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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Service Manual
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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Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
Literature reference
TMP literature reference
Further available literature
Description
TMP Transit Mixer Axial Piston Pump, Size 070/089
TMP Transit Mixer Axial Piston Pump, Size 070/089
TMP Transit Mixer Axial Piston Pump, EDC/MDC, Size 070/089
TMP Transit Mixer Axial Piston Pump, NFPE, Size 070/089
TMP EDC Axial Piston Pump, Size 070/089
TMP MDC Axial Piston Pump, Size 070/089
H1 Electrical Displacement Control (EDC)
Speed and Temperature Sensor
Hydraulic Fluids and Lubricants
Design Guideline for Hydraulic Fluid Cleanliness
Type
Technical Information
Service Manual
Repair Instruction
Repair Instruction
Datasheet
Datasheet
Technical Information
Technical Information
Technical Information
Technical Information
Literature number
L1006391
L1010109
L1031073
11029271
L1109001
L1214176
11022744
11046759
520L0463
520L0467
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Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
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
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.
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
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:
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.
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.
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.
Warning
Personal safety
Protect yourself from injury. Use proper safety equipment including safety glasses at all times.
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TMP Transit Mixer Axial Piston Pump, Size 070/089
Introduction
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
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
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
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
Warning
Personal safety
Protect yourself from injury. Use proper safety equipment including safety glasses at all times.
Hazardous material
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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Electric displacement control
Valve plate
Piston
Shaft
Shaft seal
Plate thrust
Swashplate
Swashplate feedback pin
Cylinder block Servo piston Charge pump
Cover charge pump
Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
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
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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AA
B B
L2 M3
M3
M5
M4
TMMTMP
M2L2SM2
M10
L1
C2C1
M1 L1 M1
AA
B B
L2 M3
M3
M5
M4
TMMTMP
M2
L2
M2
M10
L1 M1 L1 M1
N
‘-’ ‘+’
CW
S
Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
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
System circuit diagram of TMP MDC with 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
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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
C1 C2
High pressure relief valve
Charge pressure relief valve
Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
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
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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
Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
Operation
Charge pressure relief valve (CPRV)
The charge pressure relief valve maintains charge
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.
Charge pressure relief valve (CPRV)
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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Feedback from swash-plate
PT
M14
C1 C2
Feedback from swasch plate
T P
N
Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
Operation
EDC schematic diagram
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)
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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P003 204
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Feedback from swash-plate
PT
M14
C2
C1
Feedback from swasch plate
T P
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Service Manual
TMP Transit Mixer Axial Piston Pump, Size 070/089
Operation
Manual Over Ride (MOR)
All controls are available with a Manual Over Ride (MOR)
either standard or as an option for temporary actuation of
MOR
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.
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)
MOR schematic diagram (MDC shown)
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TMP Transit Mixer Axial Piston Pump, Size 070/089
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.
Warning
System Pressure
Charge Pressure
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 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.
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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