repair or replace high pressure relief valve.
Find location where air is entering into the
system and repair. Check that inlet line is not
restricted and is proper size.
Allow the oil to warm up to its normal
operating temperature with engine at idle
speed.
Replace loose shaft coupling.
Sluggish system response
Sluggish system response
Item Description Action
Oil level in reservoir Low oil level causes sluggish response. Fill reservoir.
High pressure relief
valves settings
Low prime mover
speed
Air in system Air in system produces sluggish system
Incorrect pressure settings affects system
reaction time.
Low engine speed reduces system
performance.
response.
Transmission operates normally in one direction only
Transmission operates normally in one direction only
Item Description Action
Exchange high
pressure relief valves
Exchanging the high pressure relief valves
will show if the problem is related to the
valve function.
Adjust or replace high pressure relief valves.
Adjust engine speed.
Fill tank to proper level. Cycle system slowly
for several minutes to remove air from
system.
If the problem changes direction, replace the
valve that does not operate correctly.
20 L1211037 • Rev AC • Apr 2014
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Troubleshooting
Low motor output torque
Low motor output torque
Item Description Action
System pressure at
motor
For internal leakage Internal leakage will reduce system pressure. Check for leakage in O-rings, gaskets, and
Improper motor output speed
Improper motor output speed
Item Description Action
Oil level in reservoir Insufficient hydraulic fluid will reduce motor
For internal leakage Internal leakage will reduce system pressure. Check for leakage in O-rings, gaskets, and
Low system pressure at the motor will reduce
torque.
speed.
Measure system pressure at motor.
other fittings. Repair unit as required or
replace leaky unit.
Fill oil to proper level
other fittings. Repair unit as required or
replace leaky unit.
L1211037 • Rev AC • Apr 2014 21
C
Connector
Target ring
200mm long
speed sensor wire
Sensor PPU,
KPP* 13808
(85) [3.346]
129.2 [5.087]
Black wire
Black wire
Red wire
Red wire
≈22
º
≈22
º
Magnetic target ring
Direction
signal high
Direction
signal low
Direction
signal high
Direction
signal low
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Adjustments
Standard procedures
This section offers the instruction on inspection and adjustment of motor components.
Caution
Contamination can damage internal components and void your warranty.
Take precautions to ensure system cleanliness when removing and reinstalling system lines.
1. With the prime mover off, thoroughly clean the outside of the motor.
2. If removing the motor, tag each hydraulic line. When you disconnect hydraulic lines, cap them and
plug each open port to prevent contamination.
3. Ensure the surrounding area is clean and free of contaminants like dirt and grime.
4. Inspect the system for contamination.
5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil, sludge, or metal
particles.
6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain the hydraulic
system. Flush the lines and refill the reservoir with the correct filtered hydraulic fluid.
7. Before re-installing the motor, test for leaks.
Speed sensor PPU adjustment
When installing or adjusting the speed sensor on a motor, it must be set at a specific distance from the
speed ring on the unit’s cylinder. To locate the position of the speed sensor on the unit or description see
the corresponding section.
1. Loosen the sensor lock nut with an 1 1/16 inch hex wrench.
2. Turn the sensor clockwise by hand until it contacts the speed ring.
3. Turn the sensor counterclockwise ½ turn (180°) to establish the nominal gap of 0.71 mm [0.028 in].
4. Then turn the sensor clockwise until the wrench flats on sensor body are positioned at a 22° angle to
the motor shaft center line.
Many adjustable wrenches have a 22° handle offset.
5. The final sensor position should be between ½ (180°) and ¼ turn (90°) counterclockwise from the
point where the sensor contacts the speed ring.
6. Hold sensor in position with a ½ inch hex wrench while tightening the lock nut to 13 N•m (10 lbf•ft).
Sensor PPU, KPP*13808
22 L1211037 • Rev AC • Apr 2014
C
C
D
F
A
B
E
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Minor Repair
Standard procedures, removing the motor
Before working on the motor, thoroughly clean the outside. Tag and cap all hydraulic lines as they are
disconnected, and plug all open ports to ensure that dirt and contamination do not get into the system.
Caution
Contamination can damage internal components and void your warranty.
Take precautions to ensure system cleanliness when removing and reinstalling system lines.
Disassembly
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the motor.
2. Tag, disconnect, and cap each hydraulic line connected to the motor. As hydraulic lines are
disconnected, plug each open port, to ensure that dirt and contamination do not get into the motor.
Inspection
1. Ensure the work surface is clean and free of contaminants such as dirt and grime.
2. Inspect the system for contamination.
3. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge,
or metal particles.
Reassembly
1. Before replacing the motor, replace all filters and drain the hydraulic system. Flush the system lines
and fill the reservoir with the correct, filtered hydraulic fluid.
2. Attach the motor to the flange. Torque mounting screws according to the manufacturers
recommendation.
3. Fill the motor with clean, filtered hydraulic fluid.
4. Ensure the charge inlet line is filled with fluid.
Motor outline for minor repair reference
A – Loop flushing relief valve
B – Loop flushing valve
L1211037 • Rev AC • Apr 2014 23
D – High pressure relief valve
E – Speed sensor
C
B110
d
B100
B090
B065
Service Manual
Minor Repair
Shaft Seal Replacement
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
C – Anti-cavitation valve F – Shaft seal
The shaft seal is serviceable. Orient the motor on the work surface so the shaft is pointing up.
Removal
1. Using snap-ring pliers, remove the outer snap-ring (B110).
2. Remove the washer (B100)
3. Use 2 screwdrivers to remove the shaft seal (B90). Discard the seal.
Caution
Do not damage the housing bore, shaft or bearing when removing the seal.
Inspection
Inspect the housing bore, shaft and bearing. If you find any defect, replace damaged component.
Reassembly
1. Press the shaft seal (B090) with seal installation tool into housing.
2. Install the remaining washer (B100).
3. Install the remaining snap-ring (B110).
Shaft seal assembly
High Pressure Relief Valves (HPRV)
Removal
Using a 12 mm internal hex wrench, remove the HPRVs (G090). Remove and discard the O-rings
(G090A).
Inspection
Inspect the sealing surfaces in the motor for nicks or scratches. Check the valves for damage. Replace
any damaged components.
24 L1211037 • Rev AC • Apr 2014
G090A
G090
G090A
G090
I12 mm
80 N•m [59 lbf•ft]
d
d
Service Manual
Minor Repair
Loop Flushing Relief Valve
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Reassembly
1. Lubricate and install new O-rings (G090A).
2. Install HPRVs. Torque to the value 80 N•m [59 lbf•ft].
3. Check for leaks.
HPRVs
Replace the loop flushing relief valve (K00**) as a complete unit. Do not attempt to repair the internal
components of the valve. Torque to 38 N•m [28 lbf•ft].
Removal
Using an 17 mm wrench, remove the loop flushing relief valve. Discard seal O-ring on the plug (K030).
Inspection
Inspect the poppet (K010) and the sealing surfaces of the motor for nicks or scratches.
Reassembly
1. Lubricate and install new seal O-ring.
2. Install the loop flushing relief valve, and torque to 38 N•m (28 lbf•ft).
3. Operate vehicle/machine through full range of controls to ensure proper operation.
L1211037 • Rev AC • Apr 2014 25
H10W
H20W
H30W
H50W
H20W
H30W
K010
K020
K030
K00**
H50W
h17 mm
38 N•m [28 lbf•ft]
dO-ring
h17 mm
38 N•m [28 lbf•ft]
s
dO-ring
Service Manual
Minor Repair
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Loop flushing relief valve and loop flushing valve
Loop Flushing Valve
Anticavitation Valve
Removal
1. Using an 17 mm wrench, remove the hex plugs with O-rings (H50W) from both sides of the valve.
Discard seal O-ring.
2. Remove the springs (H30W) with shoulder washers (H20W) from both sides of the valve.
3. Remove the flushing valve spool (H10W).
Inspection
Inspect parts for damage or foreign material.
Reassembly
1. Install the flushing valve spool in end cap.
2. Install the shoulder washers with spring on each end of the spool.
3. Install the hex plugs with new O-rings, and torque to 38 N•m (28 lbf•ft).
Removal
1. Using an tool for groove on plug, remove the plug (V40) with O-rings (V30). Discard seal O-ring.
2. Remove the springs (V20).
3. Remove the ball (V10).
26 L1211037 • Rev AC • Apr 2014
Inspection
Inspect parts for damage or foreign material and sealing surfaces on the motor for nicks or scratches.
V010
V020
V030
d
s
V040
V000
20 N•m
[15 lbf•ft]
W050
W030
W040A
W040
d
s
h1-1/16 hex
13 N•m [10 lbf•ft]
Service Manual
Minor Repair
Speed Sensor PPU
TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Reassembly
1. Install the ball in end cap.
2. Install the springs.
3. Lubricate and install new seal O-ring on the plug. Install the plug and torque to 20 N•m (15 lbf•ft).
Anticavitation valve
Removal
1. Disconnect the electrical connector.
2. Loosen the sensor lock nut with an 1-1/16 inch hex wrench.
3. Unscrewing the speed sensor (W40) from the motor housing.
Inspection
Inspect parts for damage or foreign material and sealing surfaces on the adapter plug for nicks or
scratches.
Reassembly
1. Always install a new O-ring before installing the sensor.
2. Reinstall the speed sensor (with lock nut and O-ring) into the housing. Adjust the gap between the
sensor and the magnetic speed ring as instructed in the section “Speed Sensor Adjustment” and torque
the sensor lock nut.
Speed Sensor PPU assembly
L1211037 • Rev AC • Apr 2014 27
W055
W040A
W040
s
d
5 mm
8 N•m [5.9 lbf•ft]
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Minor Repair
Speed and Temperature Sensor (H1)
Removal
1. Disconnect the electrical connector.
2. Using an 5 mm internal hex wrench, remove the fastening screw (W055).
3. Remove the speed sensor (W040) from the motor housing.
Inspection
Inspect parts for damage or foreign material and sealing surfaces on the motor for nicks or scratches.
Reassembly
1. Always install a new O-ring before installing the sensor.
2. Install the speed and temperature sensor into the housing.
3. Install the fastening screw and torque to 8 N•m (5.9 lbf•ft).
Speed and Temperature Sensor (H1) assembly
28 L1211037 • Rev AC • Apr 2014
V030
Anti-cavitation valve
G090
High pressure
relief valve
G090
High pressure
relief valve
G130
Screw
G120
Screw
G060
Plug-Soc-w/O-ring
H00W
Spool-Shuttle
90MF100 Assy
K30
Loop flushing Assy
W040
Speed sensor
W055
Screw
B040
Plug-Soc-w/O-ring
G050
Plug-Soc-w/O-ring
G050
Plug-Soc-w/O-ring
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
Torque Chart
Fasteners, plugs and torques
Item Fastener Wrench size Torque
B040 Plug-SOC-O-ring M22x1.5
Plug-SOC-O-ring 7/8"
G120
G130
G050,
G060
G050,
G060
K30 Loop-flushing assy 17 mm 38 ±4 N•m [28 lbf•ft]
H00W Spool-shuttle assy
V030 Anticavitation valve groove for screw driver 20 ±2 N•m [14.8 lbf•ft]
G090 High pressure relief valve 12 mm internal hex 80 ±20 N•m [59 lbf•ft]
W055 Speed sensor mounting bolt 5 mm internal hex 8 ±1 N•m [6 lbf•ft]
W030 Sensor PPU lock nut 13 ±2 N•m [10 lbf•ft]
Rear cover screw 8 mm internal hex 70 ±0.7 N•m [51.6 lbf•ft]
Plug-SOC-O-ring M12x1.5 6 mm internal hex 21 ±2 N•m [15.5 lbf•ft]
Plug-SOC-O-ring 9/16" ¼ internal hex 40 ±4 N•m [29.5 lbf•ft]
Ports and plugs description
10 mm internal hex
3/8 internal hex
40 ±5 N•m [29.5 lbf•ft]
L1211037 • Rev AC • Apr 2014 29
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
30 L1211037 • Rev AC • Apr 2014
Service Manual TMM Transit Mixer Axial Piston Motor, Size 070/084/089
L1211037 • Rev AC • Apr 2014 31
Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electronic components. We specialize in providing state-of-the-art technology and solutions that
excel in the harsh operating conditions of the mobile off -highway market. Building on our extensive
applications expertise, we work closely with our customers to ensure exceptional performance for a
broad range of off -highway vehicles.
We help OEMs around the world speed up system development, reduce costs and bring vehicles to
market faster.
Danfoss – Your Strongest Partner in Mobile Hydraulics.
Go to www.powersolutions.danfoss.com for further product information.
Wherever off -highway vehicles are at work, so is Danfoss.
We off er expert worldwide support for our customers, ensuring the best possible solutions for
outstanding performance. And with an extensive network of Global Service Partners, we also provide
comprehensive global service for all of our components.
Please contact the Danfoss Power Solution representative nearest you.
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss
Power Solutions US Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239 6000
Danfoss
Power Solutions
(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 3418 5200
Products we off er:
• Bent Axis Motors
• Closed Circuit Axial Piston
Pumps and Motors
• Displays
• Electrohydraulic Power
Steering
• Electrohydraulics
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control
Handles
• Microcontrollers and
Software
• Open Circuit Axial Piston
Pumps
• Orbital Motors
• PLUS+1® GUIDE
• Proportional Valves
• Sensors
• Steering
• Transit Mixer Drives
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmuellerinverter.com
Turolla
www.turollaocg.com
Valmova
www.valmova.com
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
Local address:
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to
products already on order provided that such alterations can be made without changes being necessary in specifications already agreed..
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
L1211037 • Rev AC • Apr 2014 www.danfoss.com
©
Danfoss A/S, 2014
Loading...