Danfoss TMP 070/089 Service guide

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Service Manual

Transit Mixer Axial Piston Pump

Size 070/089

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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

2 | © Danfoss | July 2017 L1010109 | AX00000131en-US0203

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

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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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

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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Service Manual

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

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

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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B B

L2 M3

TMMTMP

M2L2SM2

M10

C2C1

M1 L1 M1

B B

L2 M3

TMMTMP

M10

L1 M1 L1 M1

‘-’ ‘+’

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

M14

C1 C2

Feedback from swasch plate

T P

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

Feedback from swash-plate

M14

Feedback from swasch plate

T P

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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Service Manual

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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TMP Transit Mixer Axial Piston Pump, Size 070/089

Operating Parameters

The charge pressure setting listed in the order code is the set pressure of the charge relief valve with the pump in neutral, operating at 1500 min-1 (rpm), and with a fluid viscosity of 32 mm2/sec [150 SUS]. The charge pressure setting is referenced to case pressure (the differential pressure above case pressure).

Charge inlet pressure

At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure. Minimum charge inlet pressure is only allowed at cold start conditions. In some applications, you may need to warm up the fluid (start the prime mover without using the vehicle/machine functions) before moving the vehicle or operating the machine.

Case Pressure

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.

Warning

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.

Temperature and Viscosity

General specification

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.

General specifications

Design

Direction of rotation

Axial piston pump cradle swashplate design with variable displacement

Clockwise, counterclockwise

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TMP Transit Mixer Axial Piston Pump, Size 070/089

Operating Parameters

General specifications (continued)

Pipe connections

Recommended installation position

Caution

The front shaft seal must not be exposed to oil pressure from outside of the unit. Boundary position of the MDC lever must be fixed by hard stop on the customer actuation mechanism in

order to prevent any damages of MDC.

Physical Properties

Technical data

Features Unit Size

Displacement maximum cm

Oil volume l [US gal] 2 [0.53] 2 [0.53] Mounting flange SAE ISO 3019/1 flange 127-4 (SAE C), M12x1,75 Input shaft Spline shaft SAE, 21 teeth, pitch = 16/32

Auxiliary mounting flange with metric fasteners, shaft splines

Suction port ISO 6149-1 – M42x2 (O-ring boss) Main port configuration Twin ports SAE J518b Size 1, with metric screws M12 Case drain ports L1, L2 ISO 6149-1 – M22x1,5 (O-ring boss) Other ports ISO 6149-1 straight thread O-ring boss.

Main pressure ports: ISO split flange boss Remaining ports: ISO straight thread O-ring boss

Pump installation position is discretionary; however the recommended control position is on the top. The housing must always be filled with hydraulic fluid. Pump shaft connection is discretionary, however it is strongly recommended to use rubber coupling if pump is driven via “cardan” shaft. Correct installation has a significant influence on a life time of the pump.

070 089

[in3]

Spline shaft SAE, 23 teeth, pitch = 16/32 Coupling for Cardan, 23 teeth (only with spline shaft SAE, 23 teeth, pitch = 16/32)

SAE A, 11 teeth, pitch = 16/32 SAE B, 13 teeth, pitch = 16/32 SAE B-B, 15 teeth, pitch = 16/32

See Port Locations and Gauge Installation on page 19.

68.3 [4.17]

89.0 [5.43]

Operating parameters

Operating parameters, size 070 / 089

Features Unit Sizes 070 / 089

Input speed Minimum

Rated

Maximum

System pressure Max. working pressure

Maximum pressure

Minimum pressure

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min-1 (rpm)

bar [psi]

500

2500

2900

420 [6090]

450 [6525]

10 [145]

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TMP Transit Mixer Axial Piston Pump, Size 070/089

Operating Parameters

Operating parameters, size 070 / 089 (continued)

Features Unit Sizes 070 / 089

Charge pressure Minimum

Maximum

Control pressure Minimum (at corner

power for EDC)

Maximum

Charge pump inlet pressure

Case pressure Rated

Lip seal external pressure

Rated

Minimum (cold start)

Maximum

bar [psi]

bar (absolute) [in Hg vacuum]

bar [psi]

17 [247]

30 [436]

21 [305]

30 [435]

0.7 [9]

0.2 [24]

4 [58]

3 [44]

5 [73]

0.4 [5.8]

Fluid Specifications

Fluid specifications

Features Unit Sizes 070 / 089 Viscosity Intermittent

mm2/s [SUS] 5 [42] Minimum 7 [49] Recommended range 12-80 [66-370] Maximum 1600 [7500]

Temperature

range

Minimum (cold start) Recommended range 60-85 [140-185]

°C [°F] -40 [-40]

Rated 104 [220]

115 [240]

Filtration (recommended minimum)

Maximum intermittent Cleanliness per ISO 4406 22/18/13 Efficiency (charge pressure filtration) β-ratio β15-20 = 75 (β10 ≥ 10) Efficiency (suction and return line filtration) β35-45 = 75 (β10 ≥ 2) Recommended inlet screen mesh size µm 100 – 125

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)

Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing oxidation, rust, and foam inhibitors.

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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Fluid and Filter Maintenance

Fluid and filter recommendations

To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure. 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. Change the fluid and correct the problem immediately if these conditions occur.

Inspect vehicle for leaks daily. Change the fluid and filter per the vehicle/machine manufacturer's recommendations or at intervals shown in the table. We recommend first fluid change at 500 hours.

Fluid and Filter Change Interval

Reservoir type Max oil change interval

Sealed 2000 hours Breather 500 hours

High temperatures and pressures will result in accelerated fluid aging. More frequent fluid changes may be required.

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.

For detailed filtration information, see Danfoss publication 520L0463 Fluids and Filtration. For information on biodegradable fluids see Danfoss publication 520L0465 Biodegradable Hydraulic Fluids.

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.

Port Information

Identifier Port Description Size Wrench size Gauge size,

bar [psi]

L1, L2 Case drain ports M22x1.5 10 mm internal hex 10 [100] M1, M2, M4, M5 System A/B, charge and servo gage M12x1.5 6 mm internal hex 50 [1000] M10 Charge pump inlet pressure M12x1.5 6 mm internal hex 50 [1000] S Charge inlet port M42x2.0 10 [100]

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Gauge port M2

System pressure port B

M12 x 1.5

Gauge port M1 System pressure port A M12 x 1.5

Gauge port M4

Servo pressure

M12 x 1.5

Gauge port M5 Servo pressure M12 x 1.5

Gauge port M10 Charge pump inlet pressure M12 x 1.5

Gauge port M3 Charge pressure M12 x 1.5

O-ring plug 7/16-20 UNF use for air bleed when filling pump (only by EDC)

Case drain Port L2 M22 x 1.5 O-ring boss

System port B

Charge pump inlet S M42 x 2

System port A

Case drain Port L1 M22 x 1.5

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Fluid and Filter Maintenance

Port locations

P005443E

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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Initial Startup Procedures

General

Follow this procedure when starting-up a new pump installation or when restarting an installation in which the pump has been removed and re-installed on a machine. Ensure pump has been thoroughly tested on a test stand before installing on a machine. Prior to installing the pump, inspect for damage that may have occurred during shipping.

Warning

Start-Up procedure

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. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M

4. Fill the housing by adding filtered oil in the upper case drain port. If the control is installed on top,

open the construction plug in the top of the control to assist in air bleed.

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.

7. Close construction plug removed in Step 4.

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.

8. 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.

9. 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.

10. 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.

11. 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.

12. 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.

13. Check that the reservoir is full. Remove charge pressure gauge. The pump is now ready for operation.

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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

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 Safety

Precautions and precautions related to your specific equipment.

Safety Precautions

Caution

High inlet vacuum causes cavitation which can damage internal pump components.

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

Caution

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 environmental regulations.

Electrical Troubleshooting (TMP EDC)

Item Description Action

Control operates pump in one direction only.

No pump function No power to controller Restore power to controller. Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, reconnect wires.

Control coil failure Measure resistance at coil pins. Resistance should be 14.20 ohms (24V) or

3.66 ohms (12V) at 20°C [70°F]. Replace coil

If available, use manual override to check proper pump operation and verify electrical problem.

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. Check air flow and input air temperature for heat

22 | © Danfoss | July 2017 L1010109 | AX00000131en-US0203

Fill reservoir to proper level.

exchanger. Clean, repair or replace heat exchanger.

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Troubleshooting

Item Description Action

Charge pressure. Low charge pressure will overwork system. Measure charge pressure. Inspect and adjust or replace

charge relief valve. Inspect charge pump. Repair or replace charge pump.

Charge pump inlet vacuum. High inlet vacuum will overwork system. A dirty filter will

increase the inlet vacuum. Inadequate line size will restrict flow.

System relief pressure settings

System pressure. Frequent or long term operation over system relief setting

If the system relief valves are worn, contaminated, or valve settings are too low, the relief valves will be overworked.

will create heat in system.

Neutral Difficult or Impossible to Find

Item Description Action

Input to pump control Input to control module is operating

improperly.

Neutral Neutral set improperly Shunt servo gauge ports (M4 and M5) together with

Check charge inlet vacuum. If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions.

Verify settings of high pressure relief valves and replace valves as necessary.

Measure system pressure. If pressure is too high, reduce loads.

Disconnect input and check to see if pump comes back to neutral. If Yes, input fault, replace/repair external controller. If No, go to next step.

external hose and see if pump comes back to neutral. If Yes: Control neutral improperly set (see page 31-34) If neutral still impossible to set, balance swashplate (see Mechanical neutral adjustment, page 35-37). If you still cannot set neutral, replace control.

System Will Not Operate in Either Direction

Item Description Action

Oil level in reservoir. Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level. Pump control orifices Control orifices are blocked. Clean control orifices. Pump control screens Control screens are blocked. Replace control screens. Only a Danfoss Authorized Service

Center may remove the unit's endcap without voiding the warranty.

Low charge pressure with pump in neutral

Low charge pressure with pump in stroke

Pump charge relief valve A pump charge relief valve that is leaky, contaminated, or

Charge pump inlet filter A clogged filter will under supply system loop. Inspect filter and replace if necessary. Charge pump A malfunctioning charge pump will provide insufficient

System pressure Low system pressure does not provide enough power to

High pressure relief valve Defective high pressure relief valve cause system pressure

Input to control Input operating improperly Repair/replace control.

Low charge pressure insufficient to recharge system loop. Measure charge pressure with the pump in neutral. If

pressure is low, go to Pump charge relief valve.

Low charge pressure resulting from elevated loop leakage. Insufficient control pressure to hold pump in stroke.

set too low will depressurize the system.

charge flow.

move load.

to be low.

Deadhead the pump to isolate it from the motor.With pump in partial stroke and engaged for only a few seconds, check pump charge pressure. Low charge pressure indicates a malfunctioning pump. Continue to next step. Good charge pressure indicates a malfunctioning motor or other system component. Check motor charge relief operation (if present).

Adjust or replace pump charge relief valve as necessary.

Repair or replace the charge pump.

Measure system pressure. Continue to next step.

Repair or replace high pressure relief valve.

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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Troubleshooting

System Noise or Vibration

Item Description Action

Reservoir oil level Low oil level leads to cavitation. Fill reservoir. Aeration of the oil/pump

inlet vacuum

Cold oil If oil is cold, it may be too viscous for proper function

Pump inlet vacuum High inlet vacuum causes noise/cavitation. Check that inlet line is not restricted and is of proper size.

Shaft couplings A loose shaft coupling will cause excessive noise. Replace loose shaft coupling.. Shaft alignment Misaligned shafts create noise. Align shafts. Charge/system relief valves Unusual noise may indicate sticking valves and possible

Sluggish System Response

Item Description Action

Oil level in reservoir Low oil level causes sluggish response. Fill reservoir. High pressure relief valves settings Incorrect pressure settings affects system reaction time. Adjust or replace high pressure relief valves. Low prime mover speed Low engine speed reduces system performance. Adjust engine speed. Charge pressure Incorrect pressure affects system performance. Measure and adjust charge pressure relief or

Air in system Air in system produces sluggish system response. Fill tank to proper level. Cycle system slowly for

Contaminated control orifices Control orifices are plugged. Clean control orifices. Contaminated control screens Supply screen is plugged. Replace control screens. Pump inlet vacuum Inlet vacuum is too high resulting in reduced system

Air in system decreases efficiency of units and controls. Excessive noise, foaming oil, and hot oil all indicate air in system.

causing pump cavitation.

contamination.

pressure.

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.

Check filter and bypass switch.

Clean/replace valves and test pump.

replace charge pump.

several minutes to remove air from system.

Measure charge inlet vacuum. Inspect line for proper sizing. Replace filter. Confirm proper bypass operation.

Transmission Operates Normally in One Direction Only

Item Description Action

Input to pump control. Input to control module is operating improperly. Check control input and repair or replace as necessary. Control orifices Control orifice(s) are blocked. Clean control orifices. Control screens Control screen(s) are blocked. Replace control screens. Exchange high pressure

relief valves Servo pressure low or

decaying

Exchanging the high pressure relief valves will show if the problem is related to the valve function.

Damaged servo seals may prevent servo piston from stroking the pump.

If the problem changes direction, replace the valve that does not operate correctly.

Check for torn/missing servo seals. Replace and retest. Only a Danfoss Authorized Service Center may remove the servo piston without voiding the warranty.

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Case drain port L2

Servo pressure gauge port M4, M5

Adjustment screw 13 mm

Locknut 27 mm

65 N•m [48 lbf•ft]

Optional construction port

0 - 10 bar [0 - 100 psi]

M22x1.5

40 N•m [29.5 lbf•ft]

0 - 10 bar [0 - 100 psi]

3/16 in

12 N•m [9 lbf•ft]

0 - 50 bar [0 - 1000 psi]

M12x1.5

21 N•m [15.5 lbf•ft]

Charge pressure gauge port M3

0 - 50 bar [0 - 1000 psi]

M12x1.5

21 N•m [15.5 lbf•ft]

Locknut M40x1.5

80 N•m [59 lbf•ft]

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

Pump Adjustment

This section offers instruction on inspection and adjustment of pump components. Read through the entire topic before beginning a service activity. Refer to Port Locations and Gauge Installation on page 19, for location of gauge ports and suggested gauge size.

Standard Procedures

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 pump.

2. If removing the pump, 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 pump, test for leaks.

Charge Pressure Relief Valve Adjustments

This procedure explains how to check and adjust the charge pressure relief valve.

Charge Pressure Adjustment (P005619E)

Listed pressures assume a pump speed of 1500 min¯¹ (rpm). At higher pump speeds (with higher charge flows) the charge pressure will rise over the rated setting.

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Servo pressure gauge port M4, M5

Adjustment screw 4 mm

Locknut 13 mm

12 N•m [9 lbf•ft]

0 - 50 bar [0 - 1000 psi]

M12x1.5

21 N•m [15.5 lbf•ft]

D060 D015

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install a 10 bar [100 psi]

gauge at case drain port L1 or L2. Operate the system with the pump in neutral (zero displacement) when measuring charge pressure.

2. Nominal charge relief valve settings 20.3 - 25 bar [294 - 326 psi] (refer to model code located on serial

number plate). This pressure assumes 1500 min-1 (rpm) pump speed and a reservoir temperature of 50°C [120°F], and is referenced to case pressure.

3. Loosen the locknut and turn the adjusting screw clockwise to increase the setting; counterclockwise

to decrease it. Approximate adjustment per turn is 2.4 bar.

4. While holding the adjusting screw, torque locknut to 65 N•m [48 lbf•ft].

EDC neutral adjustment

All functions of the Electric Displacement Control (EDC), are preset at the factory. If necessary, adjust the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory results, you may need to replace the control or coils. See

Removal on page 35 for details.

Warning

Adjustment of the EDC is very sensitive. Be sure to hold the hex wrench steady while loosening the locknut. Total adjustment is less than 120 degrees.

EDC Control Adjustment (P005437E)

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Solenoid shaft

Feedback pin

Adjusting screw (cam)

P106 046E

Maximum adjustment less than 120°

Control spool

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5). Disconnect the

external control input (electrical connections) from the control. Start the prime mover and operate at normal speed.

2. Use a 4 mm internal hex wrench to hold the neutral adjusting screw (D015) stationary while

loosening the locknut (D060) with a 13 mm wrench.

3. Observe pressure gauges. If necessary, turn adjusting screw (D015) to reduce pressure differential.

4. Rotate the neutral adjusting screw (D015) clockwise until the pressure increases on the gauge. Note

the angular position of the wrench. Then rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench.

5. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted

above. The gauges should read the same pressure, indicating that the control is in its neutral position.

6. Hold the neutral adjusting screw stationary and tighten the locknut (D060). Torque to 10 N•m [7.5

lbf•ft]. Do not over torque the nut.

7. When the neutral position is set, stop the prime mover, remove the gauges, and install the gauge

port plugs. Reconnect the external control input.

Neutral adjustment (EDC, bottom view)

Illustration shows how cam on adjusting pin rotates to adjust for neutral position after pump is re-installed.

A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Zero differential is usually not possible.

MDC Control Neutral Adjustment

All functions of the Mechanical Displacement Control (MDC), are preset at the factory. If necessary, adjust

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 27

the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory results, you may need to replace the control. See

Removal on page 37 for details.

Servo pressure gauge port M4, M5

Adjustment screw 4 mm

Locknut 13 mm

10 N•m [7.5 lbf•ft]

0 - 50 bar [0 - 1000 psi]

M12x1.5

21 N•m [15.5 lbf•ft]

D060 D698

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

Warning

Adjustment of the MDC is very sensitive. Be sure to hold the hex wrench steady while loosening the locknut. Total adjustment is ±3 screw thread.

MDC Control Adjustment (P005612E)

1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5). Disconnect the

external control input (mechanical connections) from the control. Start the prime mover and operate at normal speed.

28 | © Danfoss | July 2017 L1010109 | AX00000131en-US0203

2. Use a 4mm internal hex wrench to hold the neutral adjusting screw (D698) stationary while loosening

the locknut (D060) with a 13 mm wrench.

3. Observe pressure gauges. If necessary, turn adjusting screw (D698) to reduce pressure differential.

4. Rotate the neutral adjusting screw (D015) clockwise until the pressure increases on the gauge. Note

5. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted

above. The gauges should read the same pressure, indicating that the control is in its neutral position.

6. Hold the neutral adjusting screw stationary and tighten the locknut (D060). Torque to 10 N•m [7.5

lbf•ft]. Do not over torque the nut.

Eccentric shaft

Feedback pin

Maximum adjustment ± 3 mm

Control spool

Control lever

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

7. When the neutral position is set, stop the prime mover, remove the gauges, and install the gauge

port plugs. Reconnect the external control input.

Neutral Adjustment (MDC, bottom view)(P005613E)

Mechanical Neutral Adjustment

Mechanical neutral is set with the pump running at 1500 min¯¹ (rpm). To set neutral, you must stroke the pump in each direction. You can do this with a small movement of the eccentric screw on EDC or MDC controls. To stroke a pump with EDC, you must provide a 100 Hz PWM signal to the control solenoids. If you perform this adjustment with the pump installed in a vehicle or machine, safely elevate the wheels or disconnect the mechanism to allow safe operation during adjustment.

This procedure details setting neutral for the pump. Alternate M4/M5 and M1/M2 to zero out forward and reverse directions of the unit Refer to the drawing below to identify all ports.

While performing this adjustment, you will monitor the following pressures.

•

Illustration shows how cam on adjusting pin rotates to adjust for neutral position after pump is reinstalled.

A small pressure differential of 0.15 bar [2.2 psi] or less is acceptable. Zero differential is usually not possible.

Servo pressure at M4 and M5 System pressure at M1 and M2 Pressure differential between M4 and M5 (optional) Pressure differential between A and B (optional)

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 29

Port M1 System pressure

Port M2

System pressure

Port M4 Servo pressure

Servo locking nut

Port M5

Servo pressure

System port B

Solenoid C1

System port A

Port M1 System pressure

Port M2

System pressure

Port M4 Servo pressure

Servo locking nut

Port M5

Servo pressure

System port B

Control lever

System port A

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

TMP EDC system pressure gage ports for adjusting the servo neutral position

TMP MDC system pressure gage ports for adjusting the servo neutral position

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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Adjustments

Pump setup

1. Attach a 50 bar [1000 psi] gauge to each servo pressure port M4 and M5. Attach a 600 bar [10 000 psi]

gauge to each system pressure port (M1 and M2).

2. Unscrew a nutmutter of the servo cylinder by 2-3 turns.

3. Disconnect the external control input (mechanical or electrical).

4. If using a PWM signal to set mechanical neutral, connect the control solenoids C1 and C2 to the signal

source. Ensure the source supplies no current to the solenoids until required in the following procedure.

Servo adjustment

1. Run prime mover at 1500 min¯¹(rpm).

2. If using a PWM signal TMP with EDC, ensure the signal is off. Check the servo pressure gauges. Ensure

the differential between M4 and M5 is less than 1.5 bar [22 psi].

3. Using a SW 24 wrench, unthread both servo cylinders 2-3 turns. This step ensures clearance among

the servo cylinders, the servo pistons and swashplate.

4. Stroke the pump by turning the control adjustment screw, or use mechanical or electrical input until

the servo pressure at port M4 is 1 to 2 bar [14– 29 psi] greater than at port M5 and the system pressure gauges indicate displacement. Pressure should be greater at port M1 for clockwise rotation, or M2 for counterclockwise rotation. This also indicates the servo cylinder, the servo piston are in the contact with the swashplate on side M

5. Slowly thread the servo cylinder on the M5 side in until the system pressure differential starts to

decrease. Maintain servo pressure differential between 1-2 bar [14-29 psi] during this step. Continue turning the servo cylinder in until the system pressure differential (between ports M1/M2) is less than

1.5 bar [22 psi]. This procedure sets the servo and swashplate to mechanical neutral on the M5 side.

6. To complete setting neutral, repeat steps 1-5 but stroke the pump in the opposite direction. Reverse

gauge locations (M4 for M5, M2 for M1) from those stated above since the pump is now stroking the other direction.

7. Use a SW 24 wrench to ensure the position of the servo cylinder, and secure the locking nut of the

servo cylinder.

8. Remove all gauges and replace gauge port plugs. You can find wrench sizes and plug torques in Plug

Size and Torques on page 43.

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Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

Standard Procedures, Removing the Pump

Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary pump attached, remove both pumps as a single unit. 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 the manufacturer's warranty. Take precautions to ensure system cleanliness when removing and installing system lines.

Disassembly

1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the pump.

2. Tag, disconnect, and cap each hydraulic line connected to the pump. As hydraulic lines are

disconnected, plug each open port, to ensure that dirt and contamination do not get into the pump.

3. Remove the pump and its auxiliary pump (if applicable) as a single unit.

Be careful, do not damage solenoids and electrical connections when using straps or chains to support the pump.

Inspection

1. Ensure the work surface and surrounding area are 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.

EDC/MDC Control

Reassembly

1. Before replacing the pump, replace all filters and drain the hydraulic system. Flush the system lines

and fill the reservoir with the correct, filtered hydraulic fluid.

2. Fill the pump with clean, filtered hydraulic fluid.

3. Attach the pump to the prime mover. Torque mounting screws according to the manufacturers

recommendation.

4. Replace all hydraulic lines. Ensure the charge inlet line is filled with fluid.

Removal

Refer to EDC Control on page 34.

1. Using a 5 mm internal hex wrench, remove the six cap screws (D250).

2. Remove the control module and gasket (D150). Discard the gasket.

3. If necessary, remove orifices (M180, M185) using a 3 mm internal hex wrench. Tag and number them

for reinstallation.

4. If screen (D084) is clogged, use a hook to remove retaining ring (D098) and screen. Discard screen and

replace with new screen.

Inspection

Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component.

Reassembly

Ensure you install dowel pins (M140) in housing before installing control.

D084

Incorrect screen orientation

Correct screen

orientation

D098

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

1. Install a new gasket (D150).

Proper Screen Orientation

2. If you removed screen (D084), install a new one. Install with the mesh facing outward (see drawing).

Install retaining ring (D098).

3. If previously removed, install orifices (M180, M185) using a 3 mm internal hex wrench. Torque to 2.5

N•m [1.8 lbf•ft].

4. Install the control module and six cap screws (D250).

5. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 N•m [9.8 lbf•ft].

Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the center of the control module when installing control (for EDC only).

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D025

D025A

D150

5 mm

13.5 N•m [9.8 lbf•ft]

D250

D050 (3X)

D084

5 N•m [4 lbf•ft]

4 mm

5 N•m [4 lbf•ft]

4 mm

F100 (2X)

D300 (2X)

2.5 N•m [1.8 lbf•ft]

3 mm

D098

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

EDC Control

Control Module and Solenoid Removal/Installation (P005434E)

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

Torque sequence (P106231)

Control Solenoids

Removal

1. Disconnect electrical connection and remove the three cap screws (D050) using a 4mm internal hex

wrench.

2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.

3. If necessary, remove the coil using a 12 point 26 mm socket.

Inspection

Inspect the machined surface on the control. If you find any nicks or scratches, replace the component.

Reassembly

1. Lubricate new O-ring (D025A) using petroleum jelly and install.

2. Install solenoid with three cap screws (D050) using a 4 mm internal hex wrench. Torque screws to 5

N•m [4 lbf•ft].

3. Install coil using a 12 point 26 mm socket. Torque coil nut to 5 N•m [3.7 lbf•ft].

4. Reconnect electrical connections and test the pump for proper operation.

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D025C

D025B

D025A

D025D

D025E

D025

D025F

D150

M140 (2x)

5 mm

13.5 N•m [9.8 lbf•ft]

D250

D084

M180, M185

2.5 N•m [1.8 lbf•ft]

3 mm

D098

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

MDC with CCO Control

Control Module and Solenoid Removal/Installation (P005615E)

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

Torque sequence (P005616)

Control Solenoids

Removal

1. Disconnect electrical connection, unscrew the plastic nut (D025F) and remove the coil (D025D) with

O-ring (D025E).

2. Remove the center (D025B) and O-rings (D025A and D025C) using a 17 mm internal hex wrench.

Discard the O-rings.

Inspection

Inspect the machined surface on the control. If you find any nicks or scratches, replace the component.

Reassembly

1. Lubricate new O-rings (D025A, D025C and D025E) using petroleum jelly and install.

2. Install center (D025B) with O-ring (D025A) using a 17 mm internal hex wrench. Torque to 21 N•m [15.5

lbf•ft].

3. Install coil (D025D) with O-rings (D025C and D025E).

4. Install plastic nut (D025F). Torque to 3.5 N•m [2.5 lbf•ft].

5. Reconnect electrical connections and test the pump for proper operation.

Shaft Seal Replacement

The shaft seal is serviceable. Orient the pump on the work surface so the shaft is pointing up.

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 37

[0.197]

[2.047]

B110

L020

L030

L040

L000

Ø40

[Dia 1.575]

Ø80

[Dia 3.15]

Seal installation tool

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

Removal

1. Using snap-ring pliers, remove the outer snap-ring (B110).

2. Press in the seal (L020) down 1 mm and use 2 screwdrivers to remove the carrier (L030) with seal

(L020) and O-ring (L040). Discard the seal and O-ring.

Caution

Do not damage the housing bore, shaft or bearing when removing the seal.

Inspection

Inspect the carrier. If you find any defect, replace damaged component.

Reassembly

1. Install the O-ring (L040) and shaft seal (L020) into carrier (L030).

2. Cover end of the shaft with an installation sleeve to protect the seal during installation. Lubricate the

seal. Tap on the seal replacing tool or an appropriate deep-socket to press in the seal. Remove the protective cover.

3. Install the remaining snap-ring.

Shaft Seal Assembly (P005449E)

Charge Pump

If the pump has an auxiliary pump attached, remove the auxiliary pump and coupling before removing the auxiliary pad.

Charge Pump Removal (Removable Auxiliary Pad/Cover)

1. Using a 8 mm internal hex wrench, remove cap screws (H050).

2. Remove charge pump cover or auxiliary pad (H030) and O-ring (H045). Discard the O-ring.

3. Remove charge pump coupling (H060) and Woodruff key (H020).

H050

H030

H070

H045

H010

H060

H020

H030

H050

G015

8 mm 30 Nm [22.1 ft•lb]

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

4. Remove charge pump gearset (H010).

Charge Pump Removal/Installation (P005439E)

Inspection

Inspect the components for wear, scratches or pitting. Scratches on the gearset, outer ring, cover and end cap surfaces will cause a loss of charge pressure. If any component shows signs of wear, scratching, or pitting, replace it.

Reassembly

1. Lubricate and install charge pump gearset (H010).

2. Install charge pump coupling (H060) and Woodruff key (H020).

3. Install a new O-ring (H045)

Ensure proper torque on aux pad screws (H045). If necessary, replace screws.

4. Install the auxiliary pad or charge pump cover and cap screws. Using a 8 mm internal hex wrench,

torque the cap screws (H050) to 30 N•m [22 lbf•ft]. Torque in sequence below.

If charge pump replacement is necessary, replace complete charge pump kit.

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 39

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

Cover (H030) Torque Sequence (P005438)

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 pump for nicks or scratches. Check the valves for damage. Replace any damaged components.

Reassembly

1. Lubricate and install new O-rings (G090A).

2. Install HPRVs. Torque to the value 60 N•m [44 lbf•ft].

G090

G090A

12 mm 60 N•m [44 lbf•ft]

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

3. Operate the vehicle/machine through full range of controls to ensure proper operation. Check for

leaks.

HPRVs (P005431)

Charge Pressure Relief Valve

Replace the charge pressure relief valve (K001) as a complete unit. Do not attempt to repair the internal components of the valve. Torque to 65 N•m [48 lbf•ft].

See Charge Pressure Relief Valve Adjustments on page 25 for adjustment instructions.

Removal

Using a 27 mm wrench, remove the charge pressure relief valve (K001). Discard seal O-ring (K050).

Inspection

Inspect the sealing surfaces of the pump for nicks or scratches.

Reassembly

1. Lubricate and install new seal O-ring (K050).

2. Install the charge pressure relief valve. Torque to 65 N•m [48 lbf•ft].

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 41

K050

K001

27 mm 65 N•m [48 lbf•ft]

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Minor Repair

3. Operate vehicle/machine through full range of controls to ensure proper operation.

Charge Pressure Relief Valve (P005620)

K010 Charge pressure locking nut

H050 Charge pump cover screw

G050/F050 O-ring plug M12x1.5

G090

High pressure

relief valve

G090 High pressure relief valve

G100 Rear cover

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Torque Chart

Fastener Size and Torques

Item Fastener Wrench size Torque

D015 Neutral adjust screw 4 mm internal hex NA D050 Coil mounting bolt 4 mm internal hex 8 N•m [6 lbf•ft] D060 Neutral adjust locking nut 13 mm 10 N•m [7.5 lbf•ft] D200 Swash plate feedback pin (not shown) 13 mm deep well socket 25 N•m [18 lbf•ft] D250 Electric control mounting bolt 5 mm internal hex 13.3 N•m [9.8 lbf•ft] F080 Servo cylinder locking nut 58-62 hook wrench 80 N•m [59 lbf•ft] M180, M185 Orifice 3 mm internal hex 2.5 N•m [1.84 lbf•ft] G090 High pressure relief valve 12 mm internal hex 60 N•m [44 lbf•ft] G100 Rear cover 10 mm internal hex 110 N•m [81 lbf•ft] H050 Charge Pump Cover Screw 8 mm internal hex 30 N•m [22 lbf•ft] H080 Auxiliary pad mounting bolt 8 mm internal hex 30 N•m [22 lbf•ft] K001 Charge pressure adjusting screw 13 mm hex deep socket NA

Charge pressure locking nut 27 mm 65 N•m [48 lbf•ft]

W055 Speed sensor mounting bolt 5 mm internal hex 8 N•m [6 lbf•ft]

Plug Size and Torques

Item O-ring plug Wrench size Torque

D065 7/16 - 20 3/16 internal hex 12 N•m [9 lbf•ft] B030 M22x1.5 10 mm internal hex 40 N•m [29.5 lbf•ft] G050, F090 M12x1.5 6 mm internal hex 21 N•m [15.5 lbf•ft]

EDC Fasteners and Plugs

P005433E

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 43

F080 Servo can locking nut

D060

Neutral adjust locking nut

D015 Neutral adjusting screw

D065 O-ring plug 7/16 - 20

B030

O-ring plug M22x1.5

D250 Electric control mounting bolt

D050

Coil mounting bolt

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Torque Chart

P005432E

K010 Charge pressure locking nut

H050 Charge pump cover screw

G050/F050 O-ring plug M12x1.5

G090

High pressure

relief valve

G090 High pressure relief valve

G100 Rear cover

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Torque Chart

MDC Fasteners and Plugs

P005617E

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 45

F080 Servo can locking nut

D060 Neutral adjust locking nut

B030

O-ring plug M22x1.5

D250 Mechanical control mounting bolt

D698

Neutral adjustment screw

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Torque Chart

P005618E

Service Manual

TMP Transit Mixer Axial Piston Pump, Size 070/089

Danfoss | July 2017 L1010109 | AX00000131en-US0203 | 47

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 Trading (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 offer:

Comatrol

www.comatrol.com

Turolla

www.turollaocg.com

Hydro-Gear

www.hydro-gear.com

Daikin-Sauer-Danfoss

www.daikin-sauer-danfoss.com

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

•

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 offer 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.

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.

Danfoss | July 2017 L1010109 | AX00000131en-US0203

Danfoss TMP 070/089 Service guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Literature reference

TMP literature reference

Introduction

Overview

Warranty

Symbols used in Danfoss literature

General instructions

Safety precautions

Hazardous material

Unintended machine movement

Flammable cleaning solvents

Fluid under pressure

Personal safety

Design

System circuit

Basic Closed Circuit

Case drain and heat exchanger

Operation

High pressure relief valve (HPRV) and charge check valve

Charge pressure relief valve (CPRV)

Electrical Displacement Control (EDC)

EDC Principle

Manual Displacement Control (MDC)

MDC principle

MDC with control cut off (CCO)

Manual Over Ride (MOR)

Operating Parameters

Overview

Input Speed

System Pressure

Charge Pressure

Charge inlet pressure

Case Pressure

Temperature and Viscosity

General specification

Temperature

Viscosity

Operating Parameters

Physical Properties

Fluid Specifications

Fluid and Filter Maintenance

Fluid and filter recommendations

Port Locations and Gauge Installation

Initial Startup Procedures

General

Start-Up procedure

Troubleshooting

Overview

Safety Precautions

Electrical Troubleshooting (TMP EDC)

System Operating Hot

Neutral Difficult or Impossible to Find

System Will Not Operate in Either Direction

System Noise or Vibration

Sluggish System Response

Transmission Operates Normally in One Direction Only

Adjustments

Pump Adjustment

Standard Procedures

Charge Pressure Relief Valve Adjustments

EDC neutral adjustment

MDC Control Neutral Adjustment

Mechanical Neutral Adjustment

Pump setup

Servo adjustment

Minor Repair

Standard Procedures, Removing the Pump

Disassembly

Inspection

EDC/MDC Control

Reassembly

Removal

Inspection

Reassembly

EDC Control