Danfoss TMP 070/089 Service guide

Service Manual

Transit Mixer Axial Piston Pump

Size 070/089

powersolutions.danfoss.com

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Revision history	Table of revisions
	Date	Changed	Rev
	July 2017	Updated to Engineering Tomorrow	0203
	Mar 2014	Converted to Danfoss layout – DITA CMS	BB
	19 Oct, 2012	Major update - The MDC control added	BA
	14 Oct, 2011	Images data change	AE
	Jul, 2011	Grammar spelling, new images with speed sensor	AD
	02 Nov, 2010	No technical change, word spelling	AC
	24 Aug, 2010	New Backpage	AB
	24 Jun, 2010	First Edition	AA

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TMP Transit Mixer Axial Piston Pump, Size 070/089
Contents
Literature reference
TMP literature reference ...............................................................................................................................................................	5
Introduction
Overview..............................................................................................................................................................................................	6
Warranty..............................................................................................................................................................................................	6
Symbols used in Danfoss literature............................................................................................................................................	6
General instructions........................................................................................................................................................................	6
Safety precautions............................................................................................................................................................................	7
Unintended machine movement..........................................................................................................................................	8
Flammable cleaning solvents.................................................................................................................................................	8
Fluid under pressure..................................................................................................................................................................	8
Personal safety.............................................................................................................................................................................	8
Hazardous material....................................................................................................................................................................	8
Design...................................................................................................................................................................................................	8
System circuit.....................................................................................................................................................................................	9
Basic Closed Circuit.....................................................................................................................................................................	9
Case drain and heat exchanger..............................................................................................................................................	9
Operation
High pressure relief valve (HPRV) and charge check valve.............................................................................................	11
Charge pressure relief valve (CPRV) .......................................................................................................................................	12
Electrical Displacement Control (EDC)...................................................................................................................................	12
EDC Principle..............................................................................................................................................................................	12
Manual Displacement Control (MDC).....................................................................................................................................	13
MDC principle............................................................................................................................................................................	13
MDC with control cut off (CCO)...........................................................................................................................................	13
Manual Over Ride (MOR).............................................................................................................................................................	14
Operating Parameters
Overview...........................................................................................................................................................................................	15
Input Speed......................................................................................................................................................................................	15
System Pressure..............................................................................................................................................................................	15
Charge Pressure..............................................................................................................................................................................	15
Charge inlet pressure....................................................................................................................................................................	16
Case Pressure...................................................................................................................................................................................	16
Temperature and Viscosity.........................................................................................................................................................	16
Temperature...............................................................................................................................................................................	16
Viscosity........................................................................................................................................................................................	16
General specification....................................................................................................................................................................	16
Physical Properties.........................................................................................................................................................................	17
Operating parameters..................................................................................................................................................................	17
Fluid Specifications.......................................................................................................................................................................	18
Fluid and Filter Maintenance
Fluid and filter recommendations...........................................................................................................................................	19
Port Locations and Gauge Installation...................................................................................................................................	19
Initial Startup Procedures
General ..............................................................................................................................................................................................	21
Start-Up procedure........................................................................................................................................................................	21
Troubleshooting
Overview...........................................................................................................................................................................................	22
Safety Precautions.........................................................................................................................................................................	22
Electrical Troubleshooting (TMP EDC)....................................................................................................................................	22
System Operating Hot..................................................................................................................................................................	22
Neutral Difficult or Impossible to Find...................................................................................................................................	23
System Will Not Operate in Either Direction........................................................................................................................	23
System Noise or Vibration...........................................................................................................................................................	24
Sluggish System Response.........................................................................................................................................................	24
Transmission Operates Normally in One Direction Only.................................................................................................	24
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Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
Contents
Adjustments
Pump Adjustment..........................................................................................................................................................................	25
Standard Procedures....................................................................................................................................................................	25
Charge Pressure Relief Valve Adjustments...........................................................................................................................	25
EDC neutral adjustment..............................................................................................................................................................	26
MDC Control Neutral Adjustment............................................................................................................................................	27
Mechanical Neutral Adjustment...............................................................................................................................................	29
Pump setup.................................................................................................................................................................................	31
Servo adjustment.....................................................................................................................................................................	31
Minor Repair
Standard Procedures, Removing the Pump.........................................................................................................................	32
Disassembly................................................................................................................................................................................	32
Inspection....................................................................................................................................................................................	32
Reassembly.................................................................................................................................................................................	32
EDC/MDC Control..........................................................................................................................................................................	32
Removal........................................................................................................................................................................................	32
Inspection....................................................................................................................................................................................	32
Reassembly.................................................................................................................................................................................	32
EDC Control......................................................................................................................................................................................	34
Control Solenoids...........................................................................................................................................................................	35
Removal........................................................................................................................................................................................	35
Inspection....................................................................................................................................................................................	35
Reassembly.................................................................................................................................................................................	35
MDC with CCO Control................................................................................................................................................................	36
Control Solenoids...........................................................................................................................................................................	37
Removal........................................................................................................................................................................................	37
Inspection....................................................................................................................................................................................	37
Reassembly.................................................................................................................................................................................	37
Shaft Seal Replacement...............................................................................................................................................................	37
Removal........................................................................................................................................................................................	38
Inspection....................................................................................................................................................................................	38
Reassembly.................................................................................................................................................................................	38
Charge Pump...................................................................................................................................................................................	38
Charge Pump Removal (Removable Auxiliary Pad/Cover)........................................................................................	38
Inspection....................................................................................................................................................................................	39
Reassembly.................................................................................................................................................................................	39
High Pressure Relief Valves (HPRV)..........................................................................................................................................	40
Removal........................................................................................................................................................................................	40
Inspection....................................................................................................................................................................................	40
Reassembly.................................................................................................................................................................................	40
Charge Pressure Relief Valve......................................................................................................................................................	41
Removal........................................................................................................................................................................................	41
Inspection....................................................................................................................................................................................	41
Reassembly.................................................................................................................................................................................	41
Torque Chart
Fastener Size and Torques..........................................................................................................................................................	43
Plug Size and Torques..................................................................................................................................................................	43
EDC Fasteners and Plugs.............................................................................................................................................................	43
MDC Fasteners and Plugs...........................................................................................................................................................	45

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TMP Transit Mixer Axial Piston Pump, Size 070/089

Literature reference

TMP literature reference

Further available literature

Description	Type	Literature number
TMP Transit Mixer Axial Piston Pump, Size 070/089	Technical Information	L1006391
TMP Transit Mixer Axial Piston Pump, Size 070/089	Service Manual	L1010109
TMP Transit Mixer Axial Piston Pump, EDC/MDC, Size 070/089	Repair Instruction	L1031073
TMP Transit Mixer Axial Piston Pump, NFPE, Size 070/089	Repair Instruction	11029271
TMP EDC Axial Piston Pump, Size 070/089	Datasheet	L1109001
TMP MDC Axial Piston Pump, Size 070/089	Datasheet	L1214176
H1 Electrical Displacement Control (EDC)	Technical Information	11022744
Speed and Temperature Sensor	Technical Information	11046759
Hydraulic Fluids and Lubricants	Technical Information	520L0463
Design Guideline for Hydraulic Fluid Cleanliness	Technical Information	520L0467

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Introduction

Overview

This manual includes information on the installation, maintenance, and minor repair of TMP pumps. 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.sauer-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, servo sleeves, 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

WARNING may result in injury	Clean area or part
CAUTION may result in damage to product or property	Be careful not to scratch or damage
Non-reusable part, use a new part	Note correct orientation
External hex head	Torque specification
Internal hex head	Pull out with tool – press fit
Lubricate with hydraulic fluid	Cover splines with installation sleeve
Pressure measurement/gauge location or specification	Inspect for wear or damage

The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is the most useful to the reader. In most instances, the appearance of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.

General instructions

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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Introduction

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.

Safety precautions

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

W Warning

Unintended machine movement

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.

W Warning

Flammable cleaning solvents

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.

W Warning

Fluid under pressure

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.

W Warning

Personal safety

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

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Introduction

W Warning

Hazardous material

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

Unintended machine movement

W Warning

Unintended machine movement

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

W Warning

Flammable cleaning solvents

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

W Warning

Fluid under pressure

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.

Personal safety

W Warning

Personal safety

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

Hazardous material

W Warning

Hazardous material

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

Design

Danfoss TMP closed circuit piston pumps convert input torque into hydraulic power. The input shaft transmits rotational force to the cylinder block. Bearings at the front and rear of the pump support the

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Introduction

shaft. Splines connect the shaft to the cylinder block. A lip-seal at the front end of the pump prevents leakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocating pistons. Each piston has a brass slipper connected at one end by a ball joint. The block springs, ball guide, and slipper retainer hold the slippers to the swashplate. The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation. Via the valve plate, one half of the cylinder block is connected to low pressure and the other half to high pressure. As each piston cycles in and out of its bore, fluid is replenished by charge flow and displaced to the outlet thereby imparting hydraulic power into the system. A small amount of fluid is allowed to flow from the cylinder block/valve plate and slipper/swashplate interfaces for lubrication and cooling. Case drain ports return this fluid to the reservoir.

The angle of the swashplate controls the volume and direction of fluid displaced into the system. The servo piston controls the angle of the swashplate. The pump control, by varying the pressure at the servo piston, controls the piston's position. An electric signal to the control coils or mechanical signal to the control transmits the command from the operator to the pump. Mechanical feedback of the swashplate position to the control through the feedback pins allows for very precise displacement control and increases overall system stability.

Cross section view of TMP

Electric displacement control

Valve plate

Swashplate feedback pin

Piston

Shaft

Shaft seal

Plate thrust

Swashplate

Cylinder block		Servo piston		Charge pump				Cover charge pump

System circuit

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.

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

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Introduction

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 schematics below show the function of a hydrostatic transmission using an TMP axial variable displacement pump with electric/manual proportional displacement control (EDC/MDC) and an TMM fixed displacement motor with integrated loop flushing device.

System circuit diagram of TMP EDC with TMM

C1	C2
			L1	M1
M3				A
M5
M4
				B
	M10	S	L2	M2
	TMP

L1				M1

A

B
L2	M3	M2
	TMM

System circuit diagram of TMP MDC with TMM

‘-’ N ‘+’
L1	M1
M3	A
M5
M4
CW

			B
M10	S	L2	M2
TMP

L1				M1

A

B
L2	M3	M2
	TMM

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

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

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Operation

High pressure relief valve (HPRV) and charge check valve

The TMP pumps are equipped with a combination high pressure relief and charge check valve. The highpressure relief function is a dissipative pressure control valve for the purpose of limiting excessive system pressures. The charge check function acts to replenish the low-pressure side of the working loop with charge oil. 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 charge gallery, and into the low pressure system loop via the charge check.

The pump order code allows for different pressure settings to be used at each system port.

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.

System schematic, single pump
C1	C2
	High pressure relief valve
	Charge pressure relief valve

Pressures marked on HPRV valve

Mark

Pressure bar [psi]

28

280 [4061]

42

420 [6092]

HPRV and check valve in charging mode

HPRV and check valve in relief mode

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Operation

Charge pressure relief valve (CPRV)

	The charge pressure relief valve maintains charge	Charge pressure relief valve (CPRV)
	pressure at a designated level above case pressure.
	The charge pressure relief valve is a direct acting poppet
	valve which opens and discharges fluid to the pump case
	when pressure exceeds a designated level. Standard level
	setting is ∆p = 21 ± 1.1 bar [304 ± 16 psi] with the pump
	running at 1500 min-1 (rpm) and flow = 23.8 - 29.5 l/min
	[ 6.3 - 7.8 US gal/min].
	Typical charge pressure increase is 2 bar per 10 l/min [29
	psi per 2.64 US gal/min].

Electrical Displacement Control (EDC)

EDC Principle

The Electrical Displacement Control (EDC) consists of proportional solenoids on each side of a threeposition, four-way porting spool. The proportional solenoid applies a force to the spool, which ports hydraulic fluid to either side of the servo piston. Differential pressure across the servo piston rotates the swashplate, changing the pump's displacement from full displacement in one direction to full displacement in the opposite direction.

EDC operation

EDC's are current driven controls requiring a Pulse Width Modulated (PWM) signal. Pulse width modulation allows more precise control of current to the solenoids. The PWM signal causes the solenoid pin to push against the porting spool, which pressurizes one end of the servo piston, while draining the other. Pressure differential across the servo piston moves the swashplate. A swashplate feedback link, opposing control links, and a linear spring provide swashplate position force feedback to the solenoid. The control system reaches equilibrium when the position of the swashplate spring feedback force exactly balances the input command solenoid force from the operator. As hydraulic pressures in the operating loop change with load, the control assembly and servo/swashplate system work constantly to maintain the commanded position of the swashplate.

The EDC incorporates a positive neutral dead-band as a result of the control spool porting, spring preload from the servo piston assembly, and the linear control spring. Once the neutral threshold current is reached, the swashplate position becomes directly proportional to the control current. To minimize the effect of the control neutral deadband, we recommended the transmission controller or operator input device incorporate a jump up current.

The neutral position of the control spool does provide a positive preload pressure to each end of the servo piston assembly.

When the control input signal is either lost or removed, or if there is a loss of charge pressure, the springloaded servo piston automatically returns the pump to neutral position.

The EDC is a displacement (flow) control. Pump swashplate position is proportional to the input command and therefore vehicle or load speed (excluding influence of efficiency), is dependent only on the prime mover speed or motor displacement.

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Operation

EDC schematic diagram
M14
C1	C2
Feedback from swash-plate	T	P

Manual Displacement Control (MDC)

MDC principle

The Manual Displacement Control (MDC) consists of a lever with eccentric shaft centre of a threeposition, four-way porting spool. The eccentric shaft applies a force input to the spool, which ports hydraulic pressure to either side of a double acting servo piston.

Differential pressure across the servo piston rotates the swash plate, changing the pump`s displacement from full displacement in one direction to full displacement in the opposite direction.

MDC Schematic (P005571E)

N

T P

Feedback from swasch plate

MDC with control cut off (CCO)

If solenoid is loaded by voltage directly from truck battery 24 to 32 V pump work in normal mode if the electric circuit will by switch off pump will go immediately to 0 position.

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Operation

Manual Over Ride (MOR)

All controls are available with a Manual Over Ride (MOR)

MOR

either standard or as an option for temporary actuation of

the control to aid in diagnostics.

The vehicle or device must always be in a ‘safe’ condition

(i.e. vehicle lifted off the ground) when using the MOR

function.

The MOR plunger has a 4 mm diameter and must be

manually depressed to be engaged.

Depressing the plunger mechanically moves the control

spool which allows the pump to go on stroke.

The MOR should be engaged anticipating a full stroke

response from the pump.

P003 204

W Warning

An O-Ring seal is used to seal the MOR plunger where initial actuation of the function will require a force of 45 N to engage the plunger. Additional actuations typically require a threshold force of 12 N to move the MOR plunger. Force required to keep the pump at full stroke is typically 51 N. Proportional control of the pump using the MOR should not be expected.

Refer to control flow table for the relationship of solenoid to direction of flow.

MOR schematic diagram (EDC shown)

	M14
C1	C2
	T	P

Feedback from swash-plate

MOR schematic diagram (MDC shown)

N

T P

Feedback from swasch plate

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Operating Parameters

Overview

This section defines the operating parameters and limitations for TMP pumps with regard to input speeds and pressures. For actual parameters, refer to the operating parameters for each displacement.

Input Speed

Minimum speed is the lowest input speed recommended during engine idle condition. Operating below minimum speed limits the pump's ability to maintain adequate flow for lubrication and power transmission.

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.

When determining speed limits for a particular application see Danfoss publication Pressure and speed limits.

W 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

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 pump. 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 pump. 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.

Charge Pressure

An internal charge relief valve regulates charge pressure. The internal charge pump supplies the control with pressure to operate the swashplate and to maintain a minimum pressure in the low side of the transmission loop.

Minimum charge pressure is the lowest pressure safe working conditions allow in the system loop. Minimum control pressure requirements are a function of speed, pressure, and swashplate angle, and may be higher than the minimum charge pressure shown in the technical specifications.

Maximum charge pressure is the highest charge pressure the charge relief adjustment allows, and which provides normal component life. You can use elevated charge pressure as a secondary means to reduce the swashplate response time.

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